1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2002 08 16 Revised Updated & Renumbered 1986 08 22 CF4Q RD 888002-430 Added 26 AWG 1963 07 17 F6-1082 Released Printed copies are uncontrolled Page 1 of 6 Copyright 2002, Ford Global Technologies, Inc. CABLE
2、, LOW TENSION - VINYL INSULATED ESF-M1L58-A (105 C) - BARE CABLE, LOW TENSION - VINYL INSULATED ESF-M1L59-A (105 C) - TINNED 1. SCOPE The materials defined by these specifications are stranded vinyl covered low tension cables. The vinyl covering shall be 105 C classification. 2. APPLICATION These sp
3、ecifications were released originally for materials used for automotive electrical harnesses. 3. REQUIREMENTS 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 WIR
4、E SIZE Shall be specified on the engineering drawing and/or release according to the SAE wire size numbers appearing in Table 1. Example: #16 gage ESF-M1L58-A. 3.3 COLOR The color of the vinyl cover shall be specified on the engineering drawing and/or release by a numerical suffix following the lett
5、er suffix of the materials desired. The numerical color coding suffixes shall correspond to the following: 0 Black 5 - Green 1 Brown 6 - Blue 2 Red 7 - Violet 3 Orange 8 - Gray 4 Yellow 9 - White or Natural ENGINEERING MATERIAL SPECIFICATION ESF-M1L58-A ESF-M1L59-APage 2 of 6 Copyright 2002, Ford Gl
6、obal Technologies, Inc. Example: #16 gage ESF-M1L58-A1 shall designate a stranded 16 gage, brown vinyl covered, soft or annealed bare copper conductor, corresponding to the requirements of this specification. The first color coding numerical suffix shall be the base or body color of the finished cab
7、le and the second number shall designate the tracer or other auxiliary marking. 3.4 CABLE QUALITY Shall meet all of the requirements listed herein and must be equal to the original approved purchase sample. ESF-M1L58-A similar to M-1L17-C ESF-M1L59-A similar to M-1L17-D 3.5 WIRE QUALITY The strands
8、of the conductors prior to stranding shall consist of the following grades of wire: ESF-M1L58-A: ESF-M2L1-A, soft or annealed bare copper wire ESF-M1L59-A: ESF-M2L3-A, soft or annealed tinned copper wire 3.6 CABLE CONSTRUCTION See Tables I & II The cross sectional area of stranded conductors shall n
9、ot be less than 98% of the values specified in Table I. 3.7 INSULATION QUALITY The insulating material shall be a good grade vinyl chloride copolymer which will pass the following test requirements: The material shall adhere closely to, but strip readily from the conductors, leaving them reasonably
10、clean and in suitable condition for soldering. Insulation thickness shall be in accordance with Table II for the various wire sizes and shall be determined by measuring the diameter over the insulation, then removing the insulation and measuring the diameter of the conductor. Half of the difference
11、of the two measurements shall be considered as the wall thickness. ENGINEERING MATERIAL SPECIFICATION ESF-M1L58-A ESF-M1L59-APage 3 of 6 Copyright 2002, Ford Global Technologies, Inc. 3.7.1 Mechanical Properties A test specimen of the thermoplastic insulation prepared as in the SAE J200 section on s
12、ampling shall be used. The dumbbell cut sample shall have marks placed upon it 50 mm apart. The sample shall then be stretched at the rate of 305 mm/min. The tensile strength shall be calculated upon the original cross section of the test specimen before stretching. Testing shall be conducted at 23
13、+ 2 C. Care should be exercised in cutting samples to obtain uniform cross section. The properties shall be as follows: Tensile Strength, min 15.9 MPa Elongation, min 125% 3.7.2 High Temperature Resistance Remove 25 mm of insulation from each end of a 610 mm sample of the finished cable. The sample
14、shall be suspended around a cylindrical mandrel having a diameter specified in Table III. Each end of the conductor shall have suspended from it, the weight shown in Table III. This condition shall be maintained for 120 h in a mechanical convection oven maintained at a temperature of 135 - 137 C. Wh
15、en cool, the weight shall be removed from the specimen and it shall be taken off the mandrel, bent in the reverse direction around a mandrel of the diameter specified for the bend test in Table III at a rate not to exceed one complete turn/min and then be subjected to the dielectric test, para 3.7.3
16、. 3.7.3 Dielectric Test A specimen of the cable 610 mm long shall be formed into a loop. Remove 25 mm of insulation from each end of the wire and twist the ends together. The loop thus formed shall be immersed in water containing 5% salt by weight at 23 + 2 C, so that not more than 152 mm of each en
17、d of the specimen protrudes above the solution. After being immersed for 5 h and while still immersed, the specimen shall withstand the application of 1000 volts (rms) at 60 Hz between the conductor and the water for 1 min without rupture of the insulation. 3.7.4 Oil Absorption Test A specimen 610 m
18、m long shall be immersed to within 38 mm from the ends in a mixture of equal parts of M14J167 hydrocarbon thinner and ESE-M2C36 heavy duty lubricating oil at a temperature of 48 - 50 C for a period of 20 h. The sample shall then be removed from the solution, examined for deterioration of the insulat
19、ion compound and gaged for swelling. The outside diameter of the insulation of the cable shall not increase more than 15%. The sample shall then be bent around a mandrel (Table III) and checked for cracking. After the bend test, the cable shall be subjected to the dielectric test, para 3.7.3. ENGINE
20、ERING MATERIAL SPECIFICATION ESF-M1L58-A ESF-M1L59-APage 4 of 6 Copyright 2002, Ford Global Technologies, Inc. 3.7.5 Cold Bend Test A straight specimen shall be reduced to a temperature of 40 C at a rate not to exceed 50 C/min. After maintaining this temperature for 3 h and while still at this low t
21、emperature, the cable shall be wrapped around the mandrel specified in Table III for 180 C at the uniform rate of one turn in 10 s. The insulation shall be removed for a distance of 25 mm from each end of the specimen and the specimen subjected to the dielectric test, para 3.7.3. 3.7.6 Flame Test A
22、610 mm specimen shall be suspended in a vertical position within a partial enclosure which allows a flow of sufficient air for complete combustion but is free from drafts. The tip of a 50 mm gas flame with an inner cone one-third its height shall then be applied to the end of the specimen for 15 s.
23、After removal of the flame the specimen shall not continue to burn for more than 30 s. 3.7.7 Abrasion Resistance As per Table IV (FLTM BO 023-01) ENGINEERING MATERIAL SPECIFICATION ESF-M1L58-A ESF-M1L59-APage 5 of 6 Copyright 2002, Ford Global Technologies, Inc. TABLE I - CABLE CONSTRUCTION SAE No.
24、Approx. Dia. Wire of of Stranded Area of Size Wires Nominal Strand Size Conductor Conductor Awg mm mm mm226 7 35 0.142 0.483 0.110 24 7 32 0.203 0.610 0.227 22 7 30 0.254 0.787 0.355 22 19 34 0.160 0.813 0.382 20 7 28 0.320 1.02 0.554 18 16 30 0.254 1.27 0.795 16 26 30 0.254 1.52 1.186 16 19 29 0.28
25、7 1.52 1.186 16 16 28 0.320 1.52 1.186 14 26 28 0.320 1.91 1.914 14 19 27 0.361 1.91 1.914 12 65 30 0.254 2.29 3.013 12 41 28 0.320 2.29 3.013 12 19 25 0.455 2.29 3.013 10 105 30 0.254 2.92 4.785 10 65 28 0.320 2.92 4.785 10 49 27 0.361 2.92 4.785 10 19 23 0.574 2.92 4.785 8 103 28 0.320 4.06 7.654
26、8 49 25 0.455 4.06 7.654 8 19 21 0.724 4.06 7.654 6 172 28 0.320 5.33 12.340 6 123 27 0.361 5.33 12.340 6 37 21 0.724 5.33 12.340 4 133 25 0.455 6.99 19.472 4 61 22 0.643 6.99 19.472 4 49 21 0.724 6.99 19.472 TABLE II - INSULATION SAE Wire Nominal Insulation Maximum Diameter Size Wall Thickness of F
27、inished Cable mm mm 26 0.28 1.04 24 0.27 1.20 22 0.27 1.35 22 0.27 1.35 20 0.58 2.41 18 0.58 2.54 16 0.58 2.92 16* 0.79 3.15 14 0.58 3.18 12 0.66 3.81 10 0.79 4.70 8 0.94 6.22 6 1.09 7.75 4 1.12 9.53 *Specified values for #16 gage, 26 strand (30 Awg) wire only. ENGINEERING MATERIAL SPECIFICATION ESF
28、-M1L58-A ESF-M1L59-APage 6 of 6 Copyright 2002, Ford Global Technologies, Inc. TABLE III - MANDREL SIZES Gage High Temperature Bend and Cold Suspension Weight for Size Test Resistance Test High Temperature Test mm mm kg 26 114 76 0.45 24 114 76 9.45 22 114 76 0.45 20 114 76 0.45 18 114 76 0.45 16 16
29、5 76 0.45 14 165 152 0.45 12 165 152 1.36 10 254 152 1.36 8 254 152 1.36 6 254 254 2.72 4 254 254 2.72 TABLE IV - ABRASION RESISTANCE DATA Minimum Resistance Weight Gage Length Support Size of Tape Bracket Weight mm kg 26 127 A 0.23 24 152 A 0.23 22 152 A 0.23 20 457 A 0.45 18 533 A 0.45 16 559 A 0.45 14 305 B 1.36 12 406 B 1.36 10 508 B 1.36 8 635 B 1.36 6 635 C 1.93 4 762 C 1.93
