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INCH-POUND

MIL-DTL-3885H
23 May 2016
SUPERSEDING
MIL-C-3885G
29 November 2010

DETAIL SPECIFICATION

CABLE ASSEMBLIES AND CORD ASSEMBLIES, ELECTRICAL

This specification is approved for use by all Departments and Agencies of the
Department of Defense.

1. SCOPE

1.1 Scope. This specification covers the minimum requirements, unless otherwise
specified, for electrical cable and cord assemblies for use in communication equipment (referred
to as cable assemblies (see 6.5.1)), except for radio frequency coaxial cable assemblies and fiber
optic cable assemblies.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this
specification. This section does not include documents cited in other sections of this specification or
recommended for additional information or as examples. While every effort has been made to
ensure the completeness of this list, document users are cautioned that they must meet all specified
requirements of documents cited in sections 3 and 4 of this specification, whether or not they are
listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbook. The following specifications, standards,

and handbook form a part of this document to the extent specified herein. Unless otherwise
specified, the issues of these documents are those cited in the solicitation or contract.

Comments, suggestions, or questions on this document should be addressed to Defense Logistics

Agency Aviation VEB, 8000 Jefferson Davis Highway, Richmond, VA 23297-5616, or
e-mailed to [email protected]. Since contact information can change, you may want to
verify the currency of this address information using the ASSIST Online database at
https://assist.dla.mil/.

AMSC N/A FSC 5995

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FEDERAL STANDARDS

FED-STD-228 - Cable and Wire, Insulated; Methods of Testing

FED-STD-601 - Rubber: Sampling and Testing

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-T-3530 - Thread and Twine, Mildew Resistant or Water

Repellent Treated
MIL-DTL-15024 - Plates, Tags, and Bands for Identification of
Equipment, General Specification for
MIL-M-24041 - Molding and Potting Compound, Chemically Cured,
Polyurethane

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-202-106 - Method 106, Moisture Resistance

MIL-STD-202-107 - Method 107, Thermal Shock
MIL-STD-202-201 - Method 201, Vibration
MIL-STD-202-301 - Method 301, Dielectric Withstanding Voltage
MIL-STD-202-302 - Method 302, Insulation Resistance
MIL-STD-252 - Classification of Visual and Mechanical Defects for
Equipment, Electronic, Wired, and Other Devices
MIL-STD-13231 - Marking of Electronic Items

DEPARTMENT OF DEFENSE HANDBOOK

MIL-HDBK-454 - General Guidelines for Electronic Equipment

(Copies of these documents are available online at http://quicksearch.dla.mil.)

2.3 Non-Government publications. The following documents form a part of this document
to the extent specified herein. Unless otherwise specified, the issues of these documents are those
cited in the solicitation or contract.

AMERICAN SOCIETY FOR QUALITY (ASQ)

ASQ Z1.4 - Sampling Procedures and Tables for Inspection by

Attributes

(Copies of this document are available online at http://www.asq.org/.)

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SAE INTERNATIONAL

SAE AS5942 - Marking of Electrical Insulating Materials

SAE AMS-DTL-23053/5 - Insulation Sleeving, Electrical, Heat Shrinkable,
Polyolefin, Flexible, Crosslinked

(Copies of these documents are available online at http://www.sae.org/.)

UNIFIED ABRASIVES MANUFACTURERS' ASSOCIATION (UAMA)

UAMA B74.18 - Grading of Certain Abrasive Grain on Coated

Abrasive Products

(Copies of these documents are available online at http://uama.org/.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of
a conflict between the text of this document and the references cited herein, the text of this
document takes precedence. Nothing in this document, however, supersedes applicable laws and
regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Detail requirements. The individual cable assemblies shall comply with all the
requirements specified herein as well as those cited on the applicable detail specification,
specification sheet, or drawing (see 6.2). In the event of a conflict between the requirements of
this specification and other requirements of the applicable device specification, the precedence in
which requirements shall govern, in descending order, is as follows:

a. Applicable device specification (detail specification or drawing).

b. This specification.
c. Specifications, standards, and other documents referenced in section 2.

3.2 First article. When specified (see 6.2), a sample shall be subjected to first article
inspection in accordance with 4.2. First article inspection shall consist of all tests specified
herein, and shall include materials inspection (see 4.2.1). Tests for insulation resistance and
dielectric-withstanding voltage shall be performed manually and the insulation resistance readings
shall be recorded (see 4.4.2 and 4.4.3).

3.3 Material. The material shall be specified in the applicable specification or drawing.
However, when a definite material is not specified, a material shall be used which will enable the
cable assembly to meet the performance requirements of this specification and shall be submitted
to the contracting officer for approval. Acceptance or approval of any constituent material shall
not be construed as a guarantee of the acceptance of the finished product (see 4.2.1).

3.3.1 Polyurethane. Molded polyurethane shall conform to MIL-M-24041 or shall meet

material reversion test requirements (see 3.9.11).

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3.3.2 Solders. MIL-HDBK-454, guideline 5, provides guidance on soldering of electrical

connections (see 3.8.2).

3.4 Marking. Marking shall conform to MIL-STD-13231. Size of the characters and
properties of the marking shall be as specified in SAE AS5942. Unless otherwise specified
(see 3.1), the marking shall be on yellow heat-shrinkable tubing, type K2 per MIL-DTL-15024 or
class 1 per SAE AMS-DTL-23053/5. All cable assemblies shall have markers applied as
specified by the applicable drawings, contract, or order. The information to be marked on the
cable band shall be as follows:

Line 1. Type designation and length, if part of the nomenclature. The length shall be in
parentheses.
Line 2. Procurement instrument identification number (contract number).
Line 3 (if space permits). Manufacturer CAGE.
Line 4 (if space permits). National stock number.

3.5 Connectors. Connectors shall meet the requirements of the individual connector
specification listed on the drawing or in the contract (see 6.2).

3.6 Design and construction.

3.6.1 Treatment of textiles. Staycords, fillers, binders, braids, and other textiles used in
the construction of cable assemblies shall be treated in accordance with MIL-T-3530, using
type I, class 1 mildew-inhibiting agent, with the following requirements waived:

a. First article sample approval.

b. Acidity (pH).
c. Mildew-resistance.
d. Color.
e. Breaking strength.
f. Length per pound.
g. Sewing finish.

The treatment shall be applied only with an alcoholic solution. The methods of treatment shall be
as specified in 3.6.1.1 or 3.6.1.2, as applicable. Treatment is not required for nylon, cellulose
acetate, rayon acrylic fibers, polyester, and ends of cable assemblies that terminate in a potted or
molded connector (see 6.5.3 and 6.5.4), or a molded crotch.

3.6.1.1 Cut lengths. Prior to attachment of any terminations, such as terminals and
connectors, the cut lengths of the cable or cord, prepared for terminations, shall be immersed in
the specified mildew-inhibiting solution as shown in table I.

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TABLE I. Cable or cord mildew inhibition.

Outer covering of cable or cord Degree of immersion
Textile, or textile covered by shielding Complete length, uncoiled
Jacket of natural or synthetic rubber or of Three inches beyond the edge at which the
plastic textile is exposed

Immersion shall be for the minimum period of time necessary to obtain complete saturation, but
shall not exceed five minutes. As soon as practical after immersion, the treated cable or cord shall
be dried so that it may be free of residual solvent.

3.6.1.2 Pretreatment. Textiles may be treated prior to fabrication into cable or cord,
provided that the textile is not subsequently covered by insulation or a jacket of natural or
synthetic rubber, or plastic, which is applied with the use of heat.

3.6.2 Length of cable assembly. The length of the required cable assembly shall be as
specified in the applicable drawing, specification, or contract (see 6.2). The length of the cable
assembly as specified should be sufficient to allow for field repairs at each connector or stub end
if intended use and storage conditions permit.

3.6.2.1 Cable assembly length tolerance. The tolerance of the overall length of the cable
assembly shall be in accordance with table II. Other desired or critical tolerances for specific
applications shall be as noted on the applicable drawing, specification, or contract (see 6.2).

TABLE II. Cable assembly length tolerances.

Range of minimum cable lengths 1, 2 Standard tolerance
Less than 12 +0.25
12 to 23.875 +1.0
24 to 35.875 +1.5
36 to 53.875 +2.0
54 to 71.875 +2.5
72 to 150 +3.0
Greater than 150 +2 percent
1
The length of a cable assembly is defined as the overall length, including terminations.
2
Unless otherwise specified, all values are in inches.

3.7 Electrical requirements.

3.7.1 Continuity. Each circuit shall be continuous within the assembly, when tested as
specified in 4.4.1.

3.7.2 Insulation resistance. The insulation resistance of the cable assembly shall be a
minimum of 100 megohms when tested as specified in 4.4.2, except the insulation resistance of a
shielded conductor shall be a minimum of 30 megohms.

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3.7.3 Dielectric withstanding voltage. There shall be no evidence of voltage breakdown

when tested as specified in 4.4.3.

3.7.4 Contact resistance variation (applicable only to assemblies using tinsel conductors).
The contact resistance variation of each terminal and the tinsel conductor shall not exceed 0.06
ohm when tested as specified in 4.4.4.

3.8 Mechanical requirements.

3.8.1 Interchangeability. Connectors shall be tested as specified in 4.5.1. Like units,

assemblies, and subassemblies shall be physically and functionally interchangeable, without
modification. Individual items shall not be handpicked for fit.

3.8.2 Soldering. MIL-HDBK-454, guideline 5, provides guidance on soldering of

electrical connections. All soldered electrical connections shall be tested in accordance with
4.5.2.

3.8.3 Pull. After being subjected to the test specified in paragraph 4.5.3, the cable
assembly shall show no straining of individual conductors (when visible without major
disassembly) or physical damage, and shall meet the requirements of 3.7.1, 3.7.2, 3.7.3, and 3.8.5.
The pull shall be applied gradually to the required force and held at that force for 30 seconds.

3.8.4 Pull on connector components. Terminals and taper pins shall not pull off of the
conductor ends or out of connectors when subjected to the test specified in 4.5.4.

3.8.5 Immersion (cable assemblies with watertight connectors and splices covered with
molded rubber or shrinkable tubing). Cable assemblies shall be subjected to the test specified in
4.5.5. There shall be no evidence of moisture penetration into the connector, splice, or molded
sections. The tested cable assemblies shall meet the requirements of insulation resistance
(see 3.7.2).

3.8.6 Durability. Connectors that must be assembled to given dimensions, and that must
be potted or molded in accordance with the information contained on the cable assembly drawing,
shall be subjected to the durability test specified in 4.5.6. Following the test, and while still
mated, the connectors shall meet the electrical requirements of 3.7. In addition, there shall be no
physical damage, and the force required to unmate the connectors shall be within 10 percent of
that measured prior to performing the durability test (see 6.6).

3.9 Service conditions.

3.9.1 Grind test (cables assemblies with molded or potted components only). After
grinding as specified in 4.6.1, molded and potted components of the cable assembly shall show no
voids or pits when viewed with 3X magnification.

3.9.2 Low temperature flex-life (cable assemblies with added transition). Each portion of
a cable assembly containing a splice, crotch, or cable to jacket transition, shall be tested as
specified in 4.6.2. Upon examination after test, there shall be no visible cracks, separation of the

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bond, or other damage in the molded section or adjacent portion of the cable jacket. Following
the test, the cable assembly shall meet the requirements of 3.7.1, 3.7.2, and 3.7.3.

3.9.3 Thermal shock. After being subjected to the test specified in 4.6.3, the assembly
shall not exhibit any physical damage. Following the test, the cable assembly shall meet the
requirements of 3.7.1, 3.7.2, and 3.7.3.

3.9.4 Moisture resistance (cable assemblies with watertight connectors). After testing as
specified in 4.6.4, there shall be no visual evidence of blistering, corrosion, or exposure of the
base metal of the connector, degradation of elastomers or separation of bonded materials.
Following the test, the cable assemblies shall meet the requirements of 3.7.2.

3.9.5 Conductor insulation overcure (molded or heat-cured potted cable assemblies only).
The same assembly that has met the requirements of 3.9.3 shall be tested as specified in 4.6.5.
The insulation of each conductor within any portion of the cable jacket encased by a molded
crotch, molded termination, or molded section shall be tested for overcure. The percent
elongation shall be not less than 90 percent of the minimum unaged elongation requirement of the
appropriate Government-approved material specification as tested in accordance with method
3031.1 of FED-STD-228.

3.9.6 Bend relief flexibility (flexible molded cable assemblies with bend reliefs only).
The cable assembly shall be subjected to the test specified in 4.6.6. There shall be no bond
separation or cracking between the bend relief and the cable jacket, connector housing, or back
shell. The assemblies shall meet the requirements of 3.7.1, 3.7.2, and 3.7.3 (see 6.5.2).

3.9.7 Vibration. The cable assembly shall be tested as specified in 4.6.7. There shall be
no evidence of bond separation at the cable jacket or connector, nor loosening of component parts
or other mechanical fastening device from the mating receptacle. Following the test, the cable
assembly shall meet the requirements of 3.7.1, 3.7.2, and 3.7.3.

3.9.8 Ozone resistance (molded rubber only). Cable assemblies with molded rubber shall
be tested for ozone resistance as specified in 4.6.8. At the completion of the exposure period,
there shall be no evidence of cracking in the bend relief or cable jacket when examined under
7X magnification.

3.9.9 Cable re-verification. The test shall be performed on cable manufactured 12 months
prior to the date of shipment of the cable assembly to the government, and the test specimen shall
meet the unaged elongation requirements listed in the applicable Government-approved material
specification selected by the manufacturer. The cable shall be tested in accordance with 4.6.9,
except that benchmarks shall be 2 inches apart, flat, and smooth steel grips of the self-aligning
type may be used. The elongation after aging shall be based on the benchmarks applied before
aging.

3.9.10 Durometer hardness. The durometer hardness Shore "A" of a molded termination
and other molded sections shall be measured as specified in 4.6.10 and shall be not less than
50 Shore "A" durometer or as specified on the drawing or in the contract (see 6.2).

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3.9.11 Reversion (polyurethane and polyacrylic compounds only). Polyurethane and

polyacrylic molding, potting, insulating, or jacketing compounds used on cable assemblies shall
be subjected to the test specified in 4.6.11 and as a result of the test the material shall not crack,
run, drip, or deform, and the hardness after conditioning shall be no more than 10 points below
the durometer hardness Shore "A" measured in 4.6.10. Except that for polyurethane compounds
cured with non-carcinogenic agents, the change shall be no more than 15 points.

3.10 Workmanship. Cable assemblies shall be manufactured in such a manner as to be

uniform in quality and shall be free from defects that will affect life or serviceability when tested
as specified in 4.7.

3.11 Recycled, recovered, environmentally preferable, or biobased materials. Recycled,

recovered, environmentally preferable, or biobased materials should be used to the maximum
extent possible, provided that the material meets or exceeds the operational and maintenance
requirements, and promotes economically advantageous life cycle costs.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are

classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3).

4.2 First article inspection. First article inspection, when specified, shall be performed by
the contractor, after award of contract, and prior to production, at a location acceptable to the
government (see 6.3). First article inspection shall be performed on sample units that have been
produced with equipment and procedures to be used in production (see 3.2).

4.2.1 Materials inspection. Material inspection shall consist of the tests in table III and
any other tests required. Other material inspections not in table III shall consist of test data
certification by the contractor that the materials meet the drawings and other procurement
documents for the cable assembly, as applicable (see 6.2).

TABLE III. Material inspection requirements.

Test requirement Requirement paragraph Test method paragraph
Cable re-verification 3.9.9 4.6.9
Durometer hardness 3.9.10 4.6.10
Material reversion 3.9.11 4.6.11

4.2.1.1 Sampling.

4.2.1.1.1 Cable re-verification. A specimen shall be selected from every length of bulk
cable to be used in the manufacture of the assemblies, except for pre-cut cable lengths which shall
have specimens selected on a sampling basis with an acceptance quality limit (AQL) as specified
in the contract (see 6.2).

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4.2.1.1.2 Other tests. Unless otherwise specified, the AQL for all other material
inspections shall be as specified in the contract (see 6.2).

4.2.2 Sample size. Fifteen sample units shall be submitted for first article inspection,
unless an alternate quantity is specified in the contract or order (see 6.2).

4.2.3 Testing routine. All of the first article samples shall be subjected to groups A and B
inspection. In addition, samples shall be taken for testing as shown in table IV.

TABLE IV. First article inspection requirements.

Number of
Requirement Test test
Test requirement paragraph paragraph samples
Moisture resistance 3.9.4 4.6.4 2
Ozone resistance 3.9.8 4.6.8 2
Grind 3.9.1 4.6.1
11
Conductor insulation overcure 3.9.5 4.6.5
Thermal shock 3.9.3 4.6.3
Low temperature flex-life 3.9.2 4.6.2
Vibration 3.9.7 4.6.7 42
Bend relief flexibility 3.9.6 4.6.6
Durability 3.8.6 4.5.6
1
Grind and conductor insulation overcure tests to be performed on the same sample.
2
Thermal shock, low temperature flex-life, vibration, bend relief flexibility, and durability
tests to be performed on the same four samples in the sequence shown.

All samples shall be selected at random for each test. The balance of untested samples shall be
held in reserve and may be substituted for samples that fail. The substituted sample must be
subjected to all of the tests where more than one test is being performed. Reason for the
substitution must be fully documented and explained in the test report. The cause for failure and
subsequent meeting of requirements will be considered as part of the overall review of the test
report and its acceptance or rejection (see 6.3).

4.2.4 Preconditioning. The contractor shall be permitted to precondition the cable

assemblies prior to performing any electrical tests. The preconditioning shall consist of removing
surface moisture from the assemblies by wiping, drying, or blowing. As an alternate, a 24-hour
waiting period in an ambient room temperature is permitted.

4.3 Conformance inspection.

4.3.1 Inspection of product for delivery. Inspection of product for delivery shall consist
of group A, B, and C inspections except as otherwise indicated.

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4.3.1.1 Inspection lot. An inspection lot shall consist of cable assemblies covered by the
drawing or procurement document employing the same type and size of connector, the same type
and size of cable, and the same materials and methods of assembly, produced under essentially
the same conditions, and offered for inspection at one time.

4.3.1.2 Unit of product. The unit of product, for purposes of sampling, shall be each
cable assembly as specified in the contract or order (see 6.2).

4.3.1.3 Sample. The sample consists of one or more units of product drawn from a lot,
the units of the sample being selected at random without regard to their quality. The number of
units of product in the sample is the sample size.

4.3.1.4 Specimen. A specimen may be one unit of product or any portion of the unit of
product that is to be subjected to inspection.

4.3.1.5 Rejected lots. If an inspection lot is rejected after group A or group B inspection,
the contractor may withdraw the lot, rework it to correct the defects, or screen out the defective
units, as applicable, and reinspect. Such lots shall be separate from new lots, and shall be clearly
identified as reinspected lots. Resubmitted lots shall be inspected using tightened inspection.

4.3.2 Group A inspection. Group A inspection shall be performed in the order specified
in table V.

TABLE V. Group A inspection.

Requirement Test method
Test requirement paragraph paragraph
Subgroup I
Visual and mechanical (end item) 3.1, 3.3, 3.4, 3.6, 3.10 4.7
Visual (solder inspection) 3.8.2 4.5.2
Subgroup II - Electrical
Continuity 3.7.1 4.4.1
Insulation resistance 3.7.2 4.4.2
Dielectric withstanding voltage 3.7.3 4.4.3
Subgroup III - Mechanical
Pull 3.8.3 4.5.3
Pull on connector components 3.8.4 4.5.4
Immersion 3.8.5 4.5.5

4.3.2.1 Major and minor defects. Major and minor defects shall be as defined in table VI
and in the applicable parts of MIL-STD-252. Sampling shall be in accordance with ASQ Z1.4;
the AQL shall be as specified in the contract (see 6.2). This listing should not be construed as
being all-inclusive. Criteria for sample unit major-minor defect rates shall be as specified in the
contract (see 6.2).

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TABLE VI. Major and minor defects.

Major Defect
100 Dimensions not as specified.
101 Material not as specified.
102 Scratches, cuts, and abrasions exposing conductors or conductor insulation.
103 Scratches, cuts, and abrasions, etc., exposing base metal.
104 Conductor or cable jackets showing through a molded surface.
105 Voids in the surface of the molded termination or section caused by insufficient filling.
106 Broken bond.
107 Incomplete bonding.
108 Electrical failure.
109 Missing parts.
110 Staycord not tied and secured in insert.
Minor Defect
200 Scratches and abrasions of the molded termination or molded section.
201 Markings are dirty, smudged, or incorrectly placed, but legible.

4.3.2.2 Sampling plan. For the samples, the inspection level shall be level II in
accordance with ASQ Z1.4. The AQL shall be as specified in the contract (see 6.2).

4.3.2.2.1 Rejection of sample units. If a sample unit is rejected because it failed the
electrical tests specified in subgroup II, the contractor may withdraw the sample unit and rework
it to correct the defects. These units shall then be subjected to the inspection tests.

4.3.2.3 Disposition of sample units. Sample units that have passed group A inspection are
deliverable on the contract or order.

4.3.3 Group B inspection. Group B inspection, including sampling, shall conform to

table VII and to the procedures for small-sample inspection levels. Group B inspection shall be
performed on inspection lots that have passed group A inspection and on specimens selected from
units of product that have been subjected to and met the group A inspection. The special
inspection level shall be S-2.

TABLE VII. Group B inspection.

Requirement Test method
Test requirement paragraph paragraph
Contact resistance variation 1 3.7.4 4.4.4
Interchangeability 3.8.1 4.5.1
1
This sampling may be performed by fabricating specimens of terminals attached to tinsel conductors,
provided the samples are prepared in the same manner using the same materials as in the cable assemblies
being subjected to group B inspection. The number of samples (terminals attached to tinsel conductors)
shall be predicated on the sample size selected for group B inspection multiplied by the number of
conductors within the cable assembly.

4.3.3.1 Disposition of sample units. Sample units that have passed group B inspection
may be delivered on the contract or order.

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4.3.4 Group C inspection. This inspection shall consist of the tests specified in
tables VIII, IX, and X and shall be performed on sample units that have been subjected to and met
group A and B inspections. Sample units shall be selected at random without regard to their
quality. Sample units may be subjected to grand lot group C testing as explained in 6.4. A
declaration of participation in grand lot testing must be made prior to submission of samples for
group C inspection. If grand lot testing is not utilized, samples shall be selected from first units
produced at the start of production on each contract. Delivery of cable assemblies that have
passed group A and B inspection shall not be delayed pending results of group C inspection.

TABLE VIII. Group C-1 inspection.

Requirement Test method Number of test
Test requirement paragraph paragraph samples
Durability 3.8.6 4.5.6 2 units

TABLE IX. Group C-2 inspection.

Requirement Test method Number of test
Test requirement paragraph paragraph samples
Grind test 3.9.1 4.6.1 1 unit
Conductor insulation overcure 3.9.5 4.6.5 1 unit
*
Bend relief flexibility 3.9.6 4.6.6 1 unit
*
Vibration 3.9.7 4.6.7 1 unit
*
Ozone resistance 3.9.8 4.6.8 1 unit
* See 4.3.4.4.

TABLE X. Group C-3 inspection.

Requirement Test method Number of test
Test requirement paragraph paragraph samples
Low temperature flex-life 3.9.2 4.6.2 1 unit
*
Thermal shock 3.9.3 4.6.3 1 unit
*
Moisture resistance 3.9.4 4.6.4 2 units
* See 4.3.4.4.

4.3.4.1 Group C-1 inspection. This inspection shall consist of the test specified in
table VIII and shall be performed every 1000 units or periodically, as specified in the contract
(see 6.2), whichever comes first.

4.3.4.2 Group C-2 inspection. This inspection shall consist of the tests specified in
table IX and shall be performed every 6000 units or periodically, as specified in the contract
(see 6.2), whichever comes first.

4.3.4.3 Group C-3 inspection. This inspection shall consist of the tests specified in
table X and shall be performed every 12,000 units or periodically, as specified in the contract
(see 6.2), whichever comes first.

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4.3.4.4 Disposition of samples. Sample units that have been subjected to group C
inspection shall not be delivered on contract or order, except those units that have undergone tests
as indicated by an asterisk (*) in tables IX and X. These units may be delivered on contract or
order provided they have been reconditioned and are subjected to, and meet the requirements of,
group A inspection.

4.4 Electrical tests.

4.4.1 Continuity. Each circuit of each assembly shall be tested for continuity and correct
connections between its terminations, using a potential of not more than 10 volts. A suitable
indicator or automatic continuity tester may be used. The cable assemblies shall meet the
requirements of 3.7.1.

4.4.2 Insulation resistance. Insulation resistance shall be measured in accordance with

MIL-STD-202-302, test condition A. The insulation resistance shall be measured between each
conductor and the remaining conductors connected together to shielding and metal shell, when
present. The cable assemblies shall meet the requirements of 3.7.2.

4.4.3 Dielectric withstanding voltage. Dielectric withstanding voltage testing shall be

performed in accordance with MIL-STD-202-301. A potential of 1000 ±10 volts direct current
shall be applied for one minute when performed manually. The potential shall be applied
between each conductor and the remaining conductors connected together to shielding and metal
shell, when present. The cable assemblies shall meet the requirements of 3.7.3. This test shall be
performed only once on units to be furnished on contract. This test may be performed during
final inspection.

4.4.4 Contact resistance variation (assemblies using tinsel conductors only). Each
terminal shall be clamped so that it cannot move and the conductor shall be bent at the point of
attachment to the terminal so that it is moved 90 degrees to each side of the axial position for a
total excursion of 180 degrees. The stressing shall be done in two mutually perpendicular planes.
The resistance variation shall be measured with a bridge or by the use of an electronic voltmeter
to measure the voltage variation, with a current of 0.30 to 0.50 ampere flowing through the
conductors and mated connectors. Contact resistance variation shall meet the requirements of
3.7.4.

4.5 Mechanical tests.

4.5.1 Interchangeability. Contact locations and interfacial dimensions of the connector as

specified in the applicable connector specification or drawing, shall be measured. Gages, when
specified in the drawing or contract (see 6.2), shall be used to determine conformance to the
physical and functional interchangeability requirements. Gaging may be performed prior to
assembly provided assembly of the connector components will not cause a dimensional change to
the connector. Acceptance shall be in accordance with the requirements of 3.8.1.

4.5.2 Soldering. Soldering inspection shall be performed during the manufacturing

process using a minimum 4X magnification. All connections shall be soldered and meet the
requirements of 3.8.2.

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4.5.3 Pull test. Cable assemblies shall be subjected to a static load, which shall be applied
between the connector and cable with at least two feet of cable subjected to the load. The pull
shall be applied parallel to the axis of the cable. A static load of not less than 20 pounds shall be
applied to cable assemblies having cable of 0.5-inch diameter or less. Cable assemblies having a
cable diameter exceeding 0.5 inch and less than 0.75 inch shall be subjected to a static load of 40
pounds. Cable assemblies having cable diameters over 0.75 inch shall be subjected to a static
load of 60 pounds. The pull test shall be performed on each end terminated with a connector.
The cable assemblies shall meet the requirements of 3.8.3 following the test.

4.5.4 Pull test on connector components. Terminals crimped to tinsel conductors and
crimped sleeves inserted into a connector shall be subjected to a three-pound minimum pull.
Terminals crimped to stranded or solid conductors shall be subjected to a 12-pound pull. Taper
pins inserted into a connector shall be subjected to a 10-pound pull-out force. Tested components
shall meet the requirements of 3.8.4.

4.5.5 Immersion. The cable assemblies shall be immersed in three feet of water at room
temperature for a period of one hour. Cable assemblies with a watertight connector on one end
only and less than three feet long shall have the watertight connector immersed to a depth not less
than 75 percent of the length of the cable assembly. The cable assemblies shall meet the
requirements of 3.8.5.

4.5.6 Durability. Measure the force required to connect and disconnect the connectors
prior to and following the durability test. The connectors shall be mated and unmated to their
mating connector or like (hermaphroditic) connectors 500 times and shall meet the requirements
of 3.8.6.

4.6 Service tests.

4.6.1 Grind test. Molded and potted components shall be ground down to one inch, or
one half of the component thickness, whichever is less. Ground surfaces shall be examined for air
bubbles and other irregularities that are caused by poor molding or potting procedures or
materials. Grinding shall be performed using silicon carbide-coated abrasive sheets in accordance
with UAMA B74.18, grit size 150 to 220. An equivalent abrasive is acceptable. The assembly
shall meet the requirements of 3.9.1.

4.6.2 Low temperature flex-life. The cable assembly containing molded sections or heat-
shrunken transitions shall be aged in a circulating air oven for a minimum of 48 hours at
71 ±1 °C. The cable assembly shall then be conditioned for a minimum of 48 hours at the lower
limit of the cable operating temperature range. If not specified, the temperature shall
be -55 ±1 °C. This temperature shall be continuously recorded during conditioning and testing.
Each crotch or molded section shall be held in a mechanical device so that the portion of the cable
entering the molded section flexes when the cable is flexed. The cable shall be flexed
mechanically. Any part of a mechanical device that will be in contact with the test specimen shall
be cold-conditioned. At the end of the conditioning period, and while at the conditioning
temperature, the cable shall be flexed rapidly for 30 cycles through a 180 degree arc (±90 degrees
off cable axis). The flexing procedure shall be repeated in a plane 90 degrees to the plane of
initial flexing and parallel to the cable axis. At the conclusion of the test, the specimen shall be

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examined visually at room temperature under 3X magnification. The cable assembly shall meet
the requirements of 3.9.2.

4.6.3 Thermal shock. The cable assemblies shall be tested in accordance with MIL-STD-
202-107, test condition A, and meet the requirements of 3.9.3.

4.6.4 Moisture resistance. The cable assemblies shall be tested as specified in 3.9.4 in
accordance with MIL-STD-202-106 and meet the requirements of 3.7.1 and 3.7.2. The following
conditions shall apply:

a. Measure initial continuity (see 4.4.1) and insulation resistance (see 4.4.2).
b. Cable assemblies shall be placed in the chamber unmated and fully exposed. However,
the connectors may be placed in such a manner so as to prevent water accumulation on the contact
face of the connector.
c. Cable assemblies under test shall not be subjected to electrical loading during exposure.
d. MIL-STD-202-106: The vibration test as required in step 7 is not required.
e. MIL-STD-202-106: After completion of step 6 cycling, and prior to the opening of the
test chamber, condition the cable assemblies for 24 hours at 23 ±1 °C and 50 ±10 percent relative
humidity. Following the conditioning period, the cable assemblies shall meet the requirements of
3.9.4.

4.6.5 Conductor insulation overcure. The insulated conductor shall be removed from that
section of cable that has been subjected to heat through molding or heat-cured potting. The
insulation with conductors removed shall be of a sufficient length to permit testing per
method 3031.1 of FED-STD-228. The conductor insulation shall meet the requirements of 3.9.5.

4.6.6 Bend relief flexibility. Each bend relief in the cable assembly shall be manually
subjected to 500 continuous flexure cycles, at room temperature, through a 180-degree arc, at
approximately 30 cycles per minute. The connector shall be held in place so that the bend relief is
free to flex with the cable in one direction through 90 degrees from the axially in-line starting
position, back to the starting position, then through 90 degrees in the opposite direction, and
return to the starting position. Following this test, the cable assembly shall meet the requirements
of 3.9.6.

4.6.7 Vibration. The assembly shall be tested as specified in MIL-STD-202-201.

Following this test, the assemblies shall meet the requirements of 3.9.7. The following details and
exceptions shall apply:

a. Approved mating receptacles shall be rigidly mounted and the cable assembly
connectors mated with the connector-cable axis in the vertical plane.
b. Resonance-free mounting in accordance with MIL-STD-202-201 is not applicable.
c. Test and measurements during vibration are not required.

4.6.8 Ozone resistance. The ozone resistance pre-conditioning, ozone concentration,

temperature, and any other chamber conditions shall be the same as specified for the bend relief
elastomer (rubber) and cable jacket. If no ozone resistance test is specified for the bend relief
elastomer, the ozone resistance test shall be the same as specified for the cable jacket material.
The bend relief and adjacent section of cable shall be so constrained that the bend relief is curved
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in a 90-degree arc while in the ozone chamber. The assembly shall meet the requirements of
3.9.8.

4.6.9 Cable re-verification. The elongation test for cable re-verification shall be in
accordance with method 3031.1 of FED-STD-228, and meet the requirements of 3.9.9.

4.6.10 Durometer hardness. Durometer hardness shall be measured in accordance with

method 3021 of FED-STD-601. The tolerance shall be ±5. Durometer hardness shall be as
specified on the applicable drawings and shall meet the requirements of 3.9.10.

4.6.11 Material reversion. The molding, potting, insulating, and jacketing material shall
be tested using specimens approximately 4 inches square by 0.125 inch thick for durometer
hardness Shore "A" testing (see 4.2.1.1.2). Then, they shall be placed in a chamber maintained at
100 ±1 °C and 95 ±2 percent relative humidity without condensation for 28 days. The specimens
shall be so arranged that they do not come into contact with each other or with the chamber walls
or floor. After conditioning, the specimens shall be tested in accordance with 3.9.11.

4.7 Visual and mechanical examination. The cable assemblies shall be examined for the
defects listed in 4.3.2.1, and to verify that the materials, design, construction, physical
dimensions, marking, and workmanship are in accordance with paragraphs 3.1, 3.3, 3.4, 3.5, 3.6,
and 3.10.

5. PACKAGING

5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified
in the contract or order (see 6.2). When packaging of materiel is to be performed by DoD or in-
house contractor personnel, these personnel need to contact the responsible packaging activity to
ascertain packaging requirements. Packaging requirements are maintained by the Inventory
Control Point's packaging activities within the Military Service or Defense Agency, or within the
military service's system commands. Packaging data retrieval is available from the managing
Military Department's or Defense Agency's automated packaging files, CD-ROM products, or by
contacting the responsible packaging activity.

6. NOTES

(This section contains information of a general or explanatory nature that may be helpful,
but is not mandatory.)

6.1 Intended use. The cable assemblies covered by this specification are intended for use
in electronic, communication, and associated electrical equipment.

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of this specification.

b. Quantity of cable assemblies required.
c. Detail specification, specification sheet, or drawing (see 3.1).
d. First article inspection, if required (see 3.2).
e. Cable assembly marking requirements, if different from those specified (see 3.4).
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f. Type of connectors required (see 3.5)

g. Length of cable assembly (see 3.6.2).
h. Cable assembly tolerances, if different from those specified (see 3.6.2.1).
i. Durometer hardness testing, if required (see 3.9.10).
j. Materials inspection, if different from that specified (see 4.2.1).
k. First article inspection sample size, if different from that specified (see 4.2.2).
l. AQL (see 4.2.1.1.1, 4.2.1.1.2, 4.3.2.1, 4.3.2.2).
m. Unit of product, if different from that specified (see 4.3.1.2).
n. Major-minor defect rates (see 4.3.2.1).
o. Group C lot sampling schedule for conformance testing, if required (see 4.3.4.1,
4.3.4.2, and 4.3.4.3).
p. Gages for interchangeability testing, if required (see 4.5.1).
q. Packaging requirements (see 5.1).

6.3 First article inspection. Information pertaining to first article inspection of cable
assemblies covered by this specification should be obtained from the procuring activity for the
specific contracts involved (see 3.2).

6.4 Grand lot testing. Grand lot, group C inspection is a means of eliminating costly and
repetitive testing of cable assemblies on multiple contracts that use the same type of connectors and
cable and are assembled in essentially the same manner.

a. Each cable assembly factory having two or more contracts for cable assemblies meeting
the above criteria may qualify for grand lot testing by submitting samples from current production
for the tests specified in the group C tables.
b. Potted and molded cable assemblies may be subject to grand lot inspection when multiple
contracts exist for the same cable assembly type, regardless of length. These assemblies should not
be grouped with any other grand lot testing.
c. Samples submitted for each grand lot, group C inspection will be of one type. For
example, sample units employing the same type of connectors and cable for each assembly. Sample
units should be selected at random from one contract.
d. Grand lot, group C testing will be performed on a calendar basis as specified in 4.3.4.1,
4.3.4.2, 4.3.4.3, and 6.2.

6.5 Definitions.

6.5.1 Cable assemblies and cord assemblies. Cable assemblies and cord assemblies are
procurement items consisting of definite lengths of finished cable or cord, respectively, and having
processed terminations at one or both ends (see 1.1).

6.5.2 Bend relief. A bend relief (flex-relief) is a device (e.g., tube, spiral, cone, or boot)
placed around a cable (after the cable is manufactured), or a portion of a cable, to prevent a sharp
radius of curvature when the cable is bent or flexed. The bend relief may not necessarily be secured
(molded or bonded) to the cable jacket, but it is secured (molded, bonded, clamped) to the device
(connector, equipment or component housing, or splice) (see 3.9.6).

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6.5.3 Potted termination. A potted termination is one in which an insulating material

encloses the terminated conductors, filling all voids inside the back end of the connector or
equipment housing.

6.5.4 Molded termination. A molded termination is one which has a bend relief or strain-
relief bonded to the connector or equipment housing and to the cable jacket. The termination may be
a one-step operation of potting or molding a material around the connector pins and terminated wires
and over the connector and cable; or a two-step operation in which the back end of the connector and
the wires are first potted and then the bend relief or flex-relief is molded over the connector and
cable.

NOTE: The term "equipment" as used above includes any device in a housing molded to the cable
jacket.

6.5.5 Premolded boot. A premolded boot is normally a nylon or rubber device molded to a
fixed shape to fit a given-sized connector. The boot is slipped over the cable, the cable is installed in
the connector, and the boot is slipped over the connector-cable interface and attached to the
connector with an adhesive or a metal ring.

6.5.6 Transition. A transition is a device that provides a watertight covering to a cable

splice, crotch or cable termination-to-connector housing.

6.6 Connector durability. In some types of molded terminations, the connector shell
surrounds only the insulator and front end of the pins. The coupling mechanism for mating
connectors cannot be assembled until the cable and nosepiece are wired and the termination molded.
Therefore, some tests, which are usually included in connector specifications, cannot be performed
until the cable termination is completed (see 3.8.6).

6.7 Subject term (key word) listing.

Audio
Bend relief
Connector
Data
Insulation
Interconnect
Interconnecting
Jacket
Molded termination
Patch
Potted termination
Pre-molded
Pull test
Teletype
Termination

6.8 Changes from previous issue. Marginal notations are not used in this revision to
identify changes with respect to the previous issue due to the extent of the changes.
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Custodians: Preparing Activity:

Army - CR DLA - GS8
Navy - EC
Air Force - 85 (Project 5995-2016-001)
DLA - GS

Review Activities:
Army - AR, AT, CR4, EA, MI
Navy - AS, MC, OS
Air Force - 19, 99

NOTE: The activities listed above were interested in this document as of the date of this
document. Since organizations and responsibilities can change, you should verify the currency of
the information above using the ASSIST Online database at https://assist.dla.mil/.

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