MIL-PRF-62540A(AT)
is not less than 91.44 cm (36 in.) long and an overlap of not less than 5 cm (2 in.) is maintained.
All joints including overlaps, shall be sealed watertight using adhesive specified on the applicable
harness or cable assembly drawing or commercial equivalent (see 4.6.1 and 4.6.2).
3.3.4.4 Harness transitions. The harness transitions shall be positioned only after the
harness jacketing has been installed over the individual branches (see figures 2 and 4). All
transitions shall be watertight and free of cracks, splits, or abrasions. The transition shall withstand
a horizontal load of not less than 90.7 kilograms (kg) (200 pounds (lbs)) without damage. The
transition shall provide for internal accessibility to permit cable repair. Transition reassembly shall
be performed without the aid of adhesives. When optional material is specified, only one option
shall be used on any individual harness assembly. The existence of a heat shrinkable transition and
a heat sealable tape transition on the same assembly is unacceptable (see 4.6.2 and 4.6.3).
3.3.4.4.1 Heat shrinkable transition. All heat shrinkable transition entries shall be sealed
with the adhesive specified on the applicable harness or cable assembly drawing or commercial
equivalent (see 4.6.2).
3.3.4.4.2 Heat sealable tape transition. The heat sealable tape transitions shall be
constructed of not less than two layers of tape at all locations (see 4.6.2).
3.3.5 Pull strength. The harness and cable assemblies shall meet the requirements of 3.4.1
and 3.4.2 after being subjected to a force of 445 Newton ( N) (100 lbs) applied along the cable axis
between the cable terminations for 30 seconds (sec) (see 4.6.4).
3.3.6 Bend radius. The natural bend radius of harness and cable assemblies under
91.44 cm (3 feet (ft)) in length shall not stress the internal wires when a 2.26 kg(5 lbs) load is
applied to the free end of the assembly (see 4.6.5).
3.3.7 Connector assembly.
3.3.7.1 Crimping.
3.3.7.1.1 Connector contacts. The crimp type connector contacts shall be crimped in
accordance with the manufacturer's standard crimping procedures. The acceptable crimp tensile
strength shall be not less than 249.8 (kg) (550 lbs) axial load when measured as specified in 4.6.6.
3.3.7.2 Unused contact locations. All unused connector contact locations shall be filled
with contacts and all unused grommet feed through holes shall be plugged (see 4.6.2).
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