Approvals and origin
At a glance
- AssembliesAssemblies
- 18 AWG to 1000 MCM
- TerminationsTerminations
- 18 AWG to 1000 MCM
- StrengthStrength
- 4/0 to 1000 MCM
- ConductorsConductors
- 1 to 3
- Class 3Workmanship
- IPC/WHMA-A-620 Class 3
- PPAPDocumentation
- PPAP levels 1 through 5
What we build
1 to 3 conductor cable assemblies. Battery, ground, starter, jumper, and jump-start. Assemblies and terminations run from 18 AWG to 1000 MCM.
Battery, ground, starter
1 to 3 conductor power and battery cable. Large-gauge is the strength.
Jumper and jump-start
Jumper battery-harness sets and SAE J1283 jump-start cables.
Built to a drawing
Your print, your ends, your length. One cable or a production run.
Terminations to 1000 MCM
Compression lugs and splices. Stud sizes #10 to 5/8 inch.
Runs start at one cable. Send your annual requirement and the quote answers it.
Terminations through 1000 MCM
Compression lugs and splices on copper conductor. UL Listed and CSA Certified to 194°F (90°C), rated for 35 kV applications. Stud sizes #10 to 5/8 inch.
What a quote needs
A drawing usually covers the first four. Quantity and date are the ones that get left out.
- Wire
- Type and gauge, or the spec it has to meet
- Terminations
- Both ends, with stud size and any angle
- Length
- Finished length, and how it is measured
- Quantity
- Per release and per year, if they differ
- Date
- When you need the first parts
- Documentation
- PPAP levels 1 through 5, first article, or none
Standard combinations can be priced in the cable configurator. The quote is for drawings, non-standard ends, and production volume.
What the program is checked on
Credentials, not adjectives. Full detail is on the quality page, including the Limited Lifetime Warranty on sealed custom cables.
IPC/WHMA-A-620 Class 3
The highest acceptance class in the cable and harness standard. Class 2 is what most shops advertise.
PPAP documentation levels 1 through 5
Available where a program requires them. Say so at quote time. A PPAP package has its own schedule.
UL assemblies
Assemblies using UL listed and recognized components and processes. Distinct from the five UL wire files.
ISO 9001 compliant processes
Processes and documentation run to ISO 9001.
Prototyping from stock typically ships in 5 to 10 days. Full production typically reaches shipment in 15 to 30 days from order. Orders under 50 assemblies ship within 10 days on average.
Frequently asked questions
Cable assemblies 18 AWG to 1000 MCM. Battery, ground, starter, jumper, and jump-start. Send a drawing.
What harnesses does Polar Wire build?
1 to 3 conductor cable assemblies: battery, ground, starter, jumper, and jump-start. Assemblies and terminations run from 18 AWG to 1000 MCM. The strength is 4/0 through 1000 MCM.
What volume can you handle?
Send your annual requirement and it comes back in the quote. Runs start at one cable. Workmanship is IPC/WHMA-A-620 Class 3. PPAP documentation levels 1 through 5 are available where a program requires them.
Is there a minimum order quantity on assemblies?
No minimum on assemblies built from a stocked construction. Custom colors or a print legend on the wire are private label, from 10,000 ft.
How fast can you go from drawing to production parts?
Prototyping from wire already in stock typically ships in 5 to 10 days. Full production typically reaches shipment in 15 to 30 days from order. Orders under 50 assemblies ship within 10 days on average. All three are averages.
What do you need from me to quote a production run?
Wire type and gauge, both terminations including stud size and any angle, finished length and how it is measured, quantity, and the date you need first parts. A drawing covers most of that. Say at quote time if you need PPAP documentation levels 1 through 5 or a first article.
Can you build to a non-standard termination?
Yes. It is quoted as tooling work. Where a stock die will not produce the section the joint needs, dies and crimp profiles are developed in-house. The crimp is proven by pull testing and micrograph analysis.
Send a drawing
Wire, both ends, length, quantity, and the date. ISO 9001 compliant processes.