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Vehicle Systems

Cable USA is a leading ITAR Registered manufacturer of rugged military cable and coil cords designed to perform in the most severe battle conditions. Our tactical-assured products can be found supporting nearly all ground vehicle platforms ranging from Intercom Systems to GPS Tracking.  In addition to voice transmission, our communication cables have evolved to include internet protocol (IP) based components that offer systems a level of situational awareness never before seen on vehicle systems. We provide support to NBC compliance, Tactical Displays, ANR Communications, WIN-T Battle-Ready Networking, Infrared Cameras to name a few.  Our ability to manufacture rugged military cable as small as #40 using high performance insulation helps our customers meet their size and weight requirements while staying combat ready.  With extensive knowledge of cable installation and routing we can design the shape of the cable to meet your requirement.

Vehicular Intercom System (VIS) Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable Vehicle Systems

Vehicular Intercom Systems (VIS)

Cable USA has developed a family of rugged military cable and coil cords that offer a complete capability across a wide spectrum of requirements that support Vehicular Intercom Systems (VIS) and Next-Generation Digital Intercom Systems.  We manufacture radio remote control, radio power, backbone / highway, loudspeaker, alarm, bailout and bailout extension cables.  We can incorporate power, data, and audio into single fully rugged military cable or cord with our hybrid cabling and shielding technologies.  Our products are found on numerous platforms ranging from light vehicles, to heavy armor and mobile command centers around the world.

  • Supports Push-To-Talk (PTT), Voice-Operated Transmitter (VOX), Live Mic, Active Noise Reduction(ANR) and Emergency override
  • Hybrid PWR + Data Constructions to support C4ISR
  • Ruggedized against EMI / RFI
  • Nuclear, Biological, and Chemical (NBC) Compliant
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
  • Ruggedized CAN-BUS, RS-232, RS-422, USB, HDMI, and Ethernet constructions available

Typical Applications:

  • Wideband Tactical Radio
  • UHF Soldier Radio
  • High Frequency Radio
  • Wideband Networking Radio
  • Handheld Multiband Radio
  • Multiband Tactical Handheld Radio
  • High Frequency Manpack Radio
  • Tactical Network Access Hub
  • Tactical Video Processor
  • Broadband Global Area Network (BGAN)
  • High Frequency Tactical Radio
  • International Handheld Radio
  • Multiband Networking Radio (MBNR)
  • Mobile Computing Platform
  • Secure Personal Radio
  • Situational Awareness Video Receiver (SAVR)
  • VHF Combat Net Radio (CNR)
  • High Capacity Line-of-Sight (HCLOS) Radio
  • Multi-Channel Manpack Radio
  • Mid-Tier Networking Vehicular Radio
  • Wideband Team Radio
  • Soldier Personal Radio
  • Multiband Combat Net Radio (CNR)

Typical Cable Design:

  • PPP Data Cable
  • Remote Control Cable
  • Synchronous Data Cable
  • KDU Cable and KDU Extension Cable
  • 24V AC/DC Battery Eliminator
  • Ruggedized Ethernet
  • Micro Miniature Cable
  • Micro Patch
  • Micro USB
  • Extended Length USB
  • RS-232
  • HDMI
  • CAN-BUS
  • Micro CAN-BUS
  • Digital Retransmission
  • RS-232 + Ethernet
  • Break-out/Extension
  • GPS + Remote Control + Ethernet + RS-232
  • Dual Wire, Ethernet + USB + RS-232
  • Remote Control Console
  • RS-232 + LAN + Remote Control
  • Voice + RS-232 + Ethernet
  • Ethernet + RS-232 + Remote Control + Voice
  • Triple Wire w/Voice + Remote Control + RS-232 + Ethernet
  • Vehicle Mount RS-232 + Remote Control + Ethernet
  • RS-232 + Ethernet + Remote Control + RS-232
  • Data + Console
  • RS-232 + Console
  • Voice + Data
  • Data + Remote Control
  • HPW Cable
  • GPS Data Cable (PLGR and DAGR)
  • USB Programming Cable
  • Battery Extension Cable
  • Dual Battery PWR
  • Dual Radio Battery Eliminator
  • Battery Eliminator

Vehicle Vision Systems

With proven technologies for situational awareness and vision enhancement Cable USA rugged military cable products provides a one-stop shop to outfit vehicles with reliable EO/IR systems for the harshest environments. Cable USA imaging products can be routed virtually anywhere in any vehicle, helping provide visual confirmation of the area immediately surrounding the vehicle, which provides the critical advantage to both drivers and observer.

Vehicular Vision System Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable Vehicle Systems

  • Variety of Sizes for Data Transmission Line
  • Ruggedized against EMI / RFI
  • Available with USB 2.0 or 3.0
  • Available with OTG Sense line
  • Available with Cat 5 or 6Crush and Cut Resistant TPE Jacket
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Multi-USB cables or Hybrid with other data type
  • Coil Cord Designs Available
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow

Ruggedized USB

USB is a very popular protocol on many military programs. Using off the shelf USB is dangerous to both your design and the soldier because combat environments can include impacts or excessive pull force that would damage or destroy the sensitive construction of the standard cables.  Our rugged military cables feature an external TPE crush resistant jacket over high strength insulations and conductors and bonded strength members.  USB designs can be ordered as 2.0, 3.0 and OTG.  We offer a variety of power wire sizes to meet your requirements.

  • Variety of Sizes for Data Transmission Line
  • Variety of Sizes for Power Transmission Line
  • Ruggedized against EMI / RFI
  • Available as USB 2.0 or 3.0
  • Available with OTG Sense line
  • Crush and Cut Resistant TPE Jacket
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Multi-USB cables or Hybrid with other data type
  • Coil Cord Designs Available
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
Rugged Ethernet and Backbone Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable Rugged Networking Cable

Ruggedized Ethernet Backbone

Cable USA manufactures rugged military cable compliant to CAT 5, 5e and 6 standards.  Our Micro Patch line is designed around the SWAP-C initiative and is widely used for soldier-worn applications or where routing is a concern.  We offer numerous bundle and breakout designs that can serve as the backbone to your network.

  • Low Skew and Propagation delay
  • Extended Bandwidth (increased headroom)
  • Gigabit Ethernet (1000Base-t)
  • Excellent cross-talk characteristics
  • Solid or Stranded conductors
  • BC, TPC, SPC and High Strength alloys
  • #23, #24, #26, #28  and Micro Patch constructions available
  • Polyolefin(Riser) or Fluoropolymer(Plenum) insulation
  • Cross Web Separator
  • Color Code Per TIA-568-C.2
  • Double and Triple Threat Shield designs
  • Crush and Cut Resistant TPE Jacket
  • Extra Rugged – Dual Jacket Options Available
  • Halogen-free and Low Smoke, Zero Halogen constructions available
  • PoE Type Hybrid PWR + Data Designs allowing more than 48VDC (Sim. To IEEE 802.3af)
  • Multi-Bundle, Breakout, Retractable and Coil Cord Designs Available
  • Alien Cross-talk reduction in bundles
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow

Typical Applications:

  • Gigabit Ethernet (1000Base-t)
  • High Speed Voice / Data
  • 100Base-TX
  • 100Base-T
  • Multimedia
  • 55/155 Mbps ATM
  • 100Base VG-AnyLan
  • Broadband Video

Designed to Withstand These Conditions:

  • Oil, sunlight and gasoline
  • Temperature variations
  • Abrasion and crushing
  • Flexing
  • EMI/RFI

Available Compliance and Testing:

  • RoHS Compliant
  • Tested to 350 MHz
  • Electricals Per ANSI/TIA 568-C.2
  • Most constructions ETL Verified ANSI/TIA-568-C.2
  • UL Listed Type CMR
  • UL Listed Type CMP
  • c(UL) Type CMP
  • IEEE 1202
  • UL Subject 444 Communications Cables
  • NFPA 262, Plenum Flame Test
  • ICEA S-102-700
  • NEC Article 800
  • California State Fire Marshal
Hybrid Power Over Ethernet Cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable Rugged Networking Cable

Hybrid Power over Ethernet (PoE)

Our standard COTS style cable will serve the purpose for being IEEE 802.3af compliant. However, if your system requires more than 48VDC we have Hybrid POE designs that will supply your power needs while maintaining the integrity of the data transmission.

Ruggedized HDMI

Cable USA offers rugged military grade HDMI 1.3b or 1.4. Our cables are rated up to category 5 and reliably transmit a 1080p signal. Our cable is designed to support rugged tablets, laptops, computers and tactical displays.

  • Ruggedized against EMI / RFI
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Crush and Cut Resistant TPE Jackets
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow

Ruggedized DisplayPort

Cable USA manufactures standard and mini DisplayPort cables, built to DisplayPort 1.2 standard. Our cable carries a digital audio/video signal with up to 1080p signal.  Our rugged military cable is designed to support rugged tablets, laptops, computers and tactical displays.

  • Ruggedized against EMI / RFI
  • Enhanced Flex-Life
  • Bonded Strength Members
  • Crush and Cut Resistant TPE Jackets
  • Available with Low Smoke, Zero Halogen (LSZH) Jackets
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow
Mixed Media Hybrids and Composites Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable Vehicle Systems

Mixed Media Hybrids and Composites

We offer the ability to mix media components into a round or flat composite cable.

  • SWAP-C focused designs promote smaller cable OD’s by utilizing finer gauge sizes.
  • Multi-Bundle and Composite constructions include power, communication/audio and data lines under a single jacket  i.e. 2/C #12 Power, 4/PR CAT 6, 1 x USB 2.0, 1 x USB-OTG,  3 x 1/PR #26 AUDIO in one cable.
  • Ruggedized against EMI / RFI
  • Proprietary jacketing techniques to accommodate assembly method.
  • Ethernet and USB COIL CORDS and Shotgun side-by-side designs are available.
  • Standard jacketing color is Matte Black.  Desert Tan and Flat Dark Earth are regularly specified.   Other colors are available.
  • Low Skew and Propagation delay
  • Extended Bandwidth (increased headroom)
  • Gigabit Ethernet (1000Base-t)
  • Excellent cross-talk characteristics
  • Solid or Stranded conductors
  • BC, TPC, SPC and High Strength alloys
  • #23, #24, #26, #28  and Micro Patch constructions available
  • Polyolefin(Riser) or Fluoropolymer(Plenum) insulation
  • Cross Web Separator
  • Color Code Per TIA-568-C.2
  • Double and Triple Threat Shield designs
  • Crush and Cut Resistant TPE Jacket
  • Extra Rugged – Dual Jacket Options Available
  • Halogen-free and Low Smoke, Zero Halogen constructions available
  • PoE Type Hybrid PWR + Data Designs allowing more than 48VDC (Sim. To IEEE 802.3af)
  • Multi-Bundle, Breakout, Retractable and Coil Cord Designs Available
  • Alien Cross-talk reduction in bundles
  • Standard jacket colors include Matte Black, Flat Dark Earth, Desert Tan, Olive Drab, White Snow

Typical Applications:

  • Gigabit Ethernet (1000Base-t)
  • High Speed Voice / Data
  • 100Base-TX
  • 100Base-T
  • Multimedia
  • 55/155 Mbps ATM
  • 100Base VG-AnyLan
  • Broadband Video

Designed to Withstand These Conditions:

  • Oil, sunlight and gasoline
  • Temperature variations
  • Abrasion and crushing
  • Flexing
  • EMI/RFI

Available Compliance and Testing:

  • RoHS Compliant
  • Tested to 350 MHz
  • Electricals Per ANSI/TIA 568-C.2
  • Most constructions ETL Verified ANSI/TIA-568-C.2
  • UL Listed Type CMR
  • UL Listed Type CMP
  • c(UL) Type CMP
  • IEEE 1202
  • UL Subject 444 Communications Cables
  • NFPA 262, Plenum Flame Test
  • ICEA S-102-700
  • NEC Article 800
  • California State Fire Marshal
Light weight micro and miniature coax cable Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable for Soldier-Worn Systems

Micro and Miniature Coax

We offer an extensive line of micro and miniature sized coax cable to support the discrete requirements of equipment.  Our rugged military cables are used in Night Vision and Weapon Optics, Internal Flat Panel Displays, Mounted Camera’s, Test and Measurement Sensors, Internal Wiring on electronic equipment and radio frequency.

  • Small Diameter and Lightweight
  • High Speed Transmission
  • Excellent Heat Resistance and Electrical Properties
  • Excellent Mechanical Strength
  • Enhanced Flex-Life
  • Precision controlled tolerances
  • Available in sizes from #26 to 40
  • Available with Solid, Semi-Solid, and Cellular Insulations

Equivalents

We manufacture equals to other manufacturer’s part numbers and equivalents to unnecessary agency approved cables.  In most cases, we can offer both better pricing and lower minimum buy quantities.

For example:

We offer two varieties of (non-QPL) equivalents to the standard RG/U and M17 cables.

  • Cost effective cables that are electrically and dimensionally equivalent
  • Electrically equivalent that dimensionally fit your specific application

There are other options available.  Please use our “Build Your Own” form or call your local sales representative to submit your request.

Coil and Retractable Cords Manufactured by Cable USA LLC, Custom Designed High Performance Cables | Cable Markets Rugged Military Cable Vehicle Systems

Coil and Retractable Cord

We manufacture rugged military coil cords and retractile cables that support power, data and audio transmission individually or all together as a composite design.  These Military-grade cords are resistant to harsh environments and extreme temperatures all of while maintaining maximum flex-life.

Product Attributes:

  • Constructions Available up to 200°C and 1000V
  • Wide Range of gauge sizes
  • Designs can support high speed data transmission
  • Coil Body lengths available from 1” to over 60”
  • Enhanced Flex-life
  • Tangent or Axial Tails
  • Proprietary coiling procedure effectively eliminates tangle ability
  • Available with EMI / RFI protection
  • Excellent “Snap-back” characteristics
  • RoHS Compliant
  • Custom Designs

Typical Applications:

  • Handset and Headset
  • Loudspeaker
  • Audio
  • Telescoping Mast
  • Portable Power
  • Lighting
  • Radar
  • Robots

MIL-W-22759/16

MIL-W-22759/16 wires have extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Stranded Tinned Copper
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Standard Wall

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/16 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-22759/17

MIL-W-22759/17 wires have extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Silver Plated Copper Alloy
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Standard Wall – High Strength Conductor

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/17 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-22759/18

MIL-W-22759/18 wires have thin wall extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Stranded Tinned Copper
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Thin Wall

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/18 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-22759/19

MIL-W-22759/19 wires have thin wall extruded ETFE insulation for aerospace and other applications which require light weight, tight diameter tolerances, and enhanced mechanical toughness. ETFE insulation also provides exceptional resistance to radiation and chemicals.

Cable Description:

  • Conductor: Silver Plated Copper Alloy
  • Insulation: Ethylene Tetrafluoroethylene (ETFE)
  • Thin Wall – High Strength Conductor

Ratings

  • Voltage: 600 Volts
  • Temperature: 150°C (302°F)

M22759/19 Wire Identification:

  • Green or white print on the insulation
  • Military part number including AWG

MIL-W-16878/1 Type B

MIL-W-16878/1 (Type B) PVC hook up wire is suitable for internal wiring of meters, panels and electrical or electronic equipment. It is also popular for harness applications in the military and aerospace industries. It is flame and chemical resistant.

Passes UL VW-1 Flame Test

RoHS Compliant

MIL-W-16878/1 Type B Wire (M16878/1) Construction:

  • Conductor: Stranded Tinned Copper
  • Insulation: Polyvinylchloride (PVC)
  • Nominal Wall Insulation Thickness: 0.010”

MIL-W-16878/1 Type B Wire (M16878/1) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 600 Volts

MIL-W-16878/2 Type C

MIL-W-16878/2 (Type C) PVC hook up wire is suitable for internal wiring of meters, panels and electrical or electronic equipment. It is also popular for harness applications in the military and aerospace industries. It is flame and chemical resistant.

Passes UL VW-1 Flame Test

RoHS Compliant

MIL-W-16878/2 Type C Wire (M16878/2) Construction:

  • Conductor: Stranded Tinned Copper
  • Insulation: Polyvinylchloride (PVC)
  • Nominal Wall Insulation Thickness: 0.016″

MIL-W-16878/2 Type C Wire (M16878/2) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 1000 Volts

MIL-W-16878/3 Type D

MIL-W-16878/3 (Type D) PVC hook up wire is suitable for internal wiring of meters, panels and electrical or electronic equipment. It is also popular for harness applications in the military and aerospace industries. It is flame and chemical resistant.

Passes UL VW-1 Flame Test

RoHS Compliant

MIL-W-16878/3 Type D Wire (M16878/3) Construction:

  • Conductor: Stranded Tinned Copper
  • Insulation: Polyvinylchloride (PVC)
  • Nominal Wall Insulation Thickness:
    • 14-26 AWG: 0.031″
    • 2-12   AWG: 0.037″

MIL-W-16878/3 Type D Wire (M16878/3) Ratings:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 3000 Volts

MIL-W-16878/7 Type F

Low Smoke, Zero Halogen Silicone – 600 V, 200°C

M16878/7 Wire Description:

M16878/7 Wire is designed to be flame retardant and meet Navy regulations on smoke, toxicity, and acid gas. Applications include those requiring high flexibility, durability, and high temperature applications.

M16878/7 Wire Ratings and Approvals:

  • Mil Spec: M16878/7
  • Temperature Rating: 150 °C
  • Voltage Rating: 600V

NM16878/7 Wire Construction:

  • Conductor: Soft annealed silver plated copper
  • Insulation: Extruded silicone

MIL-W-16878/8 Type FF

1000 V, 200°C

M16878/8 Wire Description:

MIL-W-16878/8 has low smoke characteristics. Type FF is designed to be flame retardant and meet Navy regulations on smoke, toxicity, and acid gas. Applications include those requiring high flexibility, durability, and high temperature applications.

M16878/8 Wire Ratings and Approvals:

  • Mil Spec: MIL-W-16878/8
  • Temperature Rating: 200 °C
  • Voltage Rating: 1000V

M16878/8 Wire Construction:

  • Conductor: Silver plated copper
  • Insulation: Extruded silicone

MIL-W-16878/10

Construction:

  • Conductor: Tinned Copper
  • Insulation: Extruded Polyethylene

Ratings:

  • Max. Temperature: 75°C
  • Max. Voltage: 600 volts

MIL-W-16878/11 | NEMA HP4 Type K

Passes UL VW-1 Flame Test

MIL-W-16878/11 Wire (NEMA HP4 Type K) Description:

  • Conductor: Tinned Copper (Silver-Coated Copper also available)
  • Insulation: Extruded FEP, .010 Nominal Wall Thickness

MIL-W-16878/11 Wire (NEMA HP4 Type K) Characteristics:

  • Temperature Range: -55°C to +150°C
  • Voltage Rating: 600 Volts

MIL-W-16878/12 | NEMA HP4 Type KK

Passes UL VW-1 Flame Test

M16878/12 Wire (NEMA HP4 Type KK) Description:

  • Conductor: Tinned Copper (Silver-Coated Copper also available)
  • Insulation: Extruded FEP

M16878/12 Wire (NEMA HP4 Type KK) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 1000 Volts

MIL-W-16878/13 | NEMA HP4 Type KT

Passes UL VW-1 Flame Test

MIL-W-16878/13 Wire (NEMA HP4 Type KT) Description:

  • Conductor: Tinned Copper (Silver-Coated Copper also available)
  • Insulation: Extruded FEP, .006 Nominal Wall Thickness

MIL-W-16878/13 Wire (NEMA HP4 Type KT) Characteristics:

  • Temperature Range: -55°C to +105°C
  • Voltage Rating: 250 volts

MIL-W-16878/29 Type F

MIL-W-16878/29 Wire (M16878/29 Wire) Construction:

  • Conductor: Stranded Tinned Copper, Color Coded
  • Insulation: Extruded Silicone Rubber

MIL-W-16878/29 Wire (M16878/29 Wire) Characteristics:

  • Temperature Range: 150°C
  • Voltage Rating: 600 volts

MIL-W-16878/30 Type FF

MIL-W-16878/30 MIL Spec Wire Description:

  • Conductor: Stranded Tinned Copper, Color Coded
  • Insulation: Extruded Silicone Rubber

MIL-W-16878/30 MIL Spec Wire Characteristics:

  • Temperature Range: 150°C
  • Voltage Rating: 1,000 volts

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