Overview
Fuel system wiring runs through tank-adjacent zones where explosive-atmosphere safety and long-term fuel exposure resistance are non-negotiable design requirements.
Design & Construction
Intrinsically Safe Circuit Design
Low-energy circuit design and spark-resistant connector systems meet explosive-atmosphere safety requirements for in-tank and tank-adjacent fuel sensor wiring.
Fuel-Resistant Insulation Systems
Fluoropolymer insulation resists long-term immersion and vapor exposure to jet fuel, maintaining insulation integrity across the airframe’s service life.
Manufacturing Process
Built under AS9100D quality management with full first-article inspection and lot traceability, supporting fuel system OEMs and MRO providers on new-build and retrofit programs.
Typical Applications
- Fuel quantity sensor wiring
- Fuel pump control cabling
- Tank level indicator harnesses
- Fuel valve actuator wiring
- Refueling panel interconnects
Common installations include Fuel quantity sensor wiring, Fuel pump control cabling, and Tank level indicator harnesses, where flight-critical reliability and stringent weight optimization are the primary design drivers. The same base design can also be adapted for Fuel valve actuator wiring and Refueling panel interconnects with minor changes to connector type or cable length.
Technical Specifications
Standard configurations are available with the following technical specifications; custom configurations outside these ranges can be discussed with our engineering team. Wire Gauge: AWG 26 – 14. Conductor Count: 4 – 36 circuits. Insulation: Fluoropolymer, fuel-resistant. Temp Range: -55°C to +200°C. Safety Design: Intrinsically safe, low-energy circuits. Fluid Resistance: Jet fuel immersion and vapor rated. Connector Standard: Spark-resistant, MIL-spec.
Quality & Certification
Manufactured under AS9100D and ISO 9001 certification, with intrinsically safe circuit documentation suitable for fuel system airworthiness certification.
Customization & Lead Time
Standard lead time for the Aircraft Fuel System & Sensor Wiring Harness is 6–8 weeks prototype, 3–4 weeks production reorder. Connector type, cable length, and conductor configuration can be customized to match your exact application, including MIL-spec connector alternatives and shielding options for specific avionics or airframe integration requirements. Contact our engineering team with your drawings or requirements for a project-specific quote.
Why XinHarness
Fuel system harnesses run on the same AS9100D-certified lines as our engine and landing gear programs, giving fuel system integrators a single certified source. See the Aerospace industry page, or request a quote for your project. For related technical background, see our article on the impact of extreme temperatures on wire harness performance.
Frequently Asked Questions
All aerospace harnesses, including the Aircraft Fuel System & Sensor Wiring Harness, are manufactured under AS9100D quality management and can be built to MIL-DTL-27500 wire and connector specifications on request.
Every Aircraft Fuel System & Sensor Wiring Harness unit undergoes continuity, insulation resistance, and dielectric withstand testing, with additional environmental and vibration testing available for flight-critical applications.
Yes. Connector types, wire gauge, shielding, and routing length can all be customized to match your specific airframe and installation requirements — contact our engineering team with your drawings or specifications.
