MIL-DTL-641F
3.4.2 Shells. Unless otherwise specified (see 3.1), shells shall be plastic and conforming to a polyarylether
material, such as a polysulfone.
3.4.3 Metal parts. All metal parts shall be of corrosion-resistant material or shall be plated to resist corrosion, to
permit compliance with the salt spray requirements of 3.6.11.
3.4.4 Springs. Contact springs shall be nickel-silver or copper alloy. Copper alloy springs shall be suitably
plated to prevent corrosion of the basis metal.
3.4.5 Contact spring lifters. Hard rubber shall not be used for contact spring lifters.
3.5 Design and construction.
3.5.1 Jacks. Jacks shall be of the design and construction specified (see 3.1).
3.5.2 Cable clamp (see 3.1). A cable clamp for anchoring the electrical cable to the frame of the jack shall be
supplied with the jack. If the cable clamp is not made as an integral part of the jack, the clamp shall be loosely
assembled to or packaged with the jack. Twine serving is not acceptable for this service.
3.5.3 Conductor strain relief (see 3.1). Provisions for anchoring the stay cord to provide strain relief for the
conductors of the electrical cable shall be included in the jack, all edges of the anchor in contact with the stay cord
shall be rounded off.
3.5.4 Screw threads. Screw threads on removable or replaceable threaded parts shall be in accordance with
ASME B107.100-2010.
3.5.5 Solder-lug terminals. Solder-lug terminals shall have circular or oval holes which will accommodate, after
coating, two size 20 AWG, 7-strand wires for connections to electrical circuits. Stacked terminals shall be
staggered. The exposed parts of the terminals shall be hot-tin-dipped or hot-solder-dipped, to facilitate soldering.
Care shall be taken that the terminal-lug holes are not closed by the solder. Where solder-dipping is employed,
only noncorrosive fluxes shall be used.
3.6 Performance.
3.6.1 Contact resistance. When jacks are tested as specified in 4.6.2, the contact resistance shall not exceed
0.02 ohm, except following the shock, vibration, and spring life test, the contact resistance shall not exceed 0.02
ohms, and following the salt spray test, the contact resistance shall not exceed 0.10 ohm.
3.6.2 Insulation resistance. When jacks are tested as specified in 4.6.3, the insulation resistance shall be
10,000 megohms or greater, and 1,000 megohms or greater after the moisture resistance test (see 4.6.7) or the
3.6.3 Dielectric withstanding voltage. When tested as specified in 4.6.4, jacks shall withstand a minimum of
500 volts root mean square (rms) without dielectric breakdown or flashover.
3.6.4 Insertion and withdrawal forces. When jacks are tested as specified in 4.6.5, the insertion and withdrawal
forces shall be as specified (see 3.1).
3.6.5 Thermal shock. When jacks are tested as specified in 4.6.6, the insulation shall not be cracked, warped,
or delaminated; all marking shall remain legible; and it shall be possible to remove and replace screw-on shells
(where used) without the use of tools other than a screwdriver inserted in the slot in the end of the metal portion of
the jack.
3.6.6 Moisture resistance. When jacks are tested as specified in 4.6.7, the initial insulation resistance shall be
as specified in 3.6.2. Following step 6 of the final cycle, at a relative humidity of 90 to 98 percent, the insulation
resistance shall be not less than 1 megohm. Following the drying period, the insulation resistance, contact
resistance, and dielectric withstanding voltage shall be as specified in 3.6.2, 3.6.1, and 3.6.3, respectively; the
insulation shall not be cracked, warped, or delaminated; there shall be no excessive corrosion (see 3.6.11) of
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