MIL-DTL-642E
3.2 Classification of requirements. The requirements for the plugs are classified herein as follows:
Requirement
Paragraph
Qualification - - - - - - - - - -
Materials - - - - - - - - - - - - -
Design and construction - -
Performance - - - - - - - - - - -
3.3 Qualification. Plugs furnished under this specification shall be products that are authorized by the
qualifying activity for listing on the applicable qualified products list before contract award
3.4 Materials. The materials shall be as specified herein. However, when a definite material is not
specified, a material shall be used which enables the plugs to meet the performance requirements of this
specification. Acceptance or approval of any constituent material shall not be construed as a guaranty of
the acceptance of the finished product.
3.4.1 Fungus-inert. Materials used in the construction of these plugs shall be fungus-inert.
3.4.2 Shells. Unless otherwise specified (see 3.1), shells shall be plastic in accordance with ASTM
D4066, molded rods or molded tubes, type PBE, of MIL-I-24768/10; type II of ASTM D787; a substituted
polyarylether material, such as a polysulfone; or acrylonitrile-butadiene-styrene (ABS) in accordance with
ASTM D4673.
3.4.3 Screws, nuts and washers. Screws nuts and washers shall be made of corrosion-resistant materiel,
or shall be suitably protected against corrosion to permit compliance with the salt spray requirement of
3.4.4 Plating of metal parts. When specified (see 3.1), the plating shall be sufficient to prevent corrosion of
the basis metal.
3.5 Design and construction.
3.5.1 Plugs. Plugs shall be of the design and construction specified (see 3.1).
3.5.2 Shell screws, terminal screws, and lugs. Shell screws, terminal screws, and terminal lugs
(MS35430-1) shall be supplied unassembled and packaged with each plug.
3.5.3 Screw threads. Screw threads on removable or replaceable threaded parts shall be in accordance
with ASME B107.100.
3.5.4 Cable clamp (see 3.1). A cable clamp for anchoring the electrical cable to the frame of the plug shall
be supplied with the plug. If the cable clamp is not made as an integral part of the plug, the clamp shall be
loosely assembled to or packaged with the plug. Twine serving is not acceptable for this service.
3.5.5 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 plug. All edges of the anchor in contact with the
stay cord shall be rounded off.
3.6 Performance.
3.6.1 Torque (unless otherwise specified (see 3.1). When plugs are tested as specified in 4.6.2, the
torque applied between the separate metal parts of the plug finger shall cause no damage to, or loosing
of, any parts thereof.
3.6.2 Dielectric withstanding voltage. When tested as specified in 4.6.3, plugs shall withstand a minimum
of 500 volts root mean square (rms) without dielectric breakdown or flashover.
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