MIL-DTL-83538D
In order to meet alternative aircraft wiring requirements, alternative contacts are available. Documents
JN1003, JN1104, JN1057 and JN1120 are equivalent to SAE-AS39029 contacts, but feature slightly
different cable accommodation requirements to fit alternative cables. Users wishing to use alternative
contacts should order receptacles without contacts (using the "L" designator), and source the contacts
separately. In order to satisfy all aircraft wiring requirements, qualifications shall be conducted on
connectors wired with a mixture of wires from military specifications as well as JN/PAN documents
(see 4.4.1).
3.4.2.1 Contact arrangement. The contact arrangement shall be in accordance with the 25-20
insert arrangement as specified in MIL-STD-1560. The engaging ends of the pin contacts and socket
contacts in assembled connectors shall be located within 0.38 mm (.015 inch) diameter of true position.
Test voltages for service ratings shall be as specified in table XI.
3.4.2.2 Installing and removal tools. Both the MIL-I-81969/8 and the MIL-I-81969/14 tools shall
properly assemble and disassemble the socket contacts into their connector inserts. If the connectors
are to be supplied with contacts, then one MIL-I-81969/14 tool for each contact size shall also be supplied
in the unit package. If the connectors are to be supplied without contacts, then no tools shall be supplied
in the unit package. For indirect shipments, connectors may be ordered without installing and removal
tools (see 6.2).
3.4.3 Insert design. The insert and wire sealing or wire supporting member of the connector shall be
designed to provide suitable sealing and support around the wires installed in the connector. The design
shall permit the removal and replacement of individual contacts into the launcher receptacle and store
receptacle insert with the tools defined in 3.4.2.2. Individual contacts in the buffer plug are not
removable. The contact locking device shall be sufficient to meet the contact retention requirements of
3.18. Inserts shall be secured in the connector shell to prevent rotation or axial movement.
3.4.4 Sealing.
3.4.4.1 Wire sealing. Assemblies shall be designed to meet the environmental requirements of this
specification using wire outer diameter within the applicable range as shown in table I.
TABLE I. Wire sizes and diameters.
Finished wire outside dimensions
Contact Size
Wire size (AWG)
Minimum
Maximum
mm
Inches
mm
Inches
24, 22, 20
20
1.02
.040
2.11
.083
20, 18, 16
16
1.65
.065
2.77
.109
14, 12
12 coaxial
2.46
.097
3.61
.142
12 (JN1088WT)
2.46
.097
2.80
.110
3.15
.124
3.40
.134
M17/176-00002
8 twinaxial
3.15
.124
3.80
.150
PAN6421
3.4.4.2 Sealing plugs. Store receptacles shall be designed to accept sealing plugs in accordance with
MS27488 in lieu of wire where unwired contacts are employed. Sealing plugs in accordance with
SAE-AS85049/80 for coaxial, triaxial, or concentric twinaxial contact locations may be used to eliminate
requiring the installation of an unwired contact in the launcher receptacle or store receptacle. These
sealing plugs, when installed in the receptacles, shall not preclude the mating of a buffer plug that is fully
populated with pin contacts. Unless otherwise specified in the purchase order, no sealing plugs shall be
enclosed with the receptacle package.
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