MIL-DTL-25038/3E
REQUIREMENTS:
Design and construction: See figure 1.
260 °C.
Temperature rating:
Voltage:
600 V rms.
Color:
Unless otherwise specified by the Part or Identifying Number (PIN), the
color shall be white.
Thermal shock: .060 inch maximum change in insulation measurement.
PIN:
M25038/3 (wire size from table I) (color code designator in accordance with
MIL-STD-681 and MIL-DTL-25038.)
Examples: Size 20 AWG, white = M25038/3-20-9;
Size 20 AWG, white with orange stripe = M25038/3-20-93.
TABLE I. Finished wire construction and performance details.
Performance
2/
Conductor stranding
Maximum
Finished wire
details
Weight
dc
diameter (inch)
Maximum
Bend and cold bend
Wire
lbs/1,000
3/
resistance
conductor
test mandrel
size
feet
Number
Nominal
1,000 feet
diameter
AWG
1/
(max)
of
diameter
Mandrel
Load on
at 20 °C
(inch)
size
strands
(inch)
Min.
Max.
OD
mandrel
(ohms)
(inches)
(pounds)
22
19
34
.0063
.033
23.70
.040
.054
4.15
6
2
4/
22H
19
34
.0063
.033
23.70
.055
.075
6.00
6
2
20
19
32
.0080
.041
15.27
.048
.083
9.00
6
2
18
19
30
.0100
.052
8.50
.065
.097
10.50
6
2
16
19
29
.0113
.061
6.66
.068
.103
13.50
8
3
14
19
27
.0142
.074
4.32
.097
.123
19.50
8
3
12
19
25
.0179
.093
2.78
.100
.142
28.00
8
3
1/ Wire size 20 AWG and 22 AWG shall be constructed with nickel-coated high-strength copper strands.
2/ The conductor strands shall have an annular nickel coating, whose weight shall be not less than 27
percent of the total weight of the nickel-coated strand.
3/ These wires shall comply with the sealing range requirements for firewall connectors as specified in
SAE-AS50151, MIL-DTL-38999, and MIL-DTL-83723.
4/ The 22H wire is defined as heavy-wall or thick-wall version of size 22 wire for use in specific
applications. It is considered to be "light weight, small diameter" when compared with the normal
weight size 22 of MIL-DTL-25038/1. The 22H wire should only be used with a size 20 type contact for
MIL-DTL-38999 connectors.
Changes from previous issue: Marginal notations are not used in this revision to identify changes with
respect to the previous issues due to the extensiveness of the changes.
Referenced documents. In addition to MIL-DTL-25038, this document references the following:
SAE-AS50151
MIL-STD-681
MIL-DTL-38999
MIL-DTL-83723
MIL-DTL-25038/1
2
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