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Aero-Electric Connector, Inc.
Table of Contents
Mil Spec Catalog (AE101)
MIL-DTL-38999 Series I .........................................................................................2–19
MS27466 (AE166) Front Wall Mount Receptacle ................................................................5
MS27656 (AE156) Rear Wall Mount Receptacle ................................................................6
MS27496 (AE196) Front Box Mount Receptacle ................................................................7
MS27505 (AE105) Rear Box Mount Receptacle ................................................................8
MS27468 (AE168) Jam Nut Receptacle ................................................................9
MS27467 (AE167) RFI Grounding Plug ................................................................10
MIL-DTL-38999 Series II.........................................................................................20–35
MS27472 (AE272) Front Wall Mount Receptacle ................................................................23
MS27497 (AE297) Rear Wall Mount Receptacle ................................................................24
MS27499 (AE299) Front Box Mount Receptacle ................................................................25
MS27508 (AE208) Rear Box Mount Receptacle ................................................................26
MS27513 (AE213) Front Box Mount Receptacle,Long Grommet ..................................................27
MS27474 (AE274) Jam Nut Receptacle ................................................................28
MS27473 (AE273) Straight Plug ................................................................29
MS27484 (AE284) RFI Grounding Plug . ...............................................................30
MS27500 (AE200) Plug with 90º Clamp ................................................................31
MIL-DTL-38999 Series III . . . . . . . ................................................................................36–45
D38999/20 (AE320) Wall Mount Receptacle ................................................................39
D38999/24 (AE324) Jam Nut Receptacle ...............................................................40
D38999/26 (AE326) Self-Locking,RFI Grounding Plug .........................................................41
MIL-DTL-5015 (Series III) Rear Release . .......................................................................46–68
MS3450 (AE550) Wall Mount Receptacle .........................................................49
MS3451 (AE551) Cable Connecting Receptacle . ........................................................50
MS3452 (AE552) Box Mount Receptacle .........................................................51
MS3454 (AE554) Jam Nut Receptacle .........................................................52
MS3456 (AE556) Straight Plug . ........................................................53
MS3459 (AE559) Self-Locking Plug .........................................................54
MIL-DTL-26482 Series 2 ........................................................................69–85
MS3470 (AE770) Narrow Flange Receptacle .........................................................72
MS3471 (AE771) Cable Connecting Receptacle .........................................................73
MS3472 (AE772) Wide Flange Receptacle .........................................................74
MS3474 (AE774) Jam Nut Receptacle .........................................................75
MS3476 (AE776) Straight Plug .........................................................76
MS3475 (AE775) RFI Grounding Plug .........................................................77
AC3475 Arctic Coupling Nut,RFI Plug .........................................................78
MIL-DTL-83723 Series III ........................................................................86–108
M83723/71, 72 (AE83371, 72) Wall Mount Receptacle,Bayonet ..............................................89
M83723/73, 74 (AE83373, 74) Jam Nut Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
M83723/75, 76 (AE83375, 76) Straight Plug, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
M83723/77, 78 (AE83377, 78) RFI Grounding Plug,Bayonet ....................................................92
M83723/82,83 (AE83382,83) Wall Mount Receptacle,Threaded ................................................94
M83723/84, 85 (AE83384, 85) Jam Nut Receptacle, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
M83723/86, 87 (AE83386, 87) Straight Plug,Threaded ....................................................96
M83723/91, 92 (AE83391, 92) RFI Grounding Plug, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
M83723/95,96 (AE83395,96) Self-Locking Plug,Threaded ....................................................98
M83723/97, 98 (AE83397,98) Self-Locking RFI Plug,Threaded ..............................................99
M83723/68, 69 (AE83368, 69) Lanyard Release Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
M83723/70 (AE83370) Receptacle Adapter for Lanyard Release Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
MIL-DTL-26500 . .......................................................................109–123
MS24264R**B (AE664R**B) Wall Mount Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
MS24265R**B (AE665R**B) Jam Nut Receptacle, Bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
MS24266R**B (AE666R**B) Straight Plug,Bayonet ..............................................114
MS24264R**T (AE664R**T) Wall Mount Receptacle, Threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
MS24265R**T (AE665R**T) Jam Nut Receptacle,Threaded ..............................................116
MS24266R**T (AE666R**T) Straight Plug,Threaded ..............................................117
Cross Reference .......................................................................124–129
Glossary of Terms .......................................................................130–132
38999 S I 38999 S II 38999 S III 5015 S III 26482 S 2 83723 S III 26500
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MIL–DTL– 38999 S I
– –
MIL-DTL-38999
Features and Application
Series I
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Features and Application
MIL-DTL-38999 Series I is a bayonet coupling subminiature
configuration with high contact density, ideal for smaller
wire gauge, general-purpose applications. These environment-
resisting connectors are 100% “scoop-proof.” Pins are
recessed in elongated shells to prevent the possibility of
bending contacts when plugs are scooped into the mating
receptacles.
This family of connectors is offered in 5 receptacle-mounting
styles. They include square flange receptacles, for both front
and rear panel (wall) mounting; square flange receptacles, for
both front and rear box mounting; and jam nut receptacles
which incorporate “O” ring seals, designed for rear panel
“D” hole mounting.
Standard plugs provide RFI protection by incorporating a
continuous strip of attached grounding fingers attenuating
interference up to 1 GHz.
Fifty-seven insert arrangements per MIL-STD-1560 are
tooled and qualified to MIL-DTL-38999 Series I, utilizing
2 to 128 contacts. Contacts come in sizes 22M, 22D, 20, 16,
12, and 8 (coax and twinax), terminating wire sizes from 28
gauge to 12 gauge including coaxial cable.
These connectors are available in wide range of shell materials
and finishes. Aluminum shells are offered in electroless nickel,
olive drab cadmium and bright cadmium. Other finishes
such as anodic and zinc cobalt are available upon request to
commercial callouts only. In addition, we offer passivated
stainless steel shells with standard environment-resisting
inserts (commercial callouts only), and for highly corrosive
environments, nickel-aluminum-bronze shells with standard
environment-resisting inserts (commercial callouts only).
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
Scoop-Proof Design – Recessed pins in elongated shells
minimize the possibility for contact damage. In a blind
mating application, mating shells cannot “scoop” the pins,
and cause a shorting or bending of contacts.
Closed-Entry Socket Insert – Hard dielectric socket face
has lead-in chamfers for positive alignment of pins (even
partially bent within pre-established limits) with sockets.
Interfacial Pin Insert Seal – Raised moisture barriers
around each pin, which mate into lead-in chamfers of hard
face socket insert, provide individual contact sealing.
Interfacial seal is never touched by service tools.
Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in
each cavity at the rear of the connector.
Superior Contact Stability – Rear release crimp contact
system features a stamped beryllium-copper retaining clip
captivated by molded-in shoulders of each contact cavity in
the insulator. A rear-inserted M81969 plastic tool expands
the tines beyond the shoulder, releasing the contact.
Shell Polarization – Alternate key/keyway positions prevent
cross mating of adjacent connectors having identical insert
arrangement.
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MIL–DTL– 38999 S I
– –
MIL-DTL-38999
Performance Specifications
Series I
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Performance Specifications
Operating Temperature Range
Finish B: -65°C to +175°C (-85°F to +347°F)
Finish F: -65°C to +200°C (-85°F to +392°F
Finish A: -65°C to +150°C (-85°F to +302°F)
Material and Plating Data (Finish)
B – aluminum shell, olive drab cadmium over nickel base
F – aluminum shell, electroless nickel finish
A– aluminum shell, silver to light iridescent yellow color
(bright) cadmium over electroless nickel
Corrosion Resistance
Finishes A and B withstand 500-hour salt spray.
Finish F withstands 48-hour salt spray.
Durability
Minimum of 500 mating cycles
Environmental Seal
Wired, mated connectors with specified accessories
attached, shall meet the altitude-immersion test specified in
MIL-DTL-38999.
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808,
MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol
25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5),
SAE-AMS1424 Type I, and other solvents and cleaning agents.
Shell-to-Shell Conductivity
●Finish F = 1.0 millivolt maximum potential drop
●Finishes A and B = 2.5 millivolts maximum potential drop
Voltage Rating
Shielding Effectiveness
RFI and EMI attenuation at the specified frequencies meet
the requirements of MIL-DTL-38999.
●RFI shielding effectiveness of mated connectors with RFI
backshells is measured in a triaxial radio frequency leak-
age fixture.
●EMI shielding effectiveness is measured at the interface
of mated connectors and tested by the mode-stirred
technique specified in method 3008 of MIL-STD-1344.
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, nor shall
there be a current interruption longer than one microsecond
when subjected to the following:
Standard Shock
Mated connectors withstand a pulse of approximate half
sine wave of 300 G ± 15 percent magnitude with duration of
3 ± 1 milliseconds applied in three axes per MIL-STD-1344,
method 2004.
High Impact Shock
When mounted as specified in MIL-S-901, grade A, a drop
of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to
connector in three axes, totaling nine impacts.
Vibration
Mated connectors, with proper accessories, withstand the
following vibration levels:
●Sine Vibration per MIL-STD-202, method 204, test
condition G.
●Random Vibration per MIL-STD-1344, method 205, test
condition V and test condition VI, Letter “J” at ambient
temperature.
Service Rating
Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft.70,000 Ft.100,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
M400 550 1300 550 350 200
N300 450 1000 400 260 200
I600 850 1800 600 400 200
II 900 1250 2300 800 500 200
Note: The establishment of electrical safety factors is left
entirely to the designer, as he is in the best position to know
exactly what peak voltages, switching currents, transients,
etc., can be expected in a particular circuit.
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MIL–DTL– 38999 S I
MIL-DTL-38999
Part Number Development
Series I
– –
Military and Aero-Electric Part Number Development
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 1 through 26 of each contact and two spares
for inserts with more than 26 contacts and a minimum of
one sealing plug up to 10% of the number of contacts.
Spare Coax and Twinax contacts are not supplied. One
insertion/removal tool for each contact size is also included.
Note 2: Proper part number marking has no “0” in front
of single digit shell size (9) and no “0” in front of single
digit layout. Example of each: JMS27466T9B35S and
JMS27466T11B5S. In both, “N” for normal is omitted. In
addition, J or JAN must now be marked in front of the MS
part number.
Mil. Prefix MS 27467 T13 B35 P A
Aero Prefix AE 167 T13 B35 P A -340
Shell Type
27466 = Front, wall mount receptacle = 166 (Aero p/n)
27467 = RFI grounding plug = 167 (Aero p/n)
27468 = Jam nut receptacle = 168 (Aero p/n)
27496 = Front, box mount receptacle = 196 (Aero p/n)
27505 = Rear, box mount receptacle = 105 (Aero p/n)
27656 = Rear, wall mount receptacle = 156 (Aero p/n)
Class
T= With acc. thread (MS27466, MS27467, MS27468 & MS27656)
E= Same as T in line above but is not approved for new design
(E-nut is not included)
= No acc. thread, box mount (MS27496 & MS27505)
Shell Size
9, 11, 13, 15, 17, 19, 21, 23 or 25
Finish (Material & Plating)
A= Aluminum shell, silver to light iridescent yellow color (bright) cadmium over nickel base
B= Aluminum shell, olive drab cadmium over electroless nickel base
F= Aluminum shell, electroless nickel finish
S= Stainless steel shell, passivated (Aero p/n only)
Insert Arrangement
See page 15 thru 19
Contact Style
P= Pin
S= Socket
A= Pin connector less pins (with intent to use non-standard pin contacts)
B= Socket connector less sockets (with intent to use non-standard socket contacts)
Polarization (Keying)
N= Normal (Omitted in part number)
A, B,C,or D(B & C keyways are not available in shell size 9)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/27-XXX E-nut
341 = Connector kitted with M85049/49-2-XXX straight clamp
342 = Connector kitted with M85049/47XXX right angle clamp
Consult factory for other modifications
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MIL–DTL– 38999 S I
MS27466
Front, Wall Mounting Receptacle
AE166
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
[
H
MAX
GROMMET
B
A
4x
[
C
MASTER KEYWAY
[
E
BLUE COLOR BAND
J
ACCESSORY TEETH
G
ACCESSORY THREAD
1.323(33.60)
MAX
D
.219(5.56)
MIN. FULL THREAD
.060(1.52)
MAX GROMMET EXTENSION
F
4X MINOR KEYWAYS
Page 4 Completed Part Number
Page 13 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 3 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 11 Polarization
Shell
Size
A B [C D [E F G [H J
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38 Accessory No. of
±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Thread Maximum Teeth
inch mm inch mm inch mm inch mm inch mm inch mm UNEF-2A inch mm
9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 7/16-28 .299 7.59 12
11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 9/16-24 .427 10.85 16
13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 11/16-24 .541 13.74 20
15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 13/16-20 .666 16.92 24
17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28
19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32
21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36
23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40
25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44
MIL–DTL– 38999 S I
MS27656
Rear,Wall Mounting Receptacle
AE156
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
Page 4 Completed Part Number
Page 13 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 3 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 11 Polarization Note: See page 12 for panel thickness.
[ H
MAX
GROMMET
J ACCESSORY TEETH
.219 (5.56)
MIN FULL THREAD
.060 (1.52)
MAX GROMMET EXTENSION
G ACCESSORY THREAD
B
A
4x [ C
MASTER KEYWAY
[ E
BLUE COLOR BAND
1.350 (34.29)
MAX
D F
4X MINOR KEYWAYS
Shell
Size
A B [C D [E F G [H J
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38 Accessory No. of
±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Thread Maximum Teeth
inch mm inch mm inch mm inch mm inch mm inch mm UNEF-2A inch mm
9.938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 7/16-28 .299 7.59 12
11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 9/16-24 .427 10.85 16
13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 11/16-24 .541 13.74 20
15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 13/16-20 .666 16.92 24
17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 15/16-20 .791 20.09 28
19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1-1/16-18 .897 22.78 32
21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1-3/16-18 1.022 25.96 36
23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1-5/16-18 1.147 29.13 40
25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1-7/16-18 1.272 32.31 44
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MIL–DTL– 38999 S I
MS27496
Front, Box Mounting Receptacle
AE196
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
Page 4 Completed Part Number
Page 13 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 3 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 11 Polarization
[
H
MAX
GROMMET
[
G
MAX
.312(7.93)
MAX
.060(1.52)
MAX GROMMET EXTENSION
B
A
4x
[
C
MASTER KEYWAY
[
E
BLUE COLOR BAND
1.104(28.04)
MAX
FD
4X MINOR KEYWAYS
– –
Shell
Size
A B [C D [E F [G[H
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38
±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Maximum Maximum
inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
9 .938 23.83 .719 18.26 .128 3.25 .632 16.05 .572 14.53 .085 2.16 .469 11.91 .299 7.59
11 1.031 26.19 .812 20.62 .128 3.25 .632 16.05 .700 17.78 .085 2.16 .594 15.09 .427 10.85
13 1.125 28.58 .906 23.01 .128 3.25 .632 16.05 .850 21.59 .085 2.16 .719 18.26 .541 13.74
15 1.219 30.96 .969 24.61 .128 3.25 .632 16.05 .975 24.77 .085 2.16 .844 21.44 .666 16.92
17 1.312 33.32 1.062 26.97 .128 3.25 .632 16.05 1.100 27.94 .085 2.16 .969 24.61 .791 20.09
19 1.438 36.53 1.156 29.36 .128 3.25 .632 16.05 1.207 30.66 .085 2.16 1.078 27.38 .897 22.78
21 1.562 39.67 1.250 31.75 .128 3.25 .602 15.29 1.332 33.83 .115 2.92 1.203 30.56 1.022 25.96
23 1.688 42.88 1.375 34.93 .147 3.73 .602 15.29 1.457 37.01 .115 2.92 1.328 33.73 1.147 29.13
25 1.812 46.02 1.500 38.10 .147 3.73 .602 15.29 1.582 40.18 .115 2.92 1.453 36.91 1.272 32.31
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MIL–DTL– 38999 S I
MS27505
Rear, Box Mounting Receptacle
AE105
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
Page 4 Completed Part Number
Page 13 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 3 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 11 Polarization
[H
MAX
GROMMET
[G
MAX
.060(1.52)
MAX GROMMET EXTENSION
B
A
4x [C
MASTER KEYWAY
[E
BLUE COLOR BAND
1.100(27.94)
MAX
D F
4X MINOR KEYWAYS
Shell
Size
A B [C D [E F [G[H
+.010 +.25 +.000 +.00 +.001 +.03 +.015 +.38
±.020 ±.51 (TP) -.005 -.13 -.005 -.13 -.005 -.13 -.000 -.00 Maximum Maximum
inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
9 .938 23.83 .719 18.26 .128 3.25 .820 20.83 .572 14.53 .085 2.16 .547 13.89 .299 7.59
11 1.031 26.19 .812 20.62 .128 3.25 .820 20.83 .700 17.78 .085 2.16 .656 16.66 .427 10.85
13 1.125 28.58 .906 23.01 .128 3.25 .820 20.83 .850 21.59 .085 2.16 .828 21.03 .541 13.74
15 1.219 30.96 .969 24.61 .128 3.25 .820 20.83 .975 24.77 .085 2.16 .953 24.21 .666 16.92
17 1.312 33.32 1.062 26.97 .128 3.25 .820 20.83 1.100 27.94 .085 2.16 1.078 27.38 .791 20.09
19 1.438 36.53 1.156 29.36 .128 3.25 .820 20.83 1.207 30.66 .085 2.16 1.203 30.56 .897 22.78
21 1.562 39.67 1.250 31.75 .128 3.25 .790 20.07 1.332 33.83 .115 2.92 1.328 33.73 1.022 25.96
23 1.688 42.88 1.375 34.93 .147 3.73 .790 20.07 1.457 37.01 .115 2.92 1.453 36.91 1.147 29.13
25 1.812 46.02 1.500 38.10 .147 3.73 .790 20.07 1.582 40.18 .115 2.92 1.578 40.08 1.272 32.31
Note: See page 12 for panel thickness.
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MIL–DTL– 38999 S I
MS27468
Jam Nut Receptacle
AE168
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
Page 4 Completed Part Number
Page 13 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 3 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 11 Polarization
PANEL THICKNESS
.125(3.18)
.062(1.57)
[ D
3X BAYONET PINS
EQUALLY SPACED
MASTER KEYWAY
E
BLUE COLOR BAND
4X MINOR KEYWAYS
"O"-RING
K
FLAT
[ A
HEX NUT
PER MS3186
J THREAD
1.308 (33.22)
MAX
.615 (15.62)
.598 (15.19)
.920 (23.37)
.910 (23.11)
BLUE COLOR BAND
G No. OF TEETH
F ACCESSORY THREAD
[ C
MAX
GROMMET
.060 (1.52) MAX
GROMMET EXTENSION
B
Shell
Size
[A B [C[D E F G J K
+.001 +.03 +.011 +.28 Accessory No. of Jam Nut Thread Flat
-.005 -.13 -.010 -.25 Maximum ±.016 ±.41 ±.016 ±.41 Thread Teeth Class 2A ±.005 ±.13
inch mm inch mm inch mm inch mm inch mm UNEF- 2A inch mm
9 .572 14.53 .109 2.77 .299 7.59 1.188 30.18 1.062 26.97 7/16-28 12 11/16-24UNEF .650 16.51
11 .700 17.78 .109 2.77 .427 10.85 1.375 34.93 1.250 31.75 9/16-24 16 13/16-20UNEF .750 19.05
13 .850 21.59 .109 2.77 .541 13.74 1.500 38.10 1.375 34.93 11/16-24 20 1-20UNEF .937 23.80
15 .975 24.77 .109 2.77 .666 16.92 1.625 41.28 1.500 38.10 13/16-20 24 1-1/8-18UNEF 1.061 26.95
17 1.100 27.94 .109 2.77 .791 20.09 1.750 44.45 1.625 41.28 15/16-20 28 1-1/4-18UNEF 1.186 30.12
19 1.207 30.66 .140 3.56 .897 22.78 1.938 49.23 1.812 46.02 1-1/16-18 32 1-3/8-18UNEF 1.311 33.30
21 1.332 33.83 .140 3.56 1.022 25.96 2.062 52.37 1.938 49.23 1-3/16-18 36 1-1/2-18UNEF 1.436 36.47
23 1.457 37.01 .140 3.56 1.147 29.13 2.188 55.58 2.062 52.37 1-5/16-18 40 1-5/8-18UNEF 1.561 39.65
25 1.582 40.18 .140 3.56 1.272 32.31 2.312 58.72 2.188 55.58 1-7/16-18 44 1-3/4-18UNS 1.686 42.82
10www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MS27467
RFI Grounding Plug
AE167
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
Page 4 Completed Part Number
Page 13 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 3 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 11 Polarization
GROMMET
EXTENSION
D No. OF TEETH
[ A
MIN [C
MAX
GROMMET
[FMAX.
COUPLING NUT
E ACCESSORYTHREAD
.219(5.56) MIN
FULL THREAD
BLUE COLOR BAND
4 MINOR KEYS
MASTER KEY
RFI STRIP
1.294
(32.87)
MAX
.060(1.52)
MAX
Shell
Size
[A[CD E[F
No. of Accessory Thread
Minimum Maximum Teeth Class 2A Maximum
inch mm inch mm inch mm
9 .417 10.59 .299 7.59 12 7/16-28UNEF .859 21.82
11 .545 13.84 .427 10.85 16 9/16-24UNEF .984 24.99
13 .657 16.69 .541 13.74 20 11/16-24UNEF 1.156 29.36
15 .782 19.86 .666 16.92 24 13/16-20UNEF 1.281 32.54
17 .907 23.04 .791 20.09 28 15/16-20UNEF 1.406 35.71
19 1.012 25.70 .897 22.78 32 1-1/16-18UNEF 1.516 38.51
21 1.137 28.88 1.022 25.96 36 1-3/16-18UNEF 1.641 41.68
23 1.262 32.05 1.147 29.13 40 1-5/16-18UNEF 1.766 44.86
25 1.387 35.23 1.272 32.31 44 1-7/16-18UNEF 1.891 48.03
11www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-DTL-38999
Polarization
Series I
– –
Keying Positions
Notes:
1. Mating face of receptacle shown (plug is opposite).
2. The master keyway (key) has various positions relative to
DATUM F;the minor keyways (keys) remain fixed as
shown. In the Normal position, the master keyway (key)
is at 95° from DATUM F.
3. The angles for a given connector are the same whether it
contains pin or socket inserts.
4. The insert arrangement does not rotate relative to master
keyway (key).
DATUM F
D°
N°
A°
C°
B°
MASTER
KEYWAY
NORMAL
5°
Shell
Size
Keying Positions
BSC
N°A°B°C°D°
9 95 77 – – 113
11 95 81 67 123 109
13 95 75 63 127 115
15 95 74 61 129 116
17 95 77 65 125 113
19 95 77 65 125 113
21 95 77 65 125 113
23 95 80 69 121 110
25 95 80 69 121 110
12www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-DTL-38999 Series I
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
Flange and Jam Nut Mounting Dimensions
Shell
Size
A[B[C D E [F
+.000 +.00 +.010 +.25
(TP) Minimum ±.005 ±.13 Maximum -.010 -.25 -.000 -.00
inch mm inch mm inch mm inch mm inch mm inch mm
9 .719 18.26 .656 16.66 .128 3.25 .234 5.94 .670 17.02 .700 17.78
11 .812 20.62 .796 20.22 .128 3.25 .234 5.94 .771 19.59 .825 20.96
13 .906 23.01 .922 23.42 .128 3.25 .234 5.94 .955 24.26 1.010 25.65
15 .969 24.61 1.047 26.59 .128 3.25 .234 5.94 1.085 27.56 1.135 28.83
17 1.062 26.97 1.219 30.96 .128 3.25 .234 5.94 1.210 30.73 1.260 32.01
19 1.156 29.36 1.297 32.94 .128 3.25 .234 5.94 1.335 33.91 1.385 35.18
21 1.250 31.75 1.422 36.12 .128 3.25 .204 5.18 1.460 37.08 1.510 38.35
23 1.375 34.93 1.547 39.29 .154 3.91 .204 5.18 1.585 40.26 1.635 41.53
25 1.500 38.10 1.672 42.47 .154 3.91 .193 4.90 1.710 43.43 1.760 44.70
A
[F
4x [ C
FLANGE MOUNT
[ B
MIN
DMAX
PANEL THICKNESS
.125(3.18)
.062(1.57)
PANEL THICKNESS
JAM NUT
E
Note 1: Flange Mounting Dimensions ([B cutout and
D MAX)listed only for back of panel mounting (MS27505
and MS27656).
Note 2: D MAXincludes mounting hardware.
13www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-DTL-38999
Contacts, Tools and Seal Plugs
Series I
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
– –
Contact Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
22D Power/Signal M39029/58-360 M39029/56-348
MS27488-22-1 M81969/14-01
22M* Power/Signal M39029/58-361 M39029/56-349
22* Power/Signal M39029/58-362 M39029/56-350 —
20 Power/Signal M39029/58-363 M39029/56-351 MS27488-20-1 M81969/14-10
16 Power/Signal M39029/58-364 M39029/56-352 MS27488-16-1 M81969/14-03
12 Power/Signal M39029/58-365 M39029/56-353
MS27488-12-1 M81969/14-0412 Coax Coax M39029/28-211 M39029/75-416
12 Coax Coax M39029/102-558 M39029/103-559
8 Coax Coax M39029/60-367 M39029/59-366 MS27488-8-1 M81969/14-06
8 Twinax Twinax M39029/90-529 M39029/91-530 MS27488-8-1 M81969/14-12
Contact
Size/Type
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
22D,22M* M22520/2-01 M22520/2-09 M22520/2-07 M81969/8-01 M81969/8-02
22* M22520/2-01 M22520/2-09 M22520/2-07 M81969/8-03 M81969/8-04
20 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-05 M81969/8-06
M22520/2-01 M22520/2-10 M22520/2-10
16 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-07 M81969/8-08
12 M22520/1-01 M22520/1-04 M22520/1-04
M81969/8-09 M81969/8-1012 Coax Inner M22520/2-01 M22520/2-34 M22520/2-34
12 Coax Outer M22520/31-01 M22520/31-02 M22520/31-02
8 Coax Inner M22520/2-01 M22520/2-31 M22520/2-31
M81969/8-13** M81969/8-14
8 Coax Outer M22520/5-01 M22520/5-05 M22520/5-05
Die Closure B Die Closure B
8 Twinax Center M22520/2-01 M22520/2-37 M22520/2-37
——
8 Twinax Outer
& Intermediate M22520/5-01 M22520/5-200 M22520/5-200
Contact Size
Test Current Voltage Crimp Well Data Wire Range Finished Wire [Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWG mm2inch mm inch mm
22D 5.0 73 .0345 ±.0010 .141 3.58 28-22 .08-.33 .030 .76 .054 1.37
22M* 3.0 45 .028 ±.001 .141 3.58 28-24 .08-.20 .030 .76 .050 1.27
22* 5.0 73 .0365 ±.0010 .141 3.58 26-22 .13-.33 .034 .86 .060 1.52
20 7.5 55 .047 ±.001 .209 5.31 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .209 5.31 20-16 .52-1.31 .065 1.65 .109 2.77
12 23.0 42 .100 ±.002 .209 5.31 14-12 2.08-3.31 .097 2.46 .142 3.61
*Inactive for new design
** Insertion tool is not required.
Note 1: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
Note 2: Size 12 coax contacts purchased in bulk.
Note 3: Size 8 coax contacts are used with M17/095-RG180
cable, while size 8 Twinax contacts are used with
M17/176-00002 cable.
14www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-DTL-38999
Contact Installation Instructions
Series I
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the
contact. Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into the
insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to
removing insertion tool, do not try to reinsert the
insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
damage the inside of the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place the wire into the
extraction tool of the pin or socket.
3. Slowly slide the extraction tool down wire into the
contact cavities until the tool tip bottoms against the
contact shoulder, expanding the clip retaining tines. Hold
the wire firmly in the tool and pull the wired contact and
tool straight out of the rear of the insulator.
Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool
22D M39029/58-360 M39029/56-348 M22520/2-01 M22520/2-09 M22520/2-07 M81969/14-01
22M M39029/58-361 M39029/56-349 M22520/2-01 M22520/2-09 M22520/2-07 M81969/14-01
22 M39029/58-362 M39029/56-350 M22520/2-01 M22520/2-09 M22520/2-07 M81969/14-01
20 M39029/58-363 M39029/56-351 M22520/1-01 M22520/1-04 Red M22520/1-04 Red M81969/14-10
M22520/2-01 M22520/2-10 M22520/2-10
20 M39029/58-364 M39029/56-352 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03
12 M39029/58-365 M39029/56-353 M22520/1-01 M22520/1-04 YellowM22520/1-04 YellowM81969/14-04
For coax and twinax contacts refer to instructions that are supplied with contacts.
Please see next page for Shell Sizes 21/20/G thru
25/24/J layouts.
15www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-DTL-38999 Series I, II and III
Insert Availability and Contact Information
per MIL-STD-1560
Insert Availability and Contact Information
– –
Insert Arrangement
Aero-Electric Service Total Quantity of Contacts
Status No. of (by Size)
Series I Series II Series III QPL’d Tooled Rating Contacts 22D 22M 22 20 16 12 10 8
9-6* 8-6* — Yes Yes M6 6
9-35 8-35 A35 Yes Yes M66
9-98 8-98 A98 Yes Yes I3 3
11-2 — B2 Yes Yes I2 2
11-4 — B4 Yes Yes I4 4
11-5 10-5 B5 Yes Yes I5 5
11-13* 10-13* — Yes Yes M 13 13
11-35 10-35 B35 Yes Yes M 13 13
11-98 10-98 B98 Yes Yes I6 6
11-99 10-99 B99 Yes Yes I7 7
— 12-3 — Yes Yes II 3 3
13-4 12-4 C4 Yes Yes I4 4
13-8 12-8 C8 Yes Yes I8 8
13-22* 12-22* — Yes Yes M 22 22
13-35 12-35 C35 Yes Yes M 22 22
13-98 12-98 C98 Yes Yes I 10 10
15-5 14-5 D5 Yes Yes II 5 5
15-15 14-15 D15 Yes Yes I 15 14 1
15-18 14-18 D18 Yes Yes I 18 18
15-19 — D19 Yes Yes I 19 19
15-35 14-35 D35 Yes Yes M 37 37
15-37* 14-37* — Yes Yes M 37 37
15-97 14-97 D97 Yes Yes I12 84
17-6 16-6 E6 Yes Yes I6 6
17-8 16-8 E8 Yes Yes II 8 8
17-26 16-26 E26 Yes Yes I 26 26
17-35 16-35 E35 Yes Yes M 55 55
17-55* 16-55* — Yes Yes M 55 55
17-99 16-99 E99 Yes Ye s I 23 21 2
19-11 18-11 F11 Yes Yes II 11 11
19-28 18-28 F28 Yes Yes I 28 26 2
19-30 18-30 F30 Yes Yes I 30 29 1
19-32 18-32 F32 Yes Yes I 32 32
19-35 18-35 F35 Yes Yes M 66 66
— 18-53** — Yes Yes M 53 53
19-66* 18-66* — Yes Yes M 66 66
*Not approved for new design. Tooled and qualified but their separate
pictorials are not shown on pages 17 thru 19, as they are the same as
corresponding (-35) layouts that take same qty of 22D instead of 22M
contacts.
** Not approved for new design. Pictorial is shown on page 18.
— above means “not available” for that series.
38999 S II 38999 S III
16www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-DTL-38999 Series I, II and III
Insert Availability and Contact Information
per MIL-STD-1560
Insert Availability and Contact Information (continued)
– –
Insert Arrangement
Aero-Electric Service Total Quantity of Contacts
Status No. of (by Size)
Series I Series II Series III QPL’d Tooled Rating Contacts 22D 22M 22 20 16 12 10 8
21-1* 20-1* — Yes Yes M79 79
21-11 —G11 Yes Yes I11 11
21-16 20-16 G16 Yes Yes II 16 16
21-35 20-35 G35 Yes Yes M79 79
21-39 20-39 G39 Yes Yes I39 37 2
21-41 20-41 G41 Yes Yes I41 41
21-48** —G48** N/A Yes I 4 4 (Power)
21-75 —G75 Yes Yes Twinax 4 4 (Twinax)
23-1* 22-1* —Yes Yes M100 100
23-2*** 22-2*** —Ye s Yes M85 85
23-21 22-21 H21 Yes Yes II 21 21
23-32 22-32 H32 Yes Yes I32 32
23-35 22-35 H35 Yes Yes M100 100
23-53 22-53 H53 Yes Yes I53 53
23-55 22-55 H55 Yes Yes I55 55
25-1* 24-1* —Yes Yes M128 128
25-4 24-4 J4 Yes Yes I56 48 8
— — J8 Yes Yes Twinax 8 8 (Twinax)
— — J11 Yes Ye s N11 2 9
25-19 24-19 J19 Yes Yes I19 19
— — J20 Yes Yes N, Coax, Twinax 30 10 13 4 (Coax) 3 (Twinax)
25-24 24-24 J24 Yes Yes I24 12 12
25-29 24-29 J29 Yes Yes I29 29
25-35 24-35 J35 Yes Yes M128 128
25-43 —J43 Yes Yes I43 23 20
25-46 —J46**** Yes Yes I, Coax 46 40 42 (Coax)
25-61 24-61 J61 Yes Yes I61 61
— — J90 Yes Ye s I, Twinax 46 40 42 (Twinax)
* Not approved for new design.Tooled and qualified but their separate
pictorials are not shown on pages 17 thru 19, as they are same as
corresponding (-35) layouts that take same quantity of 22D instead
of 22M contacts.
** 21-48/G48 layout is not to MIL-STD-1560. It is tooled and intended for
comm’l use only.
*** Not approved for new design. Pictorial is shown on page 18.
**** J46 in Series III is not QPL’d but can be purchased to comm’l number
(Size 8 Coax contact must be used).
— above means “not available” for that series
Note 1: J20P uses 4 size 12 coax contacts as follows:
2 ea M39029/28-211 and 2 ea of M39029/102-558; J20S
uses 4 size 12 coax contacts as follows: 2 ea M39029/75-416
and 2 ea of M39029/103-559.
Note 2: Layouts (G75, J8, J20, J46 and J90) that take twinax
or coax contacts should not be used for firewall applications
(Classes K & S) in Series III.
Note 3: H and J contact styles (in lieu of P & S) are meant
for Composite (classes J & M) Series III only. Aluminum
(classes A, B, F & W) and Firewall (classes K & S) are rated
for 500 cycles regardleess what contacts are used.
38999 S II 38999 S III
17www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I, II and III Connectors
Insert Arrangements Views
– –
1
2
3
4
56
9-35/8-35
A35,
6#22D,M
A
B
C
9-98/8-98
A98,
3#20,I
A
B
11-2
B2,
2#16, I
A
B
C
D
11-4
B4,
4#20, I
A
B
C
D
E
11-5/10-5
B5,
5#20, I
1
2
3
4
5
6
7
8
9
10 11
12
13
11-35/10-35
B35,
13 # 22D, M
A
B
C
D
EF
11-98/10-98
B98,
6#20,I
A
B
C
D
E
FG
11-99/10-99
B99,
7#20,I
A
B
C
12-3
3 # 16, II
A
B
C
D
13-4/12-4
C4,
4#16, I
A
B
C
D
E
F
G
H
13-8/12-8
C8,
8#20, I
13-35/12-35
C35,
22 # 22D, M
AB
C
D
E
F
G
H
J
K
13-98/12-98
C98,
10 # 20, I
A
B
C
D
E
15-5/14-5
D5,
5 # 16, II
A
B
C
D
E
F
G
H
J
K
L
M
RN
15-15/14-15
D15,
1#16,14#20,I
A
B
C
D
E
F
G
H
J
K
L
MN
P
RS
TU
15-18/14-18
D18,
18 # 20, I
AB
C
D
E
F
G
H
J
K
L
M
NP
R
ST
UV
15-19
D19,
19 # 20, I
15-35/14-35
D35,
37 # 22D, M
A
B
C
D
E
F
G
H
J
K
L
M
15-97/14-97
D97,
4#16,8#20,I
A
B
C
D
E
F
17-6/16-6
E6,
6#12,I
A
B
C
D
E
F
G
H
17-8/16-8
E8,
8 # 16, II
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
ST
U
V
W
X
Y
Z
ab
c
17-26/16-26
E26,
26 # 20, I
17-35/16-35
E35,
55 # 22D, M
P
1
3
4
9
10
16
17
24
25
31
32
39
40
46
47
52
53
55
1
15
22
21
14
21
1
31
38999 S II 38999 S III
18www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I, II and III Connectors
Insert Arrangements Views
– –
17-99/16-99
E99,
2#16, 21 # 20, I
19-11/18-11
F11,
11 # 16, II
19-35/18-35
F35,
66 #22D, M
18-53*
53 #22,M
21-11
G11,
11 # 12, I
21-16/20-16
G16,
16 # 16, II
21-75
G75,
4#8Twinax, Twinax
A
B
C
D
E
L
F
G
H
J
K
A
B
C
D
E
F
G
HJ
K
L
M
N
P
RST
U
V
W
X
YZ
19-28/18-28
F28,
2#16, 26 # 20, I
A
B
C
D
E
F
G
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
19-30/18-30
F30,
1#16, 29 # 20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
1
3
4
9
10
16
17
24
25
33
34
42
43
50
51
57
58
63
64
66
19-32/18-32
F32,
32 # 20, I
A
B
C
D
E
F
G
JH
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
A
B
C
D
E
F
G
H
J
K
L
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
21-41/20-41
G41,
41 # 20, I
21-48**
G48**,
4#8Power, I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
XY
Z
a
b
c
d
e
f
g
h
i
j
k
m
t
n
p
q
r
s
21-39/20-39
G39,
2#16, 37 # 20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
X
Y
Z
W
a
b
c
d
e
f
g
h
i
jk
m
n
p
q
r
A
BC
D
A
B
C
D
23-21/22-21
H21,
21 # 16, II
23-2*/22-2*
85 # 22, M
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
21-35/20-35
G35,
79 # 22D, M
1
11
71
21
31
41
51
61
79
1
11
21
31
52
51
53
1
4
5
11
12
19
20
28
29
38
39
47
48
57
58
66
67
74
75
81
82
85
* Inactive for new design.
** Not MIL-STD-1560 layout (not QPL’d.).
38999 S II 38999 S III
19www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S I
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I, II and III Connectors
Insert Arrangements Views
– –
J8
8#8Twinax,
Twinax
J11
9#10, 2#20,
N
25-24/24-24
J24,
12 # 12, 12 # 16, I
23-53/22-53
H53,
53#20, I
23-35/22-35
H35,
100#22D,M
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
k
m
n
p
q
r
s
t
u
v
w
x
y
z
AA
BB
CC
DD
EE
FF
GG
HH
23-55/22-55
H55,
55#20, I
a
b
c
d
e
f
g
H
i
j
k
m
n
p
q
r
s
t
u
v
w
x
y
z
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
AA
BB
CC
DD
EE
FF
GG
HH
25-4/24-4
J4,
8#16,48#20,I
e
AB
C
D
E
F
G
H
J
K
L
M
N
X
Y
Za
bc
d
f
g
h
k
m
n
P
R
S
T
U
V
W
p
q
r
s
t
u
v
w
x
y
z
AA
BB
CC
DD
EE
FF
GG
HH
JJ
KK
LL
25-19/24-19
J19,
19 # 12, I
AB
C
D
E
F
G
H
J
K
L
M
NP
R
S
T
UV
25-43
J43,
20 # 16, 23 # 20, I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
YZ
a
b
c
d
ef
g
h
k
m
np
r
s
t
u
v
w
x
q
25-29/24-29
J29,
29# 16, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
ST
U
V
W
X
Y
Z
a
bc
d
e
f
a
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
25-46
J46,
40 # 20, 4 # 16, 2#8Coax,I/Coax
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
k
m
n
p
r
s
tu
v
w
x
y
z
AA
q
25-61/24-61
J61,
61 # 20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
YZ
ab
c
d
e
f
g
h
j
k
m
n
P
r
s
t
u
v
w
x
y
z
AA
BB
CC
DD
EE
FF
GG
HH
JJ
KK
LL
MM
NN
PP
i
q
J90,
40 # 20,4#16, 2#8Twinax,
I/Twinax
A
B
C
D
E
F
GH
A
B
C
D
E
F
G
H
L
J
K
J20
10 # 20,13 # 16, 4 # 12, 3 # 8 Twinax,
N/Coax /Twinax
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
k
m
n
p
r
s
tu
v
w
x
y
z
AA
q
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
1
2
3
4
5
6
7
1
2
3
5
6
8
715
16
24
25
34
35
45
46
55
4
56
66
67
76
77
85
86
93
94
95
96
97
98
99
10 0
25-35/24-35
J35,
128 # 22D, M
1
4
7
8
14
15
24
25
35
36
47
48
58
59
70
71
81
82 94 105
115
122
125
121
11 4
104
93
23-32/22-32
H32,
32 #20,I
A
B
C
D
E
F
G
H
J
K
L
M
N
PR
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
i
38999 S II 38999 S III
20www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
– –
MIL-DTL-38999
Features and Application
Series II
www.conesys.com sales@aero-electric.com
Features and Application
MIL-DTL-38999 Series II connectors feature a bayonet
coupling mechanism with lower profile design and
rear-removable crimp contact retention system.
These connectors were designed for military and commercial
applications where the prime requirements are lower profile
and lighter weight.
Reduction of both size and weight were achieved through
the use of thinner shell walls and length restrictions. These
design restrictions reduced the RFI attenuation characteristics
and the “scoop” protection, while yielding an excellent gen-
eral purpose, lightweight connector. Compared to Series I,
Series II connectors achieve up to 20% reduction in mated
pair length, up to 39% reduction in outside diameter and
up to 40% reduction in weight (128 pin mated pair).
This family of connectors is offered in six receptacle-mounting
styles. They include square flange receptacles, for both front
and rear panel (wall) mounting; square flange receptacles,
for both front and rear panel (box) mounting; square flange
receptacle with extended grommet, for front of panel (box)
mounting; and jam nut receptacles which incorporate
“O” ring seals, designed for rear panel “D” hole mounting.
Plugs are available in two designs, with and without RFI
grounding.
Fifty-two insert arrangement per MIL-STD-1560 are tooled
and qualified to MIL-DTL-38999 Series II, utilizing 3 to 128
M39029 contacts. Contacts come in sizes 22D, 22M, 22, 20,
16 and 12, terminating wire sizes from 28 to 12 gauge.
These connectors are available in wide range of shell materials
and finishes. Aluminum shells are offered in electroless
nickel, bright cadmium, anodized, and olive drab cadmium.
Other finishes such as zinc cobalt are available upon request
to commercial callouts only. In addition, we offer passivated
stainless steel shells with standard environment-resisting
inserts (commercial callouts only).
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
Closed-Entry Socket Insert – Hard dielectric socket face
has lead-in chamfers for positive alignment of pins (even
partially bent within pre-established limits) with sockets.
Interfacial Pin Insert Seal – Raised moisture barriers
around each pin, which mate into lead-in chamfers of hard
face socket insert, provide individual contact sealing.
Interfacial seal is never touched by service tools.
Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in
each cavity at the rear of the connector.
Superior Contact Stability – Rear release crimp contact
system features a stamped beryllium-copper retaining clip
captivated by molded-in shoulders of each contact cavity in
the insulator. A rear-inserted M81969 plastic tool expands
the tines beyond the shoulder, releasing the contact.
Shell Polarization – Alternate key/keyway positions prevent
cross mating of adjacent connectors having same insert
arrangement.
21www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MIL-DTL-38999
Performance Specifications
Series II
– –
Performance Specifications
Operating Temperature Range
Finish B: -65°C to +175°C (-85°F to +347°F)
Finishes C and F: -65°C to +200°C (-85°F to +392°F)
Finish A: -65°C to +150°C (-85°F to 302°F)
Material and Plating Data (Finish)
B – aluminum shell, olive drab cadmium over nickel base
C – aluminum shell, black anodized finish
F – aluminum shell, electroless nickel finish
A – aluminum shell, silver to light iridescent yellow color
(bright) cadmium over electroless nickel base
Corrosion Resistance
Finishes A, B and C withstand 500-hour salt spray.
Finish F withstands 48-hour salt spray.
Durability
Mated connectors withstand a minimum of 250 mating
cycles for RFI plug (MS27484) and 500 cycles for MS27473
and MS27500 plugs.
Environmental Seal
Wired, mated connectors with specified accessories
attached, shall meet the altitude-immersion test specified by
MIL-DTL-38999.
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808,
MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol
25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5),
SAE-AMS1424 Type I, and other solvents and cleaning agents.
Voltage Rating
Shell-to-Shell Conductivity
Maximum potential drop shall not exceed:
●With RFI spring fingers, finish F = 1.0 millivolt, while
finishes A and B = 2.5 millivolts.
●Without spring fingers = 200 millivolts.
●Finish C = nonconductive.
Shielding Effectiveness
RFI and EMI attenuation at the specified frequencies meet
the requirements of MIL-DTL-38999.
●RFI shielding effectiveness of mated connectors with
RFI backshells is measured in a triaxial radio frequency
leakage fixture.
●EMI shielding effectiveness is measured at the interface
of mated connectors and tested by the mode-stirred
technique specified in method 3008 of MIL-STD-1344.
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, nor shall
there be a current interruption longer than one microsecond
when subjected to the following:
Standard Shock
Mated connectors withstand a pulse of approximate half
sine wave of300 G magnitude with duration of three
milliseconds applied in three axes per MIL-STD-1344,
method 2004.
Vibration
Mated connectors withstand the following vibration levels:
●Random vibration per MIL-STD-1344, method 205 test
condition VI, Letter “J”.
Service
Rating
Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
M400 550 1300 550 350 200
N300 450 1000 400 260 200
I600 850 1800 600 400 200
II 900 1250 2300 800 500 200
Note: The establishment of electrical safety factors is left
entirely to the designer, as he is in the best position to know
exactly what peak voltages, switching currents, transients, etc.,
can be expected in a particular circuit.
22www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MIL-DTL-38999
Part Number Development
Series II
Military and Aero-Electric Part Number Development
– –
Mil. Prefix MS 27473 T12 B35 P A
Aero Prefix AE 273 T12 B35 P A -340
Shell Type
27472 = Front, wall mount receptacle = 272 (Aero p/n)
27473 = Straight plug = 273 (Aero p/n)
27474 = Jam nut receptacle = 274 (Aero p/n)
27484 = RFI grounding plug = 284 (Aero p/n)
27497 = Rear, wall mount receptacle = 297 (Aero p/n)
27499 = Front, box mount receptacle = 299 (Aero p/n)
27500 = Standard plug with 90˚ backshell = 200 (Aero p/n)
27508 = Rear, box mount receptacle = 208 (Aero p/n)
27513 = Front, box mount rec. (long grommet) = 213 (Aero p/n)
Class
T= With accessory thread (MS27472, 27473, 27474, 27484 & 27497)
E= Same as T in line above except connector is kitted with E-Nut
= No accessory thread, box mount (MS27499 & MS27508)
= No accessory thread, box mount, long grommet (MS27513)
P= Supplied with ring and potting boot (same shell types as “T” class)
Shell Size
8, 10, 12, 14, 16, 18, 20, 22 or 24
Finish (Material & Plating)
A= Aluminum shell, silver to light iridescent yellow (bright) cadmium over electroless nickel base
B= Aluminum shell, olive drab cadmium over electroless nickel base
C= Aluminum shell, black anodized finish (not available in MS27484)
F= Aluminum shell, electroless nickel finish
E= Stainless steel shell, passivated (Aero p/n only, n/a in AE284)
Insert Arrangement
See page 15 thru 19
Contact Designator
P= Pin A= Pin connector less pins (with intent to use non-std pin contacts)
S= Socket B= Socket connector less sockets (with intent to use non-std socket contacts)
Polarization (Keying)
N= Normal (Omitted in part number)
A, B, C, or D(B & C keyways are not available in shell size 8)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/27-XXX E-nut
341 = Connector kitted with M85049/49-2-XXX straight clamp
342 = Connector kitted with M85049/47XXX right angle clamp
Consult factory for other modifications
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 2 through 26 of each contact and two
spares for inserts with 27 or more contacts, and a minimum
of one sealing plug up to 10% of the number contacts. One
insertion/extraction tool for each contact size is also included.
Note 2: Proper part number marking has no “0” in front
of single digit shell size (8) and no “0” in front of single
digit layout. Example of each: JMS27472T8B35S and
JMS27472T10B5S. In both “N” for normal is omitted. Please
note that JAN or J marking is required immediately in front
of MS number.
23www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27472
Front, Wall Mounting Receptacle
AE272
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
G
NO. OF TEETH
F
ACCESSORY THREAD
4x
[
C
MASTER KEYWAY
BLUE COLOR BAND
[
E
[
H
MAX
GROMMET
K
GROMMET EXTENSION
.219(5.56)
MIN FULL THREAD
.322(8.18)
.317(8.05)
B
A
MAX .069(1.75)
.058(1.47)
D
MAX
4 MINOR KEYWAYS
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
Shell
Size
A B [C D [E F G [H K
+.010 +.25 Accessory No. of Grommet
Maximum (TP) -.005 -.13 Maximum ±.003 ±.08 Thread Teeth Maximum Extension
inch mm inch mm inch mm inch mm inch mm UNEF-2A inch mm inch mm
8 .828 21.03 .594 15.09 .120 3.05 .932 23.67 .471 11.96 7/16-28 12 .299 7.59 .150/.090 3.81/2.29
10 .954 24.23 .719 18.26 .120 3.05 .932 23.67 .588 14.94 9/16-24 16 .427 10.85 .150/.090 3.81/2.29
12 1.047 26.59 .812 20.62 .120 3.05 .932 23.67 .748 19.00 11/16-24 20 .541 13.74 .150/.090 3.81/2.29
14 1.141 28.98 .906 23.01 .120 3.05 .932 23.67 .873 22.17 13/16-20 24 .666 16.92 .150/.090 3.81/2.29
16 1.234 31.34 .969 24.61 .120 3.05 .932 23.67 .998 25.35 15/16-20 28 .791 20.09 .150/.090 3.81/2.29
18 1.328 33.73 1.062 26.97 .120 3.05 .932 23.67 1.123 28.52 1-1/16-18 32 .897 22.78 .150/.090 3.81/2.29
20 1.453 36.91 1.156 29.36 .120 3.05 .932 23.67 1.248 31.70 1-3/16-18 36 1.022 25.96 .150/.090 3.81/2.29
22 1.578 40.08 1.250 31.75 .120 3.05 .932 23.67 1.373 34.87 1-5/16-18 40 1.147 29.13 .150/.090 3.81/2.29
24 1.703 43.26 1.375 34.93 .147 3.73 1.000 25.40 1.498 38.05 1-7/16-18 44 1.272 32.31 .140/.040 3.56/1.02
24www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27497
Rear,Wall Mounting Receptacle
AE297
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
G NO. OF TEETH
F ACCESSORY THREAD
MASTER KEYWAY
4x
[
CBLUE COLOR BAND
[
E
MAX
[
H
MAX
GROMMET
K GROMMET EXTENSION
.219(5.56)
MIN FULL THREAD
B
A
MAX.447(11.35)
.442(11.23)
.069(1.75)
.058(1.47)
D
MAX
4 MINOR KEYWAYS
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization Note: See page 33 for panel thickness.
Shell
Size
A B [C D [E F G [H K
+.010 +.25 Accessory No. of Grommet
Maximum (TP) -.005 -.13 Maximum Maximum Thread Teeth Maximum Extension
inch mm inch mm inch mm inch mm inch mm UNEF-2A inch mm inch mm
8 .828 21.03 .594 15.09 .120 3.05 .988 25.10 .547 13.89 7/16-28 12 .299 7.59 .150/.090 3.81/2.29
10 .954 24.23 .719 18.26 .120 3.05 .988 25.10 .672 17.07 9/16-24 16 .427 10.85 .150/.090 3.81/2.29
12 1.047 26.59 .812 20.62 .120 3.05 .988 25.10 .844 21.44 11/16-24 20 .541 13.74 .150/.090 3.81/2.29
14 1.141 28.98 .906 23.01 .120 3.05 .988 25.10 .969 24.61 13/16-20 24 .666 16.92 .150/.090 3.81/2.29
16 1.234 31.34 .969 24.61 .120 3.05 .988 25.10 1.094 27.79 15/16-20 28 .791 20.09 .150/.090 3.81/2.29
18 1.328 33.73 1.062 26.97 .120 3.05 .988 25.10 1.219 30.96 1-1/16-18 32 .897 22.78 .150/.090 3.81/2.29
20 1.453 36.91 1.156 29.36 .120 3.05 .988 25.10 1.344 34.14 1-3/16-18 36 1.022 25.96 .150/.090 3.81/2.29
22 1.578 40.08 1.250 31.75 .120 3.05 .988 25.10 1.469 37.31 1-5/16-18 40 1.147 29.13 .150/.090 3.81/2.29
24 1.703 43.26 1.375 34.93 .147 3.73 1.056 26.82 1.594 40.49 1-7/16-18 44 1.272 32.31 .140/.040 3.56/1.02
25www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27499
Front, Box Mounting Receptacle
AE299
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
4x
[
C
MASTER KEYWAY
BLUE COLOR BAND
[
E
[
F
MAX
[
H
MAX
GROMMET
.060(1.52)
MAX
GROMMET EXTENSION
.312(7.92)
MAX
.322(8.18)
.317(8.05)
B
A
MAX
.763(19.38)
MAX
.069(1.75)
.058(1.47)
4 MINOR KEYWAYS
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
Shell
Size
A B [C[E[F[H
+.010 +.25
Maximum (TP) -.005 -.13 ±.003 ±.08 Maximum Maximum
inch mm inch mm inch mm inch mm inch mm inch mm
8 .828 21.03 .594 15.09 .120 3.05 .471 11.96 .453 11.51 .299 7.59
10 .954 24.23 .719 18.26 .120 3.05 .588 14.94 .578 14.68 .427 10.85
12 1.047 26.59 .812 20.62 .120 3.05 .748 19.00 .703 17.86 .541 13.74
14 1.141 28.98 .906 23.01 .120 3.05 .873 22.17 .828 21.03 .666 16.92
16 1.234 31.34 .969 24.61 .120 3.05 .998 25.35 .953 24.21 .791 20.09
18 1.328 33.73 1.062 26.97 .120 3.05 1.123 28.52 1.062 26.97 .897 22.78
20 1.453 36.91 1.156 29.36 .120 3.05 1.248 31.70 1.188 30.18 1.022 25.96
22 1.578 40.08 1.250 31.75 .120 3.05 1.373 34.87 1.312 33.32 1.147 29.13
24 1.703 43.26 1.375 34.93 .147 3.73 1.498 38.05 1.438 36.53 1.272 32.31
26www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27508
Rear, Box Mounting Receptacle
AE208
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization Note: See page 33 for panel thickness.
.058(1.47)
4x
[
C
MASTER KEYWAY
BLUE COLOR BAND
.317(8.05)
.322(8.18)
[
F
MAX
[
F
MAX
[
E
[
H
MAX
GROMMET
.060(1.52)
MAX
GROMMET EXTENSION
.442(11.23)
.447(11.35)
B
A
MAX
.757(19.23)
MAX
.250(6.35)
MAX
.069(1.75)
4 MINOR KEYWAYS
Shell
Size
A B [C[E[F[H
+.010 +.25
Maximum (TP) -.005 -.13 ±.003 ±.08 Maximum Maximum
inch mm inch mm inch mm inch mm inch mm inch mm
8 .828 21.03 .594 15.09 .120 3.05 .471 11.96 .547 13.89 .299 7.59
10 .954 24.23 .719 18.26 .120 3.05 .588 14.94 .672 17.07 .427 10.85
12 1.047 26.59 .812 20.62 .120 3.05 .748 19.00 .844 21.44 .541 13.74
14 1.141 28.98 .906 23.01 .120 3.05 .873 22.17 .969 24.61 .666 16.92
16 1.234 31.34 .969 24.61 .120 3.05 .998 25.35 1.094 27.79 .791 20.09
18 1.328 33.73 1.062 26.97 .120 3.05 1.123 28.52 1.219 30.96 .897 22.78
20 1.453 36.91 1.156 29.36 .120 3.05 1.248 31.70 1.344 34.14 1.022 25.96
22 1.578 40.08 1.250 31.75 .120 3.05 1.373 34.87 1.469 37.31 1.147 29.13
24 1.703 43.26 1.375 34.93 .147 3.73 1.498 38.05 1.594 40.49 1.272 32.31
27www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27513
Long Grommet, Front, Box Mount Receptacle
AE213
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
MASTER KEYWAY
BLUE COLOR BAND
.322(8.18)
.317(8.05) .312(7.92)
MAX
.069(1.75)
.058(1.47)
B
A
MAX
.907(23.04)
MAX
.516(13.11)
MAX
4x
[
C
[
E
[
F
MAX
[
H
MAX
GROMMET
4 MINOR KEYWAYS
Shell
Size
A B [C[E[F[H
+.010 +.25
Maximum (TP) -.005 -.13 ±.003 ±.08 Maximum Maximum
inch mm inch mm inch mm inch mm inch mm inch mm
8 .828 21.03 .594 15.09 .120 3.05 .471 11.96 .453 11.51 .299 7.59
10 .954 24.23 .719 18.26 .120 3.05 .588 14.94 .578 14.68 .427 10.85
12 1.047 26.59 .812 20.62 .120 3.05 .748 19.00 .703 17.86 .541 13.74
14 1.141 28.98 .906 23.01 .120 3.05 .873 22.17 .828 21.03 .666 16.92
16 1.234 31.34 .969 24.61 .120 3.05 .998 25.35 .953 24.21 .791 20.09
18 1.328 33.73 1.062 26.97 .120 3.05 1.123 28.52 1.062 26.97 .897 22.78
20 1.453 36.91 1.156 29.36 .120 3.05 1.248 31.70 1.188 30.18 1.022 25.96
22 1.578 40.08 1.250 31.75 .120 3.05 1.373 34.87 1.312 33.32 1.147 29.13
24 1.703 43.26 1.375 34.93 .147 3.73 1.498 38.05 1.438 36.53 1.272 32.31
28www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27474
Jam Nut Receptacle
AE274
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
3 BAYONET PINS
4 MINOR KEYWAYS
E
THREAD
BLUE COLOR BAND
MASTER
KEYWAY
HEX NUT
PER MS3186
[
F
D
B
FLAT
"O" RING
A
G
MAX.
M
ACCESSORY THREAD
H
NO. OF TEETH
[
J
MAX
GROMMET
SS 8-22 .150(3.81)
.090(2.29)
SS 24 .140(3.56)
.040(1.02)
.105(2.67)
.084(2.13)
GROMMET
EXTENSION
PANEL THICKNESS
.109(2.77)
.062(1.57)
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
Shell
Size
A B D E [F G H [J M
+.001 +.03 Jam Nut Thread No. of Accessory
±.005 ±.13 -.006 -.15 ±.016 ±.41 Class 2A ±.003 ±.08 Maximum Teeth Maximum Thread
inch mm inch mm inch mm inch mm inch mm inch mm UNEF-2A
8 .438 11.13 .817 20.75 1.250 31.75 7/8-20UNEF .471 11.96 .937 23.80 12 .299 7.59 7/16-28
10 .438 11.13 .941 23.90 1.375 34.93 1-20UNEF .588 14.94 .937 23.80 16 .427 10.85 9/16-24
12 .438 11.13 1.065 27.05 1.500 38.10 1-1/8-18UNEF .748 19.00 .937 23.80 20 .541 13.74 11/16-24
14 .438 11.13 1.190 30.23 1.625 41.28 1-1/4-18UNEF .873 22.17 .937 23.80 24 .666 16.92 13/16-20
16 .438 11.13 1.320 33.53 1.781 45.24 1-3/8-18UNEF .998 25.35 .937 23.80 28 .791 20.09 15/16-20
18 .438 11.13 1.440 36.58 1.890 48.01 1-1/2-18UNEF 1.123 28.52 .937 23.80 32 .897 22.78 1-1/16-18
20 .464 11.79 1.565 39.75 2.016 51.21 1-5/8-18UNEF 1.248 31.70 .931 23.65 36 1.022 25.96 1-3/16-18
22 .464 11.79 1.690 42.93 2.140 54.36 1-3/4-18UNS 1.373 34.87 .931 23.65 40 1.147 29.13 1-5/16-18
24 .464 11.79 1.815 46.10 2.265 57.53 1-7/8-16UN 1.498 38.05 .984 24.99 44 1.272 32.31 1-7/16-18
29www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27473
Straight Plug
AE273
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
H
GROMMET EXTENSION
G
MAX
4 MINOR KEYS
BLUE COLOR BAND
[
F
MAX
COUPLING NUT
MASTER KEY
[
A
MIN
SHELL
[
C
MAX
GROMMET
E
ACCESSORY THREAD
D
NO. OF TEETH
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
Shell
Size
[ A[ C D E [ F G H
No of Accessory Grommet
Minimum Maximum Teeth Thread Maximum Maximum Extension
inch mm inch mm UNEF-2A inch mm inch mm inch mm
8 .337 8.56 .299 7.59 12 7/16-28 .750 19.05 .916 23.27 .150/.090 3.81/2.29
10 .465 11.81 .427 10.85 16 9/16-24 .859 21.82 .916 23.27 .150/.090 3.81/2.29
12 .557 14.15 .541 13.74 20 11/16-24 1.031 26.19 .916 23.27 .150/.090 3.81/2.29
14 .702 17.83 .666 16.92 24 13/16-20 1.156 29.36 .916 23.27 .150/.090 3.81/2.29
16 .827 21.01 .791 20.09 28 15/16-20 1.281 32.54 .916 23.27 .150/.090 3.81/2.29
18 .927 23.55 .897 22.78 32 1-1/16-18 1.406 35.71 .916 23.27 .150/.090 3.81/2.29
20 1.052 26.72 1.022 25.96 36 1-3/16-18 1.531 38.89 .916 23.27 .150/.090 3.81/2.29
22 1.177 29.90 1.147 29.13 40 1-5/16-18 1.641 41.68 .916 23.27 .150/.090 3.81/2.29
24 1.302 33.07 1.272 32.31 44 1-7/16-18 1.766 44.86 .984 24.99 .140/.040 3.56/1.02
30www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27484
RFI Grounding Plug
AE284
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
[
F
MAX
COUPLING NUT
RFI STRIP
4 MINOR KEYS
MASTER KEY
H
GROMMET EXTENSION
G
MAX
BLUE COLOR BAND
[
A
MIN
SHELL
[
C
MAX
GROMMET
E
ACCESSORY THREAD
D
NO. OF TEETH
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
Shell
Size
[A[C D E [F G H
No of Accessory Grommet
Minimum Maximum Teeth Thread Maximum Maximum Extension
inch mm inch mm UNEF-2A inch mm inch mm inch mm
8 .337 8.56 .299 7.59 12 7/16-28 .750 19.05 .916 23.27 .150/.090 3.81/2.29
10 .465 11.81 .427 10.85 16 9/16-24 .859 21.82 .916 23.27 .150/.090 3.81/2.29
12 .557 14.15 .541 13.74 20 11/16-24 1.031 26.19 .916 23.27 .150/.090 3.81/2.29
14 .702 17.83 .666 16.92 24 13/16-20 1.156 29.36 .916 23.27 .150/.090 3.81/2.29
16 .827 21.01 .791 20.09 28 15/16-20 1.281 32.54 .916 23.27 .150/.090 3.81/2.29
18 .927 23.55 .897 22.78 32 1-1/16-18 1.406 35.71 .916 23.27 .150/.090 3.81/2.29
20 1.052 26.72 1.022 25.96 36 1-3/16-18 1.531 38.89 .916 23.27 .150/.090 3.81/2.29
22 1.177 29.90 1.147 29.13 40 1-5/16-18 1.641 41.68 .916 23.27 .150/.090 3.81/2.29
24 1.302 33.07 1.272 32.31 44 1-7/16-18 1.766 44.86 .984 24.99 .140/.040 3.56/1.02
31www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MS27500
Plug with 90° Backshell
AE200
Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight
– –
W
MAX
L MAX
Y
MAX
4 MINOR KEYS
MASTER KEY BLUE COLOR BAND
[ A
MIN
SHELL
[FMAX
COUPLING NUT
Page 22 Completed Part Number
Page 34 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 21 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 32 Polarization
Shell
Size
[A[F L W Y
Minimum Maximum Maximum Maximum Maximum
inch mm inch mm inch mm inch mm inch mm
8 .337 8.56 .750 19.05 1.859 47.22 1.000 25.40 .828 21.03
10 .465 11.81 .859 21.82 1.859 47.22 1.032 26.21 .891 22.63
12 .557 14.15 1.031 26.19 1.938 49.23 1.094 27.79 1.016 25.81
14 .702 17.83 1.156 29.36 2.125 53.98 1.219 30.96 1.141 28.98
16 .827 21.01 1.281 32.54 2.281 57.94 1.281 32.54 1.255 31.88
18 .927 23.55 1.406 35.71 2.312 58.72 1.344 34.14 1.469 37.31
20 1.052 26.72 1.531 38.89 2.375 60.33 1.375 34.93 1.550 39.37
22 1.177 29.90 1.641 41.68 2.531 64.29 1.438 36.53 1.675 42.55
24 1.302 33.07 1.766 44.86 2.828 71.83 1.719 43.66 1.800 45.72
32www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MIL-DTL-38999
Polarization
Series II
Keying Positions
– –
DATUM F
D°
N°
A°
C°
B°
MASTER
NORMAL
KEYWAY
10°
Notes:
1. Mating face of receptacle shown (plug is opposite).
2. The master keyway (key) has various positions relative to
DATUM F; the minor keyways (keys) remain fixed as
shown. In the Normal position, the master keyway (key)
is 100°from DATUM F.
3. The angles for a given connector are the same whether it
contains pin or socket inserts.
4. The insert arrangement does not rotate relative to master
keyway (key).
Shell
Size
Keying Positions
BSC
N°A°B°C°D°
8 100 82 - - 118
10 100 86 72 128 114
12 100 80 68 132 120
14 100 79 66 134 121
16 100 82 70 130 118
18 100 82 70 130 118
20 100 82 70 130 118
22 100 85 74 126 115
24 100 85 74 126 115
33www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MIL-DTL-38999 Series II
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
A
[
E
4x
[
C
FLANGE MOUNT
[
B
MIN
D
MAX
PANEL THICKNESS
.109(2.77)
.062(1.57)
PANEL THICKNESS
JAM NUT
F
Note 1: Flange Mounting Dimensions ([B cutout and
D MAX) listed only for back of panel mounting (MS27497
and MS27508).
Flange and Jam Nut Mounting Dimensions
Note 2: D MAXincludes mounting hardware.
Shell
Size
A[B[C D [E F
+.010 +.25 +.000 +.00
(TP) Minimum ±.005 ±.13 Maximum -.000 -.00 -.010 -.25
inch mm inch mm inch mm inch mm inch mm inch mm
8 .594 15.09 .557 14.15 .128 3.25 .146 3.71 .885 22.48 .830 21.08
10 .719 18.26 .682 17.32 .128 3.25 .146 3.71 1.010 25.65 .955 24.26
12 .812 20.62 .854 21.69 .128 3.25 .146 3.71 1.135 28.83 1.085 27.56
14 .906 23.01 .979 24.87 .128 3.25 .146 3.71 1.260 32.01 1.210 30.73
16 .969 24.61 1.104 28.04 .128 3.25 .146 3.71 1.385 35.18 1.335 33.91
18 1.062 26.97 1.229 31.22 .128 3.25 .146 3.71 1.510 38.35 1.460 37.08
20 1.156 29.36 1.354 34.39 .128 3.25 .168 4.27 1.635 41.53 1.585 40.26
22 1.250 31.75 1.479 37.57 .128 3.25 .168 4.27 1.760 44.70 1.709 43.42
24 1.375 34.93 1.604 40.74 .154 3.91 .168 4.27 1.885 47.88 1.835 46.61
34www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MIL-DTL-38999
Contacts, Tools and Seal Plugs
Series II
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
– –
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
22D Power/Signal M39029/58-360 M39029/57-354
MS27488-22-1 M81969/14-01
22M* Power/Signal M39029/58-361 M39029/57-355
22* Power/Signal M39029/58-362 M39029/57-356 —
20 Power/Signal M39029/58-363 M39029/57-357 MS27488-20-1 M81969/14-10
16 Power/Signal M39029/58-364 M39029/57-358 MS27488-16-1 M81969/14-03
16 Coax Coax M39029/76-424 M39029/78-432
12 Power/Signal M39029/58-365 M39029/57-359 MS27488-12-1 M81969/14-04
Contact
Size/Type
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
22D, 22M* M22520/2-01 M22520/2-09 M22520/2-06 M81969/8-01 M81969/8-02
22* M22520/2-01 M22520/2-09 M22520/2-06 M81969/8-03 M81969/8-04
20 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-05 M81969/8-06
M22520/2-01 M22520/2-10 M22520/2-10
16 M22520/1-01 M22520/1-04 M22520/1-04
M81969/8-07 M81969/8-0816 Coax Inner M22520/2-01 M22520/2-35 M22520/2-35
16 Coax Outer M22520/4-01 M22520/4-02 M22520/4-02
12 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-09 M81969/8-10
Contact
Size
Test Current Voltage Crimp Well Data Wire Range Finished Wire [Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWG mm2inch mm inch mm
22D 5.0 73 .0345 ±.0010 .141 3.58 28-22 .08-.33 .030 .76 .054 1.37
22M* 3.0 45 .028 ±.001 .141 3.58 28-24 .08-.20 .030 .76 .050 1.27
22* 5.0 73 .0365 ±.0010 .141 3.58 26-22 .13-.33 .034 .86 .060 1.52
20 7.5 55 .047 ±.001 .209 5.31 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .209 5.31 20-16 .52-1.31 .065 1.65 .109 2.77
12 23.0 42 .100 ±.002 .209 5.31 14-12 2.08-3.31 .097 2.46 .142 3.61
* Inactive for new design
Note 1: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
Note 2: Size 16 coax contacts purchased in bulk.
35www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S II
MIL-DTL-38999
Contact Installation Instructions
Series II
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the
contact. Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into
the insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to
removing insertion tool, do not try to reinsert the
insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
damage the inside of the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place the wire into the
extraction tool of the pin or socket.
3. Slowly slide the extraction tool down wire into the contact
cavities until the tool tip bottoms against the contact
shoulder, expanding the clip retaining tines. Hold the
wire firmly in the tool and pull the wired contact and
tool straight out of the rear of the insulator.
Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool
22D M39029/58-360 M39029/57-354 M22520/2-01 M22520/2-09 M22520/2-06 M81969/14-01
22M M39029/58-361 M39029/57-355 M22520/2-01 M22520/2-09 M22520/2-06 M81969/14-01
22 M39029/58-362 M39029/57-356 M22520/2-01 M22520/2-09 M22520/2-06 M81969/14-01
20 M39029/58-363 M39029/57-357 M22520/1-01 M22520/1-04 Red M22520/1-04 Red M81969/14-10
M22520/2-01 M22520/2-10 M22520/2-10
16 M39029/58-364 M39029/57-358 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03
12 M39029/58-365 M39029/57-359 M22520/1-01 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04
For coax contacts refer to instructions supplied with contacts.
36www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
– –
MIL-DTL-38999
Features and Application
Series III
www.conesys.com sales@aero-electric.com
Features and Application
MIL-DTL-38999 Series III is the newest cylindrical connector
designed for highest performance capabilities used in both
general purpose and severe environment applications.
These connectors feature an improved “one-turn” coupling
system, utilizing self-locking acme thread. Acme threads
provide coupling durability, while thicker wall sections and
greater coupling surface area improve strength and shock
resistance. Blunting of the threads on both receptacle and
plug coupling nut eliminates cross threading.
Elongated mounting holes permit the Series III Connector to
intermount with various existing Mil-spec flange mounted
receptacles, giving it a design replacement advantage.
Wall mount receptacle, jam nut receptacle and straight
self-locking RFI plug are offered in 9 shell sizes and 54 insert
arrangements utilizing M39029 contacts in sizes 22D, 20, 16,
12, 10 power and 8 twinax.
These connectors are available in wide range of shell materials
and finishes. Aluminum shells are offered in electroless nickel
and olive drab cadmium. Other finishes such as anodic and
zinc cobalt are available upon request to commercial callouts
only. In addition, we offer stainless steel shells (both passivated
and electro-deposited nickel plated) with firewall inserts, and
for highly corrosive environments, nickel-aluminum-bronze
shells with standard environment-resisting inserts (commer-
cial callouts only).
MIL-STD-1560 Insert Arrangements – Series III connectors
use insert patterns and contacts common to Series I,
making for an easy transition from bayonet to triple-lead,
acme-thread, self-locking coupling.
Metal-to-Metal Bottoming – This feature precludes relative
shell-to-shell motion, which may result in ordinary connector
wear and moisture entrapment.
Lockwiring Eliminated – Self-locking quick coupling plug
eliminates the need for lockwiring.
Firewall Capability - Stainless steel shells in both K and S
firewall classes are offered.
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
Scoop-Proof Design – Recessed pins in elongated shells
minimize the possibility for contact damage. In a blind
mating application, mating shells cannot “scoop” the pins,
and cause a shorting or bending of contacts.
Closed-Entry Socket Insert – Hard dielectric socket face
has lead-in chamfers for positive alignment of pins (even
partially bent within pre-established limits) with sockets.
Interfacial Pin Insert Seal – Raised moisture barriers
around each pin, which mate into lead-in chamfers of
hard face socket insert, provide individual contact sealing.
Interfacial seal is never touched by service tools.
Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in
each cavity at the rear of the connector.
Superior Contact Stability – Rear release crimp contact
system features a stamped beryllium-copper retaining clip
captivated by molded-in shoulders of each contact cavity in
the insulator. A rear-inserted M81969 plastic tool expands
the tines beyond the shoulder, releasing the contact.
Metric Accessory Thread – Metric thread results in
additional wall thickness giving greater strength and shock
resistance.
37www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
MIL-DTL-38999
Performance Specifications
Series III
– –
Performance Specifications
Operating Temperature Range
Classes F, K, S and BZ*: -65°C to +200°C (-85°F to +392°F)
Classes W and ZC*: -65°C to +175°C (-85°F to +347°F)
Material and Finish Data (Class)
F – aluminum shell, electroless nickel finish
K – stainless steel shell, passivated, firewall
S – stainless steel shell, electrodeposited nickel, firewall
W– aluminum shell, olive drab cadmium over nickel base
BZ* – aluminum nickel bronze shell, std insert
ZC*– aluminum shell, zinc cobalt finish
Corrosion Resistance
Classes K, W, BZ* and ZC* withstand 500-hour salt spray.
Classes F and S withstand 48-hour salt spray.
Durability
Minimum of500 mating cycles.
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808,
MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol
25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5),
SAE-AMS1424 Type I, and other solvents and cleaning agents.
Shielding Effectiveness
RFI and EMI attenuation at the specified frequencies meet
the requirements of MIL-DTL-38999.
●RFI shielding effectiveness of mated connectors with RFI
backshells is measured in a triaxial radio frequency leakage
fixture.
●EMI shielding effectiveness is measured at the interface
of mated connectors and tested by the mode-stirred
technique specified in method 3008 of MIL-STD-1344.
Voltage Rating
Environmental Seal
Wired, mated connectors with specified accessories
attached, shall meet the altitude-immersion test specified in
MIL-DTL-38999.
Shell-to-Shell Conductivity
Maximum potential drop shall not exceed:
●Classes F and S = 1.0 millivolt.
●Class W = 2.5 millivolts, Class K = 10.0 millivolts
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, nor shall
there be a current interruption longer than one microsecond
when subjected to the following:
Shock
Pulse of approximate half sine wave of 300 G ±15 percent mag-
nitude with duration of 3 ±1 milliseconds applied in three axes.
High Impact Shock
When mounted as specified in MIL-S-901, grade A, a drop
of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to
connector in three axes, totaling nine impacts.
Vibration
Wired and mated connectors withstand the following
vibration levels:
●Sine vibration where connector samples with simulated
accessory load are subjected to simple harmonic motion
from 10 to 2,000 Hz in three mutually perpendicular axes,
in 20 minute sweeps, for 12 hours in each axis at velocity of
254 mm/sec from 10-50 Hz, displacement of 1.5 mm from
50-140Hz and acceleration of 60G from 140-2,000Hz.
●Random Vibration per MIL-STD-1344, method 205,
test condition V at ambient temperature and test
condition VI, Letter “J” at elevated temperature.
* Not on QPL, can be supplied to Aero-Electric part number only.
Service
Rating
Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft.70,000 Ft.100,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
M400 550 1300 550 350 200
N300 450 1000 400 260 200
I600 850 1800 600 400 200
II 900 1250 2300 800 500 200
Note: The establishment of electrical safety factors is left
entirely to the designer, as he is in the best position to know
exactly what peak voltages, switching currents, transients, etc.,
can be expected in a particular circuit.
38www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
MIL-DTL-38999
Part Number Development
Series III
Military and Aero-Electric Part Number Development
– –
* Not on QPL, can be supplied to Aero-Electric part number only.
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 2 through 26 of each contact and two
spares for inserts with 27 or more contacts, and a minimum
of one sealing plug up to 10% of the number contacts.
Spare Coax and Twinax contacts are not supplied. One
insertion/extraction tool for each contact size is also included.
Note 2: Proper part number marking has no “0” in front
of single digit layout. Example: JD38999/20WB5SN. “N” for
normal is included. In addition, J or JAN must be marked
immediately in front of MIL part number.
Mil. Prefix D38999/ 20 W C 35 P N
Aero Prefix AE3 20 W C 35 P N -340
Shell Type (Specification Sheet Number)
20 = Wall mount receptacle
24 = Jam nut receptacle
26 = Self-locking, RFI grounding plug
Class (Material & Finish)
F= Aluminum shell, electroless nickel finish
W= Aluminum shell, olive drab cadmium over electroless nickel base
K= Stainless steel shell, passivated, with firewall insert
S= Stainless steel shell, electrodeposited nickel, with firewall insert
BZ* = Aluminum nickel bronze shell with standard insert (Aero p/n only)
ZC* = Aluminum shell, zinc cobalt plating (Aero p/n only)
Shell Size
A, B, C,D,E,F,G,Hor J
Insert Arrangement
See pages 15 thru 19
Contact Style
P= Pin
S= Socket
A= Pin connector less pins (with intent to use non-std pin contacts)
B= Socket connector less sockets (with intent to use non-std socket contacts)
Polarization (Keying)
N= Normal (Included in part number)
A, B,C, D,or E
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/15-XXX
341 = Connector kitted with M85049/38-XXX straight clamp
342 = Connector kitted with M85049/39-XXX right angle clamp
Consult factory for other modifications
39www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
D38999/20
Wall Mounting Receptacle
AE320
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
BLUE COLOR BAND
(REAR RELEASE)
B
4 MINOR KEYWAYS
E
C
D
LOCKING INDICATOR BAND
COLOR: RED
F
MATING THREAD
MASTER KEYWAY
G
MAX
31.50(1.240)
MAX
2.16(.085) MAX
GROMMET EXTENSION
J
NUMBER OF TEETH
K
ACCESSORY THREAD
7.11(.280)
MIN FULL THREAD
H
MAX
A
[
L
MAX
GROMMET
Page 38 Completed Part Number
Page 44 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 37 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 42 Polarization
Note 1: “K” Accessory Thread for AE320 is same as AE326
(“D” Accessory Thread) on page 41.
Note 2: “F” Mating Thread for AE320 is same as AE326
(“E” Mating Thread) on page 41 except it is Class 2A.
Note 3: Maximum Grommet Extension for insert layouts
incorporating size 8 and 10 contacts = 5.95(.234).
Shell
Size
A B C D E G H J [ L
No. of
±.012 ±.30 (TP) (TP) ±.008 ±.20 ±.008 ±.20 Maximum Maximum Teeth Maximum
inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
A.937 23.80 .719 18.26 .594 15.09 .216 5.49 .128 3.25 .820 20.83 .098 2.50 12 .299 7.59
B1.031 26.20 .812 20.62 .719 18.26 .194 4.93 .128 3.25 .820 20.83 .098 2.50 16 .427 10.85
C1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 3.25 .820 20.83 .098 2.50 20 .541 13.74
D1.220 31.00 .969 24.61 .906 23.01 .173 4.39 .128 3.25 .820 20.83 .098 2.50 24 .666 16.92
E1.311 33.30 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 .820 20.83 .098 2.50 28 .791 20.09
F1.437 36.50 1.156 29.36 1.062 26.97 .194 4.93 .128 3.25 .820 20.83 .098 2.50 32 .897 22.78
G1.563 39.70 1.250 31.75 1.156 29.36 .194 4.93 .128 3.25 .790 20.07 .126 3.20 36 1.022 25.96
H1.689 42.90 1.375 34.93 1.250 31.75 .242 6.15 .154 3.91 .790 20.07 .126 3.20 40 1.147 29.13
J1.811 46.00 1.500 38.10 1.375 34.93 .242 6.15 .154 3.91 .790 20.07 .126 3.20 44 1.272 32.31
40www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
D38999/24
Jam Nut Receptacle
AE324
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
"O" RING SEAL
HEX NUT
PER D38999/28
MASTER KEYWAY
4 MINOR KEYWAYS
B
FLAT
A
E MATING THREAD
C
J THREAD
LOCKING INDICATOR BAND
COLOR: RED
32.50 (1.280)
MAX
PANEL THICKNESS
3.20(.126)
1.58(.062)
K ACCESSORY THREAD
F NUMBER OF TEETH
[ H
MAX
GROMMET
2.16(.085) MAX
GROMMET EXTENSION
BLUE COLOR BAND
(REAR RELEASE)
G
D
Page 38 Completed Part Number
Page 44 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 37 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 42 Polarization
Note 1: “K” Accessory Thread for AE324 is same as AE326
(“D” Accessory Thread) on page 41.
Note 2: “E” Mating Thread for AE324 is same as AE326
(“E” Mating Thread) on page 41 except it is Class 2A.
Note 3: Maximum Grommet Extension for insert layouts
incorporating size 8 and 10 contacts = 5.95(.234).
Shell
Size
A B C D F G [H J
+.004 +.10 +.024 +.60 No. of +.035 +.90 Jam Nut
±.016 ±.40 -.006 -.15 -.000 -.00 Teeth -.004 -.10 Maximum Thread
inch mm inch mm inch mm inch mm inch mm inch mm 0.100R
A1.063 27.00 .651 16.53 .945/.859 24.00/21.82 .555 14.10 12 .087 2.20 .299 7.59 M17x1-6g
B1.252 31.80 .751 19.07 1.063/.984 27.00/24.99 .555 14.10 16 .087 2.20 .427 10.85 M20x1-6g
C1.374 34.90 .938 23.82 1.260/1.172 32.00/29.77 .555 14.10 20 .087 2.20 .541 13.74 M25x1-6g
D1.500 38.10 1.062 26.97 1.417/1.296 36.00/32.91 .555 14.10 24 .087 2.20 .666 16.92 M28x1-6g
E1.626 41.30 1.187 30.15 1.457/1.422 37.00/36.12 .555 14.10 28 .087 2.20 .791 20.09 M32x1-6g
F1.811 46.00 1.312 33.32 1.614/1.546 41.00/39.26 .555 14.10 32 .118 3.00 .897 22.78 M35x1-6g
G1.937 49.20 1.437 36.50 1.811/1.672 46.00/42.47 .555 14.10 36 .118 3.00 1.022 25.96 M38x1-6g
H2.063 52.40 1.562 39.67 1.969/1.796 50.00/45.61 .555 14.10 40 .118 3.00 1.147 29.13 M41x1-6g
J2.189 55.60 1.687 42.85 2.017/1.939 51.23/49.25 .555 14.10 44 .118 3.00 1.272 32.31 M44x1-6g
41www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
D38999/26
Self-Locking, RFI Grounding Plug
AE326
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
– –
MASTER KEY
RFI STRIP
4 MINOR KEYS
E
MATING THREAD
BLUE COLOR BAND
LOCATION OPTIONAL
(REAR RELEASE)
31.00(1.220)
MAX
D
ACCESSORY THREAD
T
NUMBER OF TEETH
2.16(.085) MAX
GROMMET EXTENSION
7.11(.280)
MIN FULL THREAD
[
A
MAX
COUPLING NUT
[
B
MAX
GROMMET
Note : Maximum Grommet Extension for insert layouts
incorporating size 8 and 10 contacts = 5.95(.234).
Page 38 Completed Part Number
Page 44 Contacts, Sealing Plugs and Tools
Pages 17–19 Insert Arrangements
Page 37 Performance Specifications
Pages 15, 16 Insert Availability and Contact Information
Page 42 Polarization
Shell
Size
[A[B D E T
Accessory Thread Mating Thread No. of
Maximum Maximum Metric Class 2B Teeth
inch mm inch mm
A.858 21.80 .299 7.59 M12x1.0-6g 0.100R .6250-0.1P-0.3L 12
B.984 25.00 .427 10.85 M15x1.0-6g 0.100R .7500-0.1P-0.3L 16
C1.157 29.40 .541 13.74 M18x1.0-6g 0.100R .8750-0.1P-0.3L 20
D1.280 32.50 .666 16.92 M22x1.0-6g 0.100R 1.0000-0.1P-0.3L 24
E1.406 35.70 .791 20.09 M25x1.0-6g 0.100R 1.1875-0.1P-0.3L 28
F1.516 38.50 .897 22.78 M28x1.0-6g 0.100R 1.2500-0.1P-0.3L 32
G1.642 41.70 1.022 25.96 M31x1.0-6g 0.100R 1.3750-0.1P-0.3L 36
H1.768 44.90 1.147 29.13 M34x1.0-6g 0.100R 1.5000-0.1P-0.3L 40
J1.890 48.00 1.272 32.31 M37x1.0-6g 0.100R 1.6250-0.1P-0.3L 44
42www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
MIL-DTL-38999
Polarization
Series III
Keying Positions
– –
C°
B°
D°
A°
MASTER KEYWAY
NORMAL
Notes:
1. Mating face of receptacle shown (plug is opposite).
2. All minor keyways (keys) are rotated to provide shell
polarization while master keyway (key) remains fixed
as shown.
3. The angles for a given connector are the same whether it
contains pin or socket inserts.
4. Insert arrangement does not rotate relative to the master
keyway (key).
Shell
Size
Key/Keyway Key/Keyway Positions
BSC
Identification Letter A°B°C°D°
A (9) N105 140 215 265
A102 132 248 320
B80 118 230 312
C35 140 205 275
D64 155 234 304
E91 131 197 240
B (11)
C (13)
D (15)
N95 141 208 236
A113 156 182 292
B90 145 195 252
C53 156 220 255
D119 146 176 298
E51 141 184 242
E (17)
F (19)
G (21)
H (23)
J (25)
N80 142 196 293
A135 170 200 310
B49 169 200 244
C66 140 200 257
D62 145 180 280
E79 153 197 272
43www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
MIL-DTL-38999 Series III
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
Note: Diameter B cutout dimensions are listed separately
for back and front of panel mounting.
A
[
E
4x
[
C
[
B
MIN
FLANGE MOUNT
3.20(.126)
1.58(.062)
PANELTHICKNESS
D
JAM NUT
Shell
Size
A[B[B[C D [E
For Back Mounting For Front Mounting +.000 +.00 +.010 +.25
(TP) Minimum Minimum ±.005 ±.13 -.010 -.25 -.000 -.00
inch mm inch mm inch mm inch mm inch mm inch mm
A (9) .719 18.26 .656 16.66 .516 13.11 .128 3.25 .670 17.02 .700 17.78
B (11) .812 20.62 .796 20.22 .625 15.88 .128 3.25 .771 19.59 .825 20.96
C (13) .906 23.01 .922 23.42 .750 19.05 .128 3.25 .955 24.26 1.010 25.65
D (15) .969 24.61 1.047 26.59 .906 23.01 .128 3.25 1.085 27.56 1.135 28.83
E (17) 1.062 26.97 1.219 30.96 1.016 25.81 .128 3.25 1.210 30.73 1.260 32.01
F (19) 1.156 29.36 1.297 32.94 1.141 28.98 .128 3.25 1.335 33.91 1.385 35.18
G (21) 1.250 31.75 1.422 36.12 1.266 32.16 .128 3.25 1.460 37.08 1.510 38.35
H (23) 1.375 34.93 1.547 39.29 1.375 34.93 .154 3.91 1.585 40.26 1.635 41.53
J (25) 1.500 38.10 1.672 42.47 1.484 37.69 .154 3.91 1.710 43.43 1.760 44.70
44www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
MIL-DTL-38999
Contacts, Tools and Seal Plugs
Series III
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
– –
† MS3348 bushing required with 12 gauge wire.
*When tested with silver-plated wire.
** Insertion tool is not required.
*** Dummy contact, used in lieu of unwired contact and seal plug.
Note: Size 8 coax contacts are used with M17/095-RG180
cable, while size 8 Twinax contacts are used with
M17/176-00002 cable.
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
22D Power/Signal M39029/58-360 M39029/56-348 MS27488-22-1 M81969/14-01
20 Power/Signal M39029/58-363 M39029/56-351 MS27488-20-1 M81969/14-10
16 Power/Signal M39029/58-364 M39029/56-352 MS27488-16-1 M81969/14-03
12 Power/Signal M39029/58-365 M39029/56-353
MS27488-12-1 M81969/14-0412 Coax Coax M39029/28-211 M39029/75-416
12 Coax Coax M39029/102-558 M39029/103-559
10 (Power) Power M39029/58-528 M39029/56-527 M85049/81-10*** M81969/14-05
8 Coax Coax M39029/60-367 M39029/59-366 MS27488-8-1 M81969/14-06
8 Twinax Twinax M39029/90-529 M39029/91-530 MS27488-8-1 M81969/14-12
Contact
Size/Type
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
22D M22520/2-01 M22520/2-09 M22520/2-07 M81969/8-01 M81969/8-02
20 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-05 M81969/8-06
M22520/2-01 M22520/2-10 M22520/2-10
16 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-07 M81969/8-08
12 M22520/1-01 M22520/1-04 M22520/1-04
M81969/8-09 M81969/8-1012 Coax Inner M22520/2-01 M22520/2-34 M22520/2-34
12 Coax Outer M22520/31-01 M22520/31-02 M22520/31-02
10 ( Power) — — — M81969/8-11 M81969/8-12
8 Coax Inner M22520/2-01 M22520/2-31 M22520/2-31
M81969/8-13** M81969/8-14
8 Coax Outer M22520/5-01 M22520/5-05 M22520/5-05
Die Closure B Die Closure B
8 Twinax Center M22520/2-01 M22520/2-37 M22520/2-37
— —
8 Twinax Outer
&Intermediate M22520/5-01 M22520/5-200 M22520/5-200
Contact
Size
Test Current* Voltage* Crimp Well Data Wire Range Finished Wire [ Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWG mm2inch mm inch mm
22D 5.0 73 .0345 ±.0010 .141 3.58 28-22 .08-.33 .030 .76 .054 1.37
20 7.5 55 .047 ±.001 .209 5.31 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .209 5.31 20-16 .52-1.31 .065 1.65 .109 2.77
12 23.0 42 .100 ±.002 .209 5.31 14-12 2.08-3.31 .097 2.46 .142 3.61
10 33.0 33 .137 ±.003 .355 9.02 12-10† 3.31-5.26 .135 3.42 .162 4.12
45www.conesys.com sales@aero-electric.com
MIL–DTL– 38999 S III
MIL-DTL-38999
Contact Installation Instructions
Series III
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the
contact. Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into
the insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to
removing insertion tool, do not try to reinsert the
insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
damage the inside of the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place the wire into the
extraction tool of the pin or socket.
3. Slowly slide the extraction tool down wire into the contact
cavities until the tool tip bottoms against the contact
shoulder, expanding the clip retaining tines. Hold the
wire firmly in the tool and pull the wired contact and
tool straight out of the rear of the insulator.
Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool
22D M39029/58-360 M39029/56-348 M22520/2-01 M22520/2-09 M22520/07 M81969/14-01
20 M39029/58-363 M39029/56-351 M22520/1-01 M22520/1-04 Red M22520/1-04 red M81969/14-10
M22520/2-01 M22520/2-10 M22520/2-10
16 M39029/58-364 M39029/56-352 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03
12 M39029/58-365 M39029/56-353 M22520/1-01 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04
10 M39029/58-528 M39029/56-527 * * * M81969/14-05
For Coax and Twinax contacts refer to instructions that are supplied with
contacts.
* Contact Daniels Manufacturing for crimp tool/positioner.
46www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
– –
MIL-DTL-5015
Features and Application
Series III (Rear Release)
www.conesys.com sales@aero-electric.com
Features and Application
The threaded coupling, environmentally sealed
MIL-DTL-5015 Series III connector with rear-removable
crimp contacts was developed to replace the earlier solder
type. This redesigned connector is intermateable and
intermountable with the MIL-DTL-5015 Series I solder type
(MS310*) as well as the MIL-DTL- 83723 Series II (USAF)
crimp type and MIL-DTL-5015 Series II Front Release
(MS340*). Thus, it provides for a minimum effort and high
economy upgrade for existing applications.
These connectors are recommended for a wide range of
applications, from commercial/industrial and mass
transportation systems to the most stringent high reliability
defense and aerospace requirements.
This family of connectors is offered in four receptacle
mounting configurations. They include two square flange
receptacles, both wall and box mounting; cable connecting
receptacles; and jam nut receptacles which incorporate “O”
ring seals, designed for rear panel “D” hole mounting.
Two plug styles are offered - standard plug with captivated
coupling nut retained by a combination “L” washer and
retaining ring to prevent inadvertent disassembly and a
self-locking, anti-decoupling plug, which eliminates the need
for safety wiring.
Eighty-eight insert arrangements per MIL-STD-1651 are tooled
and qualified to MIL-DTL-5015, utilizing 1 to 85 contacts.
Contacts come in sizes 16, 12, 8, 4 and 0, terminating wire
sizes from 20 gauge to 0 gauge.
These connectors are available in wide range of shell
materials and finishes. Aluminum shells are offered in
both electroless nickel and olive drab cadmium to both
commercial and MS callouts. Other finishes such as anodic
and zinc cobalt are available upon request to commercial
callouts only. In addition, we offer passivated stainless steel
shells with both standard and firewall-rated inserts, and
carbon steel shells with firewall inserts.
Lockwiring Eliminated – Self-locking plug eliminates the
need for lockwiring.
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
Insert Polarization – Alternate insert clocking positions aid
in mating of adjacent connectors having identical insert
arrangement.
Closed-Entry Socket Insert – Hard dielectric socket face has
lead-in chamfers for positive alignment of pins (even partially
bent within pre-established limits) with sockets.
Interfacial Pin Insert Seal – Raised moisture barriers
around each pin, which mate into lead-in chamfers of hard
face socket insert, provide individual contact sealing.
Interfacial seal is never touched by service tools.
Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in each
cavity at the rear of the connector.
Superior Contact Stability – Rear release crimp contact
system features a stamped beryllium-copper retaining clip
captivated by molded-in shoulders of each contact cavity in
the insulator. A rear-inserted M81969 plastic tool expands
the tines beyond the shoulder, releasing the contact.
47www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015
Performance Specifications
MS345*/AE55*
– –
Performance Specifications
Operating Temperature Range
Classes KS and LS: -55°C to +200°C (-67°F to +392°F)
Classes KT and W: -55°C to +175°C (-67°F to +347°F)
Class L: -55°C to +200°C (-67°F to +392°F)
Class A*: -55°C to +200°C (-67°F to +392°F)
Material and Finish Data (Class)
KT– carbon steel shell, olive drab cadmium, firewall
KS – stainless steel shell, passivated, firewall
L – aluminum shell, electroless nickel finish
LS – stainless steel shell, passivated
W – aluminum shell, olive drab cadmium over nickel base
A* – aluminum shell, black anodized finish
Corrosion Resistance
Classes KS and LS withstand 1,000-hour salt spray.
Class KT withstands 96-hour salt spray.
Class L withstands 96-hour salt spray.
Class W withstands 1,000-hour salt spray.
Environmental Seal
Wired, mated connectors with specified accessories
attached, shall meet the altitude-immersion test specified in
MIL-DTL-5015.
Durability
Minimum of 100 mating cycles
Voltage Rating
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, coupling
ring shall not loosen, and there shall be no interruption of
electrical continuity longer than 10 microseconds when
subjected to the following:
Shock
Mated connectors withstand a pulse of approximate half
sine wave of 50 G magnitude with duration of 11 milliseconds
applied in three axes per MIL-STD-1344, method 2004,
test condition A.
Vibration
Mated connectors withstand the following vibration levels:
●Random vibration per MIL-STD-1344, method 2005,
and test condition VI, letter J.
Shell-to-Shell Conductivity
Maximum potential drop shall not exceed:
●Class W = 5 millivolts
●All other classes (except A*) = 50 millivolts
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808
(lubricating oil), MIL-PRF-23699 (lubricating oil),
MIL-PRF-5606 (hydraulic fluid), M2-V Chevron oil,
Coolanol 25, MIL-DTL-83133 (turbine fuel JP-8),
MIL-DTL-5624 (turbine fuels JP-4 and JP-5), SAE-AMS1424
Type I (defrosting fluid), and other solvents and cleaning
agents.
*Not MS approved, available to Aero-Electric part number only.
**To be used by designer only as a guide.
Service
Rating
Maximum Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft 70,000 Ft.110,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
Inst. 200 250 1000 400 260 200
A500 700 2000 600 360 200
D900 1250 2800 675 400 200
E1250 1750 3500 750 440 200
B1750 2450 4500 825 480 200
C3000 4200 7000 975 560 200
48www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III
Part Number Development
Rear Release
Military and Aero-Electric Part Number Development
– –
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 2 to 26 of each contact and two spares for
inserts with 27 or more of each size, and a minimum of one
sealing plug up to 15% of the number contacts. No spares
or seal plugs are provided with one contact layouts. No
spares or seal plugs for contact sizes 0 and 4 are provided.
For contact size 8, no contact spares are provided, but seal
plugs are included. In addition, one insertion/removal tool
of each size is included.
Note 2: KS and KT firewall classes are only available to
Military part numbers for shell types MS3450, MS3456 and
MS3459. KS and KT classes are available to Aero callouts for
AE551 and 554, but not for AE552 (box mount receptacle).
Note 3: Proper part number marking has no “0” in front
of single digit (numeric) shell size (8S) and no “0” in front
of single digit layout. Examples: JMS3450W8S-1S and
JMS3450W24-2PW. Please note that J or JAN marking is
required immediately in front of MS part number.
Mil. Prefix MS34 50 L14S - 5 P X
Aero Prefix AE5 50 L14S - 5 P X -340
Shell Type
50 = Wall mount receptacle
51 = Cable connecting receptacle
52 = Box mount receptacle
54 = Jam nut receptacle
56 = Straight plug
59 = Self-locking plug
Class (Material and Finish)
A= Aluminum shell, black anodized finish (Aero part number only)
KS = Stainless steel shell, passivated, firewall (n/a in MS3451, MS3452, MS3454)
KT = Carbon steel shell, cadmium ffinish, ffirewall (n/a in MS3451, MS3452, MS3454)
LS = Stainless steel shell, passivated
L= Aluminum shell, electroless nickel finish
W= Aluminum shell, olive drab cadmium over electroless nickel base
Shell Size
8S, 10S, 10SL, 12, 12S, 14, 14S, 16, 16S, 18, 20, 22, 24, 28, 32, 36 or 40
Insert Arrangement
See pages 58 thru 68
Contact Style
P= Pin
S= Socket
A= Pin connector less pins (with intent to use non-std contact)
B= Socket connector less sockets (with intent to use non-std contacts)
Polarization
N= Normal (not included in part number)
W, X,Y or Z= Alternate insert polarizations (see pages 58 thu 62 for position availability)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/31-XXX E-nut
341 = Connector kitted with M85049/52-1-XXX straight clamp
342 = Connector kitted with M85049/51-1-XXX right angle clamp
Consult factory for other modifications
49www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MS3450 per AS34501
Wall Mount Receptacle
AE550
Threaded Coupling, Crimp Removable, Rear Release
– –
Note 1:L MAXis same as L MAXfor AE551 on next page.
Note 2: Maximum grommet O.D. is same as [E MAXfor
AE551 on next page.
BLUE COLOR BANDS
J
ACCESSORY THREAD
G
F
A
MATING THREAD
DB
POLARIZING KEY
4x
[
H
HOLES
3 ACCESSORY TEETH
L
MAX
MIN FULL THREAD
.290(7.37) FOR 8S-24
.467(11.86) FOR 28-40
GROMMET
EXTENSION .190(4.83)
.130(3.30)
FOR 16 AND 12 CONTACTS
.340(8.64)
.130(3.30)
FOR 8,4, AND 0 CONTACTS
Page 48 Completed Part Number
Page 56 Contacts, Sealing Plugs and Tools
Pages 63–68 Insert Arrangements
Page 47 Performance Specifications
Pages 58–62 Insert Availability and Contact Information
Page 58 Polarization
Shell
Size
A B D F G [HJ
Mating Classes L, LS, WClasses KS, KT Accessory
Thread +.031 +.79 +.010 +.25 +.010 +.25 Thread
Class 2A ±.015 ±.38 -.000 -.00 (TP) ±.031 ±.79 -.005 -.13 -.005 -.13 Class 2A
inch mm inch mm inch mm inch mm inch mm inch mm
8S 1/2-28 UNEF .083 2.11 .562 14.27 .594 15.09 .875 22.23 .120 3.05 .150 3.81 1/2-20UNF
10S 5/8-24 UNEF .083 2.11 .562 14.27 .719 18.26 1.000 25.40 .120 3.05 .150 3.81 5/8-24UNEF
10SL 5/8-24 UNEF .083 2.11 .562 14.27 .719 18.26 1.000 25.40 .120 3.05 .150 3.81 5/8-24UNEF
12 3/4-20 UNEF .083 2.11 .750 19.05 .812 20.62 1.094 27.79 .120 3.05 .150 3.81 3/4-20UNEF
12S 3/4-20 UNEF .083 2.11 .562 14.27 .812 20.62 1.094 27.79 .120 3.05 .150 3.81 3/4-20UNEF
14 7/8-20 UNEF .083 2.11 .750 19.05 .906 23.01 1.188 30.18 .120 3.05 .150 3.81 7/8-20UNEF
14S 7/8-20 UNEF .083 2.11 .562 14.27 .906 23.01 1.188 30.18 .120 3.05 .150 3.81 7/8-20UNEF
16 1-20 UNEF .083 2.11 .750 19.05 .969 24.61 1.281 32.54 .120 3.05 .150 3.81 1-20UNEF
16S 1-20 UNEF .083 2.11 .562 14.27 .969 24.61 1.281 32.54 .120 3.05 .150 3.81 1-20UNEF
18 1 1/8-18 UNEF .125 3.18 .750 19.05 1.062 26.97 1.375 34.93 .120 3.05 .177 4.50 1-1/16-18UNEF
20 1 1/4-18 UNEF .125 3.18 .750 19.05 1.156 29.36 1.500 38.10 .120 3.05 .177 4.50 1-3/16-18UNEF
22 1 3/8-18 UNEF .125 3.18 .750 19.05 1.250 31.75 1.625 41.28 .120 3.05 .177 4.50 1-5/16-18UNEF
24 1 1/2-18 UNEF .125 3.18 .812 20.62 1.375 34.93 1.750 44.45 .147 3.73 .177 4.50 1-7/16-18UNEF
28 1 3/4-18 UNS .125 3.18 .812 20.62 1.562 39.67 2.000 50.80 .147 3.73 .177 4.50 1-3/4-18UNS
32 2-18 UNS .125 3.18 .875 22.23 1.750 44.45 2.250 57.15 .173 4.39 .209 5.31 2-18UNS
36 2 1/4-16 UN .125 3.18 .875 22.23 1.938 49.23 2.500 63.50 .173 4.39 .209 5.31 2-1/4-16UN
40 2 1/2-16 UN .125 3.18 .875 22.23 2.188 55.58 2.750 69.85 .173 4.39 .209 5.31 2-1/2-16UN
50www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MS3451 per AS34511
Cable Connecting Receptacle
AE551
Threaded Coupling, Crimp Removable, Rear Release
– –
[
S
[
E
MAX
GROMMET
BLUE COLOR BANDS
V
ACCESSORY THREAD
A
MATING THREAD
M
L
MAX
R
ACROSS FLATS
3 ACCESSORY TEETH
MIN FULL THREAD
.290(7.37) FOR 8S-24
.467(11.86) FOR 28-40
.083±.015(2.11±.38) FOR 8S-16S
.125±.015(3.18±.38) FOR 18-40
POLARIZING KEY
GROMMET
EXTENSION .190(4.83)
.130(3.30)
FOR 16 AND 12 CONTACTS
.340(8.64)
.130(3.30)
FOR 8,4, AND 0 CONTACTS
Shell
Size
A[EL MAXM R [SV
Mating Thread 16 & 12 8, 4 & 0 +.031 +.79 Accessory Thread
Class 2A Maximum Contacts Contacts -.000 -.00 ±.031 ±.79 Class 2A
inch mm inch mm inch mm inch mm inch mm inch mm
8S 1/2-28 UNEF .305 7.75 2.031 51.59 ––.562 14.27 .504/.496 12.80/12.60 .729 18.52 1/2-20UNF
10S 5/8-24 UNEF .405 10.29 2.031 51.59 ––.562 14.27 .629/.621 15.98/15.77 .854 21.69 5/8-24UNEF
10SL 5/8-24 UNEF .405 10.29 2.031 51.59 ––.562 14.27 .629/.621 15.98/15.77 .854 21.69 5/8-24UNEF
12 3/4-20 UNEF .549 13.94 2.125 53.98 ––.750 19.05 .754/.746 19.15/18.95 .974 24.74 3/4-20UNEF
12S 3/4-20 UNEF .549 13.94 2.031 51.59 ––.562 14.27 .754/.746 19.15/18.95 .974 24.74 3/4-20UNEF
14 7/8-20 UNEF .665 16.89 2.125 53.98 ––.750 19.05 .879/.871 22.33/22.12 1.099 27.91 7/8-20UNEF
14S 7/8-20 UNEF .665 16.89 2.031 51.59 ––.562 14.27 .879/.871 22.33/22.12 1.099 27.91 7/8-20UNEF
16 1-20 UNEF .790 20.07 2.125 53.98 2.500 63.50 .750 19.05 1.005/.996 25.53/25.30 1.224 31.09 1-20UNEF
16S 1-20 UNEF .790 20.07 2.031 51.59 ––.562 14.27 1.005/.996 25.53/25.30 1.224 31.09 1-20UNEF
18 1 1/8-18 UNEF .869 22.07 2.125 53.98 2.500 63.50 .750 19.05 1.131/1.121 28.73/28.47 1.349 34.26 1-1/16-18UNEF
20 1 1/4-18 UNEF .994 25.25 2.125 53.98 2.500 63.50 .750 19.05 1.256/1.246 31.90/31.65 1.474 37.44 1-3/16-18UNEF
22 1 3/8-18 UNEF 1.119 28.42 2.125 53.98 2.500 63.50 .750 19.05 1.381/1.371 35.08/34.82 1.599 40.61 1-5/16-18UNEF
24 1 1/2-18 UNEF 1.244 31.60 2.125 53.98 2.500 63.50 .812 20.62 1.506/1.496 38.25/38.00 1.715 43.56 1-7/16 -18UNEF
28 1 3/4-18 UNS 1.465 37.21 2.125 53.98 2.500 63.50 .812 20.62 1.756/1.746 44.60/44.35 1.974 50.14 1-3/4-18UNS
32 2-18 UNS 1.715 43.56 2.125 53.98 2.500 63.50 .875 22.23 2.007/1.996 50.98/50.70 2.224 56.49 2-18UNS
36 2 1/4-16 UN 1.930 49.02 2.125 53.98 2.500 63.50 .875 22.23 2.257/2.246 57.33/57.05 2.474 62.84 2-1/4-16UN
40 2 1/2-16 UN 2.145 54.48 2.125 53.98 2.500 63.50 .875 22.23 2.511/2.496 63.78/63.40 2.724 69.19 2-1/2-16UN
Page 48 Completed Part Number
Page 56 Contacts, Sealing Plugs and Tools
Pages 63–68 Insert Arrangements
Page 47 Performance Specifications
Pages 58–62 Insert Availability and Contact Information
Page 58 Polarization
51www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MS3452
Box Mount Receptacle
AE552
Threaded Coupling, Crimp Removable, Rear Release
– –
S
R
A
MATING THREAD
M
L
MAX
[
GG
4x
[
T
HOLES
.083±.015(2.11±.38) FOR 8S-16S
.125±.015(3.18±.38) FOR 18-40
BLUE COLOR BAND
POLARIZING KEY
Page 48 Completed Part Number
Page 56 Contacts, Sealing Plugs and Tools
Pages 63–68 Insert Arrangements
Page 47 Performance Specifications
Pages 58–62 Insert Availability and Contact Information
Page 58 Polarization
Note 1: The insulation material shall be above, flush with,
or no more than .015 inches (.38 mm) below the metal shell.
Note 2: At time ofcatalog printing, MS3452 was not
superseded by SAE document - AS34521.
Shell
Size
A[GG L MAXM R S [T
Mating Thread 16 & 12 8, 4 & 0 +.031 +.79 +.010 +.25
Class 2A ±.016 ±.41 Contacts Contacts -.000 -.00 (TP) ±.031 ±.79 -.005 -.13
inch mm inch mm inch mm inch mm inch mm inch mm inch mm
8S 1/2-28 UNEF .500 12.70 1.662 42.21 ––.562 14.27 .594 15.09 .875 22.23 .120 3.05
10S 5/8-24 UNEF .625 15.88 1.662 42.21 ––.562 14.27 .719 18.26 1.000 25.40 .120 3.05
10SL 5/8-24 UNEF .625 15.88 1.662 42.21 ––.562 14.27 .719 18.26 1.000 25.40 .120 3.05
12 3/4-20 UNEF .750 19.05 1.662 42.21 ––.750 19.05 .812 20.62 1.094 27.79 .120 3.05
12S 3/4-20 UNEF .750 19.05 1.662 42.21 ––.562 14.27 .812 20.62 1.094 27.79 .120 3.05
14 7/8-20 UNEF .875 22.23 1.662 42.21 ––.750 19.05 .906 23.01 1.188 30.18 .120 3.05
14S 7/8-20 UNEF .875 22.23 1.662 42.21 ––.562 14.27 .906 23.01 1.188 30.18 .120 3.05
16 1-20 UNEF 1.000 25.40 1.662 42.21 1.937 49.20 .750 19.05 .969 24.61 1.281 32.54 .120 3.05
16S 1-20 UNEF 1.000 25.40 1.662 42.21 ––.562 14.27 .969 24.61 1.281 32.54 .120 3.05
18 1 1/8-18 UNEF 1.062 26.97 1.662 42.21 1.937 49.20 .750 19.05 1.062 26.97 1.375 34.93 .120 3.05
20 1 1/4-18 UNEF 1.187 30.15 1.662 42.21 1.937 49.20 .750 19.05 1.156 29.36 1.500 38.10 .120 3.05
22 1 3/8-18 UNEF 1.312 33.32 1.662 42.21 1.937 49.20 .750 19.05 1.250 31.75 1.625 41.28 .120 3.05
24 1 1/2-18 UNEF 1.437 36.50 1.662 42.21 1.937 49.20 .812 20.62 1.375 34.93 1.750 44.45 .147 3.73
28 1 3/4-18 UNS 1.750 44.45 1.662 42.21 1.937 49.20 .812 20.62 1.562 39.67 2.000 50.80 .147 3.73
32 2-18 UNS 2.000 50.80 1.662 42.21 1.937 49.20 .875 22.23 1.750 44.45 2.250 57.15 .173 4.39
36 2 1/4-16 UN 2.250 57.15 1.662 42.21 1.937 49.20 .875 22.23 1.938 49.23 2.500 63.50 .173 4.39
40 2 1/2-16 UN 2.500 63.50 1.662 42.21 1.937 49.20 .875 22.23 2.188 55.58 2.750 69.85 .173 4.39
52www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MS3454 per AS34541
Jam Nut Receptacle
AE554
Threaded Coupling, Crimp Removable, Rear Release
– –
MIN FULL THREAD
.290(7.37) FOR 8S-24
.467(11.86) FOR 28-40
BLUE COLOR BAND
BLUE COLOR BAND
D
.180(4.57)
.165(4.19)
F
MATING THREAD
H
ACCESSORY THREAD
[
.032(.81) MAX
SAFETY WIRE HOLE
(3 EQALLY SPACED)
"O" RING
A
B
[
C
SPRING PIN
MS171430
PANEL THICKNESS
.128(3.25) MAX
.196(4.98)
.186(4.72)
E
MAX
3 ACCESSORY TEETH
GROMMET
EXTENSION .190(4.83)
.130(3.30)
FOR 16 AND 12 CONTACTS
.340(8.64)
.130(3.30)
FOR 8,4, AND 0 CONTACTS
POLARIZING KEY
Page 48 Completed Part Number
Page 56 Contacts, Sealing Plugs and Tools
Pages 63–68 Insert Arrangements
Page 47 Performance Specifications
Pages 58–62 Insert Availability and Contact Information
Page 58 Polarization
Note: Maximum grommet O.D. is same as [E MAXon next
page.
Shell
Size
A B [C D E MAXF H
16 & 12 8, 4 & 0 Mating Thread Accessory Thread
±.005 ±.13 ±.010 ±.25 ±.005 ±.13 ±.005 ±.13 Contacts Contacts Class 2A Class 2A
inch mm inch mm inch mm inch mm inch mm inch mm
8S 1.187 30.15 .687 17.45 1.272 32.31 .720 18.29 2.031 51.59 ––1/2-28 UNEF 1/2-20UNF
10S 1.312 33.32 .812 20.62 1.397 35.48 .720 18.29 2.031 51.59 ––5/8-24 UNEF 5/8-24UNEF
10SL 1.312 33.32 .812 20.62 1.397 35.48 .720 18.29 2.031 51.59 ––5/8-24 UNEF 5/8-24UNEF
12 1.437 36.50 .937 23.80 1.522 38.66 .970 24.64 2.125 53.98 ––3/4-20 UNEF 3/4-20UNEF
12S 1.437 36.50 .937 23.80 1.522 38.66 .720 18.29 2.031 51.59 ––3/4-20 UNEF 3/4-20UNEF
14 1.562 39.67 1.125 28.58 1.647 41.83 .970 24.64 2.125 53.98 ––7/8-20 UNEF 7/8-20UNEF
14S 1.562 39.67 1.125 28.58 1.647 41.83 .720 18.29 2.031 51.59 ––7/8-20 UNEF 7/8-20UNEF
16 1.687 42.85 1.250 31.75 1.772 45.01 .970 24.64 2.125 53.98 2.500 63.50 1-20 UNEF 1-20UNEF
16S 1.687 42.85 1.250 31.75 1.772 45.01 .720 18.29 2.031 51.59 ––1-20 UNEF 1-20UNEF
18 1.812 46.02 1.375 34.93 1.897 48.18 .970 24.64 2.125 53.98 2.500 63.50 1 1/8-18 UNEF 1-1/16-18UNEF
20 1.937 49.20 1.500 38.10 2.022 51.36 .970 24.64 2.125 53.98 2.500 63.50 1 1/4-18 UNEF 1-3/16-18UNEF
22 2.156 54.76 1.625 41.28 2.241 56.92 .970 24.64 2.125 53.98 2.500 63.50 1 3/8-18 UNEF 1-5/16-18UNEF
24 2.281 57.94 1.750 44.45 2.366 60.10 .970 24.64 2.125 53.98 2.500 63.50 1 1/2-18 UNEF 1-7/16-18UNEF
28 2.531 64.29 2.000 50.80 2.616 66.45 .970 24.64 2.125 53.98 2.500 63.50 1 3/4-18 UNS 1-3/4-18UNS
32 2.781 70.64 2.375 60.33 2.866 72.80 .970 24.64 2.125 53.98 2.500 63.50 2-18 UNS 2-18UNS
36 3.031 76.99 2.625 66.68 3.116 79.15 .970 24.64 2.125 53.98 2.500 63.50 2 1/4-16 UN 2-1/4-16UN
40 3.281 83.34 2.875 73.03 3.366 85.50 .970 24.64 2.125 53.98 2.500 63.50 2 1/2-16 UN 2-1/2-16UN
53www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MS3456
Straight Plug
AE556
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 48 Completed Part Number
Page 56 Contacts, Sealing Plugs and Tools
Pages 63–68 Insert Arrangements
Page 47 Performance Specifications
Pages 58–62 Insert Availability and Contact Information
Page 58 Polarization
MIN FULL THREAD
.290(7.37) FOR 8S-24
.467(11.86) FOR 28-40
GROMMET
EXTENSION .190(4.83)
.130(3.30)
FOR 16 AND 12 CONTACTS
.340(8.64)
.130(3.30)
FOR 8,4, AND 0 CONTACTS
POLARIZING
KEYWAY
[
A
MAX
C
MATING THREAD
BLUE COLOR BAND
H
MAX
3x
[
.035(.89) SAFETY
WIRE HOLES
EQUALLY SPACED
F
ACCESSORY THREAD
3 TEETH
EQUALLY SPACED
[
E
MAX
GROMMET
[
B
Shell
Size
[A[B C [EF H MAX
Mating Thread Accessory Thread 16 & 12 8, 4 & 0
Maximum ±.005 ±.13 Class 2B Maximum Class 2A Contacts Contacts
inch mm inch mm inch mm inch mm inch mm
8S .844 21.44 .360 9.14 1/2-28 UNEF .305 7.75 1/2-20UNF 2.031 51.59 ––
10S .969 24.61 .435 11.05 5/8-24 UNEF .405 10.29 5/8-24UNEF 2.031 51.59 ––
10SL .969 24.61 .443* 11.25* 5/8-24 UNEF .405 10.29 5/8-24UNEF 2.031 51.59 ––
12 1.062 26.97 .550 13.97 3/4-20 UNEF .549 13.94 3/4-20UNEF 2.125 53.98 ––
12S 1.062 26.97 .550 13.97 3/4-20 UNEF .549 13.94 3/4-20UNEF 2.031 51.59 ––
14 1.156 29.36 .670 17.02 7/8-20 UNEF .665 16.89 7/8-20UNEF 2.125 53.98 ––
14S 1.156 29.36 .670 17.02 7/8-20 UNEF .665 16.89 7/8-20UNEF 2.031 51.59 ––
16 1.250 31.75 .800 20.32 1-20 UNEF .790 20.07 1-20UNEF 2.125 53.98 2.500 63.50
16S 1.250 31.75 .800 20.32 1-20 UNEF .790 20.07 1-20UNEF 2.031 51.59 ––
18 1.344 34.14 .925 23.50 1 1/8-18 UNEF .869 22.07 1-1/16-18UNEF 2.125 53.98 2.500 63.50
20 1.469 37.31 1.045 26.54 1 1/4-18 UNEF .994 25.25 1-3/16-18UNEF 2.125 53.98 2.500 63.50
22 1.594 40.49 1.170 29.72 1 3/8-18 UNEF 1.119 28.42 1-5/16-18UNEF 2.125 53.98 2.500 63.50
24 1.719 43.66 1.295 32.89 1 1/2-18 UNEF 1.244 31.60 1-7/16-18UNEF 2.125 53.98 2.500 63.50
28 1.969 50.01 1.515 38.48 1 3/4-18 UNS 1.465 37.21 1-3/4-18UNS 2.125 53.98 2.500 63.50
32 2.219 56.36 1.765 44.83 2-18 UNS 1.715 43.56 2-18UNS 2.125 53.98 2.500 63.50
36 2.469 62.71 1.975 50.17 2 1/4-16 UN 1.930 49.02 2-1/4-16UN 2.125 53.98 2.500 63.50
40 2.719 69.06 2.225 56.52 2 1/2-16 UN 2.145 54.48 2-1/2-16UN 2.125 53.98 2.500 63.50
* Tolerance for this dimension is ± .003(.08)
Note: At time ofcatalog printing, MS3456 was not
superseded by SAE document - AS34561.
54www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MS3459 per AS34591
Self-Locking Plug
AE559
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 48 Completed Part Number
Page 56 Contacts, Sealing Plugs and Tools
Pages 63–68 Insert Arrangements
Page 47 Performance Specifications
Pages 58–62 Insert Availability and Contact Information
Page 58 Polarization
L
MAX
[
C
MAX
B
ACCESSORY THREAD
3
ACCESSORY TEETH
BLUE COLOR BAND
MIN FULL THREAD
.290(7.37) FOR 8S-24
.467(11.86) FOR 28-40
[
D
[
E
MAX
GROMMET
POLARIZING
KEYWAY
GROMMET
EXTENSION .190(4.83)
.130(3.30)
FOR 16 AND 12 CONTACTS
.340(8.64)
.130(3.30)
FOR 8,4,AND 0 CONTACTS
A
MATING THREAD
Shell
Size
A B [C[D[EL MAX
Mating Thread Accessory Thread 16 & 12 8, 4 & 0
Class 2B Class 2A Maximum ±.005 ±.13 Maximum Contacts Contacts
inch mm inch mm inch mm inch mm inch mm
8S 1/2-28 UNEF 1/2-20UNF .963 24.46 .360 9.14 .305 7.75 2.031 51.59 ––
10S 5/8-24 UNEF 5/8-24UNEF 1.088 27.64 .435 11.05 .405 10.29 2.031 51.59 ––
10SL 5/8-24 UNEF 5/8-24UNEF 1.088 27.64 .443* 11.25* .405 10.29 2.031 51.59 ––
12 3/4-20 UNEF 3/4-20UNEF 1.213 30.81 .550 13.97 .549 13.94 2.125 53.98 ––
12S 3/4-20 UNEF 3/4-20UNEF 1.213 30.81 .550 13.97 .549 13.94 2.031 51.59 ––
14 7/8-20 UNEF 7/8-20UNEF 1.358 34.49 .670 17.02 .665 16.89 2.125 53.98 ––
14S 7/8-20 UNEF 7/8-20UNEF 1.358 34.49 .670 17.02 .665 16.89 2.031 51.59 ––
16 1-20 UNEF 1-20UNEF 1.463 37.16 .800 20.32 .790 20.07 2.125 53.98 2.500 63.50
16S 1-20 UNEF 1-20UNEF 1.463 37.16 .800 20.32 .790 20.07 2.031 51.59 ––
18 1 1/8-18 UNEF 1-1/16-18UNEF 1.588 40.34 .925 23.50 .869 22.07 2.125 53.98 2.500 63.50
20 1 1/4-18 UNEF 1-3/16-18UNEF 1.713 43.51 1.045 26.54 .994 25.25 2.125 53.98 2.500 63.50
22 1 3/8-18 UNEF 1-5/16-18UNEF 1.788 45.42 1.170 29.72 1.119 28.42 2.125 53.98 2.500 63.50
24 1 1/2-18 UNEF 1-7/16-18UNEF 1.963 49.86 1.295 32.89 1.244 31.60 2.125 53.98 2.500 63.50
28 1 3/4-18 UNS 1-3/4-18UNS 2.213 56.21 1.515 38.48 1.465 37.21 2.125 53.98 2.500 63.50
32 2-18 UNS 2-18UNS 2.463 62.56 1.765 44.83 1.715 43.56 2.125 53.98 2.500 63.50
36 2 1/4-16 UN 2-1/4-16UN 2.713 68.91 1.975 50.17 1.930 49.02 2.125 53.98 2.500 63.50
40 2 1/2-16 UN 2-1/2-16UN 2.963 75.26 2.225 56.52 2.145 54.48 2.125 53.98 2.500 63.50
* Tolerance for this dimension is ± .003(.08)
55www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III, Rear Release
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
A
[
C
[
B
E
[
D
.100(2.54) DIA.
.095(2.41)
MS3454 (AE554) CUTOUT
Flange and Jam Nut Mounting Dimensions
Shell
Size
A[B[C [D E
Classes L, LS, W Classes KS, KT
+.010 +.25 +.010 +.25 +.015 +.38
(TP) ±.010 ±.25 -.005 -.13 -.005 -.13 -.000 -.00 ±.005 ±.13
inch mm inch mm inch mm inch mm inch mm inch mm
8S .594 15.09 .562 14.27 .120 3.05 .150 3.81 .505 12.83 .323 8.20
10S, 10SL .719 18.26 .688 17.48 .120 3.05 .150 3.81 .630 16.00 .385 9.78
12, 12S .812 20.62 .812 20.62 .120 3.05 .150 3.81 .755 19.18 .448 11.38
14, 14S .906 23.01 .938 23.83 .120 3.05 .150 3.81 .880 22.35 .510 12.95
16, 16S .969 24.61 1.062 26.97 .120 3.05 .150 3.81 1.005 25.53 .573 14.55
18 1.062 26.97 1.188 30.18 .120 3.05 .177 4.50 1.130 28.70 .635 16.13
20 1.156 29.36 1.312 33.32 .120 3.05 .177 4.50 1.255 31.88 .698 17.73
22 1.250 31.75 1.438 36.53 .120 3.05 .177 4.50 1.380 35.05 .760 19.30
24 1.375 34.93 1.562 39.67 .147 3.73 .177 4.50 1.505 38.23 .823 20.90
28 1.562 39.67 1.812 46.02 .147 3.73 .177 4.50 1.755 44.58 .948 24.08
32 1.750 44.45 2.062 52.37 .173 4.39 .209 5.31 2.005 50.93 1.073 27.25
36 1.938 49.23 2.312 58.72 .173 4.39 .209 5.31 2.255 57.28 1.198 30.43
40 2.188 55.58 2.562 65.07 .173 4.39 .209 5.31 2.505 63.63 1.323 33.60
56www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015
Contacts, Tools and Seal Plugs
MS345*/AE55*
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
– –
†MS3348 bushings required in crimp barrel to accommodate 10, 6 and
2 wire gauges. Bushings are ordered separately.
Note 1: 16S socket contacts are only used in shell sizes 8S,
10S, 10SL, 12S, 14S and 16S.
Note 2:Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
* No spare size 0, 4 and 8 contacts are provided in connector contact packages.
** Not supplied as part of connector contact packages.
Note 3: Metal Insertion tool is not req’d for size 8, 4
and 0 contacts. Metal insertion tool for size 16 contacts =
M81969/8-207. Metal insertion tool for size 12 contacts =
M81969/8-209.
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
16S Power/Signal N/A M39029/30-217 MS27488-16-1 M81969/14-03
16 Power/Signal M39029/29-212 M39029/30-218
12 Power/Signal M39029/29-213 M39029/30-219 MS27488-12-1 M81969/14-04
8 Power M39029/29-214* M39029/30-220* MS27488-8-1 M81969/14-06
4 Power M39029/29-215* M39029/30-221* MS27488-4-1** M81969/14-07
0Power M39029/29-216* M39029/30-222* MS27488-0-1** M81969/14-08
Contact
Size
Crimp Tool Positioner Die Set Locator Extraction Tool
Pin & Socket Contacts Pin & Socket Contacts Pin & Socket Contacts Metal
Military No. Military No. Military No. Military No. Military No.
16/16S M22520/1-01 M22520/1-02 N/A N/A M81969/8-208
12 M22520/1-01 M22520/1-02 N/A N/A M81969/8-210
8 M22520/23-01 N/A M22520/23-02 M22520/23-09 M81969/15-01
4 M22520/23-01 N/A M22520/23-03 M22520/23-11 M81969/15-02
0 M22520/23-01 N/A M22520/23-04 M22520/23-13 M81969/15-03
Contact
Size
Test Current Voltage Crimp Well Data Wire Range Finished Wire [Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWGmm2inch mm inch mm
16/16S 13 49 .067 ±.001 .250 6.35 20-16 0.52-1.31 .053 1.35 .103 2.62
12 23 42 .100 ±.002 .250 6.35 14-12 2.08-3.31 .085 2.16 .158 4.01
846 26 .181 ±.002 .485 12.32 10-8† 5.26-8.37 .132 3.35 .255 6.48
480 23 .281 ±.002 .485 12.32 6-4† 13.30-21.15 .237 6.02 .370 9.40
0150 21 .453 ±.002 .580 14.73 2-0† 33.63-53.48 .360 9.14 .550 13.97
57www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015
Contact Installation Instructions
MS345*/AE55*
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the
contact. Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into
the insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to
removing insertion tool, do not try to reinsert the
insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
damage the inside of the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place the wire into the
extraction tool of the pin or socket.
3. Slowly slide the extraction tool down wire into the contact
cavities until the tool tip bottoms against the contact
shoulder, expanding the clip retaining tines. Hold the
wire firmly in the tool and pull the wired contact and
tool straight out of the rear of the insulator.
I/R = Insertion/Removal
*16S socket contact is only used in shell sizes 8S, 10S, 10SL, 12S, 14S and 16S.
Size Pin Contact Socket Contact Crimp Tool Positioner Die Set Locator I/R Tool
16S* —M39029/30-217 M22520/1-01 M22520/1-02 Blue — — M81969/14-03
16 M39029/29-212 M39029/30-218 M22520/1-01 M22520/1-02 Blue — — M81969/14-03
12 M39029/29-213 M39029/30-219 M22520/1-01 M22520/1-02 Yellow — — M81969/14-04
8 M39029/29-214 M39029/30-220 M22520/23-01 — M22520/23-02 M22520/23-09 M81969/14-06
4 M39029/29-215 M39029/30-221 M22520/23-01 — M22520/23-04 M22520/23-11 M81969/14-07
0M39029/29-216 M39029/30-222 M22520/23-01 —M22520/23-05 M22520/23-13 M81969/14-08
58www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III (Rear Release)
Polarization, Insert Availability & Contact Information
per MIL-STD-1651
Insert Availability, Contact Information and Clocking Positions
– –
Polarization (Insert Clocking)
1. In the normal insert clocking position (position N),
the insert centerline coincides with the centerline of the
master keyway (key) of the shell: L = 0°.
2. In the alternate clocking positions (W, X, Y and Z),
the pin insert (viewing from mating side) is rotated
clockwise relative to the centerline of the master
keyway (key) of the shell.
3. The socket insert is rotated counter-clockwise.
4. Plugs have keyways; receptacles have keys.
Note: Be careful with alternate positions. See table below for
position availability on layouts of interest.
* Inactive for new design
** Pin contact is size 16, socket contact is size 16S
*** Service Rating = Inst. for classes KS and KT only.
Shell Size
& Insert
Arrangement
Aero-Electric Contacts Insert Positions
Status Total Quantity by Size Service Contact “L” Degrees
QPL’d Tooled Number Qty Size Rating Location N W X Y Z
8S-1 Yes Yes 1 1 16/16S** AAll 0 — — — —
10S-2 Yes Yes 1 1 16/16S** AAll 0 — — — —
10SL-3*** Yes Yes 3 3 16/16S** AAll 0 — — — —
10SL-4 Yes Yes 2 2 16/16S** A All 0 — — — —
12-5 Yes Yes 1 1 12 D All 0 — — — —
12S-3 Yes Yes 2 2 16/16S** AAll 070 145 215 290
12S-4 Yes Yes 1 1 16/16S** DAll 0 — — — —
14-3 Yes Yes 1 1 8 A All 0 — — — —
14S-1* Yes Yes 3 3 16/16S** AAll 0 — — — —
14S-2 Yes Yes 4 4 16/16S** Inst. All 0 — 120 240 —
14S-5 Yes Yes 5 5 16/16S** Inst. All 0 — 110 — —
14S-6 Yes Yes 6 6 16/16S** Inst. All 0 — — — —
14S-7 Yes Yes 3 3 16/16S** A All 090 180 270 —
14S-9* Yes Yes 2 2 16/16S** AAll 070 145 215 290
16-10 Yes Yes 3 3 12 AAll 090 180 270 —
16-11 Yes Yes 2 2 12 A All 035 110 250 325
16-12 Yes Yes 1 1 4 A All 0 — — — —
16S-1 Yes Yes 7 7 16/16S** A All 080 — — 280
16S-4 Yes Yes 2 2 16/16S** DAll 035 110 250 325
16S-5* Yes Yes 3 3 16/16S** AAll 070 145 215 290
16S-8 Yes Yes 5 5 16/16S** AAll 0 — 170 265 —
PIN INSERT
MATING FACE
(SOCKET INSERT IS OPPOSITE)
INSERT
VERTICAL
CENTERLINE
MASTER
KEYWAY(KEY)
OF A SHELL
L°
59www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III (Rear Release)
Insert Availability, Contact Information and Clocking
per MIL-STD-1651
Insert Availability, Contact Information and Clocking Positions
– –
Shell Size
& Insert
Arrangement
Aero-Electric Contacts Insert Positions
Status Total Quantity by Size Service Contact “L” Degrees
QPL’d Tooled Number Qty Size Rating Location N W X Y Z
18-1 Yes Yes 10 416 A B,C,F,G 070 145 215 290
616 Inst. All others
18-4 Ye s Yes 4 4 16 DAll 035 110 250 325
18-5 Yes Yes 3116 DAll 080 110 250 280
212
18-6 Ye s Yes 1 1 4 D — 0 — — — —
18-8 Ye s Yes 8716 AAll 070 — — 290
112
18-9 Yes Yes 7516 Inst. All 080 110 250 280
212
18-10* Yes Yes 4 4 12 AAll 0 — 120 240 —
18-11 Yes Yes 5 5 12 AAll 0 — 170 265 —
18-12 Yes Yes 6 6 16 AAll 080 — — 280
18-20* Yes Yes 5 5 16 A All 090 180 270 —
20-2 Yes Yes 1 1 0 D --- 0 — — — —
20-3* Yes Yes 3 3 12 DAll 070 145 215 290
20-4 Ye s Yes 4 4 12 DAll 045 110 250 —
20-7 Yes Yes 8416 DA,B,G,H 080 110 250 280
416 A All others
20-8 Ye s Yes 6416 Inst. All 080 110 250 280
2 8
20-11* Yes Yes 13 13 16 Inst. All 0 — — — —
20-14 Yes No 5312 AAll 080 110 250 280
2 8
20-15 Yes Yes 7 7 12 AAll 080 — — 280
20-16 Yes Yes 9716 AAll 080 110 250 280
212
20-17 Yes Yes 6116 AAll 090 180 270 —
512
20-18 Yes Yes 9616 AAll 035 110 250 325
312
20-22 Yes Yes 6316 AAll 080 110 250 280
3 8
20-24* Yes Yes 4216 A All 035 110 250 325
2 8
20-27 Yes Yes 14 14 16 AAll 035 110 250 325
20-29 Yes Yes 17 17 16 A All 080 — — 280
20-33 Yes Yes 11 11 16 AAll 0 — — — —
22-1* Yes Yes 2 2 8 D All 035 110 250 325
*Inactive for new design
60www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III (Rear Release)
Insert Availability, Contact Information and Clocking
per MIL-STD-1651
Insert Availability, Contact Information and Clocking Positions
– –
* Inactive for new design
** Alternate positions X,Y are cancelled after June 26, 1968.
Shell Size &
Insert
Arrangement
Aero-Electric Contacts Insert Positions
Status Total Quantity by Size Service Contact “L” Degrees
QPL’d Tooled Number Qty Size Rating Location N W X Y Z
22-2 Yes Yes 3 3 8 D All 070 145 215 290
22-9 Yes Yes 3 3 12 EAll 070 145 215 290
22-12 Yes Yes 5316 DAll 080 110 250 280
2 8
22-13* Yes Yes 5116 D E 035 110 250 325
412 AAll others
22-14** Yes Yes 19 19 16 AAll 080 110 250 280
22-18 Yes Yes 8316 A C,D,E 080 110 250 280
516 D All others
22-19 Yes Yes 14 14 16 A All 080 110 250 280
22-20* Yes Yes 9 9 16 AAll 035 110 250 325
22-22 Yes Yes 4 4 8 A All 0 — 110 250 —
22-23 Yes Yes 8112 D H 035 —250 —
712 A All others
22-27 Yes Yes 91 8 D J 080 —250 280
816 AAll others
22-33* Yes Yes 7316 AE,F,G 080 110 250 280
416 D All others
24-2 Yes Yes 7 7 12 D All 080 — — 280
24-4 Yes Yes 4316 DAll 080 110 250 280
1 0
24-6 Yes Yes 8312 DA,G,H 080 110 250 280
512 AAll others
24-7 Yes Yes 16 14 16 A All 080 110 250 280
212
24-9* Yes Yes 2 2 4 A All 035 110 250 325
24-10 Yes Yes 7 7 8 A All 080 — — 280
24-11 Yes Yes 9612 AAll 035 110 250 325
3 8
24-12 Yes Yes 5312 AAll 080 110 250 280
2 4
24-20 Yes Yes 11 916 DAll 080 110 250 280
212
24-21 Yes No10 916 D All 080 110 250 280
1 8
24-22 Yes Yes 4 4 8 D All 045 110 250 —
24-27 Yes Yes 7 7 16 E All 080 — — 280
24-28 Yes Yes 24 24 16 Inst. All 080 110 250 280
61www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III (Rear Release)
Insert Availability, Contact Information and Clocking
per MIL-STD-1651
Insert Availability, Contact Information and Clocking Positions
– –
*Inactive for new design
Shell Size &
Insert
Arrangement
Aero-Electric Contacts Insert Positions
Status Total Quantity by Size Service Contact “L” Degrees
QPL’d Tooled Number Qty Size Rating Location N W X Y Z
28-1 Yes Yes 9
212 DA,E
080 110 250 280
412 A B,D,F,H
1 8 D J
2 8 A G,C
28-2 Yes Yes 14 12 16 DAll 035 110 250 325
212
28-3 Yes Yes 3 3 8 E All 070 145 215 290
28-5 Yes Yes 5
216
D All 035 110 250 325112
2 4
28-8 Yes Yes 12
212 EL,M
116 DB 080 110 250 280
916 AAll others
28-9 Yes Yes 12 616 D All 080 110 250 280
612
28-11 Yes Yes 22 18 16 AAll 080 110 250 280
412
28-12 Yes Yes 26 26 16 A All 090 180 270 —
28-15 Yes Yes 35 35 16 A All 080 110 250 280
28-16* Yes Yes 20 20 16 AAll 080 110 250 280
28-19 Yes Yes 10
216 BH,M
080 110 250 280
216 DA,B
216 AAll others
412
28-20 Yes Yes 14 416 A All 080 110 250 280
10 12
28-21 Yes Yes 37 37 16 AAll 080 110 250 280
28-22 Yes Yes 6316 DAll 070 145 215 290
3 4
32-1 Yes Yes 5
112 E A
080 110 250 280212 DD,C
2 0 B,E
32-3 Yes Yes 9
416
DAll 080 110 250 280
212
2 4
1 0
32-5* Yes Yes 2 2 0 D All 080 110 250 325
32-6 Yes Yes 23
16 16
AAll 080 110 250 280
212
3 8
2 4
62www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-DTL-5015 Series III (Rear Release)
Insert Availability, Contact Information and Clocking
per MIL-STD-1651
Insert Availability, Contact Information and Clocking Positions
– –
* Inactive for new design
** Alternate positions U (100 degrees) and V (260 degrees) are also
available per MIL-STD-1651.
Shell Size
& Insert
Arrangement
Aero-Electric Contacts Insert Positions
Status Total Quantity by Size Service Contact “L” Degrees
QPL’d Tooled Number Qty Size Rating Location N W X Y Z
32-7 Yes Yes 35
416 Inst. A,B,h,j
080 125 235 28024 16 AAll others
712
32-8* Yes Yes 30 24 16 AAll 0 80 125 235 280
612
32-10* Yes Yes 7
216 EA,F
080 110 250 280
116 B G
2 8 D B,E
2 4 A C,D
32-15 Yes Yes 8612 DAll 035 110 250 280
2 0
32-17 Yes Yes 4 4 4 D All 045 110 250 ---
32-22** Yes Yes 54 54 16 AAll 080 110 250 280
32-63 Yes Yes 5 5 4 D All 0 — — — —
32-73 Yes Yes 46 46 16 A All 036 — — —
36-3 Yes No 6312 D All 070 145 215 290
3 0
36-5 Yes Yes 4 4 0 A All 0 — 120 240 —
36-6 Yes Yes 64 4 AAll 035 110 250 325
2 0
36-7 Yes Yes 47 40 16 A All 080 110 250 280
712
36-8 Yes Yes 47 46 16 AAll 080 110 250 280
112
36-9 Yes Yes 31
14 16
AAll 080 125 235 280
14 12
2 8
1 4
36-10 Yes Yes 48 48 16 AAll 080 125 235 280
40-10 Yes Yes 29
16 16
AAll 065 125 225 3109 8
4 4
40-56 Yes Yes 85 85 16 AAll 072 144 216 288
63www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-STD-1651
Insert Arrangements (Pin Front View)
for MIL-DTL-5015 Connectors
Insert Arrangements Views
– –
A
B
C
D
8S-1
1- #16
10S-2
1- #16
A
B
C
10SL-3
3- #16
AB
10SL-4
2- #16
AB
12S-3
2- #16
12S-4
1- #16
12-5
1- #12
A
B
C
14S-1*
3- #16
A
B
C
D
14S-2
4- #16
14-3
1- #8
A
B
C
D
E
14S-5
5- #16
A
B
C
D
E
F
14S-6
6- #16
A
B
C
14S-7
3- #16
A
B
14S-9*
2- #16
A
B
C
D
E
F
G
16S-1
7- #16
A
B
16S-4
2-#16
A
B
C
16S-5*
3- #16
A
B
C
D
E
16S-8
5- #16
A
B
C
16-10
3- #12
A
B
16-11
2- #12
16-12
1- #4
A
I
J
B
C
D
E
G
H
F
18-1
10- #16
A
B
C
D
18-4
4- #16
A
B
C
D
E
18-11
5- #12
A
B
C
D
E
F
18-12
6- #16
AB
C
D
E
18-20*
5- # 16
A
B
C
18-5
1- #16, 2- #12
18-6
1- #4
A
B
C
D
E
G
H
F
18-8
7- #16,1-#12
A
B
C
D
E
G
F
18-9
5- #16,2-#12
18-10*
4- #12
20-2
1- #0
A
B
C
20-3*
3- #12
*Inactive for new design
64www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-STD-1651
Insert Arrangements (Pin Front View)
for MIL-DTL-5015 Connectors
Insert Arrangements Views
– –
20-15
7- #12
20-24*
2- #16, 2- #8
A
B
C
D
E
F
G
H
J
K
L
M
N
I
20-27
14- #16
A
B
C
D
E
T
F
G
H
J
K
L
M
N
P
R
S
20-29
17- #16
A
B
C
D
E
F
H
J
K
L
M
20-33
11- #16
20-16
7- #16, 2- #12
20-17
1- #16, 5- #12
20-18
6- #16,3-#12
20-22
3- #16,3-#8
A
B
22-1*
2- #8
22-2
3- #8
A
B
C
D
E
F
G
H
I
A
B
C
D
E
F
G
A
B
C
D
E
F
A
B
CDE
F
GH
I
A
B
C
D
E
F
A
B
C
D
A
B
C
A
B
C
22-9
3- #12
22-12
3- #16, 2- #8
A
B
C
D
E
22-13*
1- #16,4-#12
A
B
C
D
E
A
B
C
D
E
F
G
H
J
K
LM
N
P
R
S
V
U
T
22-14
19- #16
A
B
C
D
E
G
H
F
A
B
C
D
20-4
4- #12
20-7
8- #16
A
B
C
D
E
F
20-8
4- #16, 2- #8
A
BC
D
EF
GH
J
K
L
M
N
20-11*
13- #16
A
B
C
D
E
20-14
3- #12,2-#8
*Inactive for new design
65www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-STD-1651
Insert Arrangements (Pin Front View)
for MIL-DTL-5015 Connectors
Insert Arrangements Views
– –
A
B
A
B
C
D
E
F
G
A
B
C
D
E
F
H
JK
G
A
B
C
D
A
B
C
D
E
F
G
A
B
C
D
J
EF H
K
LM N P Q
RSTUV
WX Y Z
G
24-7
14- #16, 2- #12
24-9*
2- #4
24-10
7- #8
24-11
6- #12,3-#8
24-12
3- #12,2-#4
24-20
9- #16, 2- #12
24-21
9- #16, 1- #8
24-22
4- #8
24-27
7- #16
24-28
24- #16
A
B
C
L
D
E
F
H
G
J
K
A
B
C
DEF
HJ
G
A
B
C
D
E
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
B
A
C
D
E
F
G
H
22-18
8- #16
A
B
J
C
D
E
F
G
HA
B
C
D
E
F
G
22-27
1- #8, 8- #16
22-33*
7- #16
A
B
C
D
E
F
G
H
J
K
L
M
N
P
22-19
14- #16
A
B
C
DE
F
GH
J
22-20*
9- #16
A
B
C
D
22-22
4- #8
A
B
C
D
E
F
G
H
22-23
8- #12
A
B
C
D
E
F
G
24-2
7- #12
A
B
C
D
24-4
3- #16,1-#0
A
B
C
D
E
F
H
G
24-6
8- #12
*Inactive for new design
66www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-STD-1651
Insert Arrangements (Pin Front View)
for MIL-DTL-5015 Connectors
Insert Arrangements Views
– –
28-1
6- #12, 3- #8
28-2
12- #16, 2- #12
28-3
3- #8
28-5
2- #16,1-#12,2-#4
28-8
2- #12, 10- #16 28-9
6- #16, 6- #12
28-11
18- #16,4-#12
28-12
26- #16
28-15
35- #16
28-16*
20- #16
28-19
6- #16,4-#12
28-20
4- #16,10- #12
28-21
37- #16
28-22
3- #16, 3- #4
32-1
3- #12,2-#0
A
P
B
C
D
E
F
G
H
J
K
L
M
N
A
B
C
DEF
H
J
G
A
B
C
A
B
C
D
E
A
B
C
D
E
F
G
H
J
K
L
M
A
B
C
D
E
F
G
H
J
K
L
M
A
B
C
D
E
F
G
H
I
J
K
L
M
N
P
R
S
T
U
V
W
X
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
d
A
ab c
defgh
l
jk
m
B
CDEFG
HJKLMN
PR STUVW
XY Z
AB
C
D
EF
G
H
J
K
LM
N
P
Q
R
S
T
U
V
AB
C
E
G
H
J
K
L
M
A
B
C
D
E
F
G
H
J
K
L
M
N
P
ABCD
EFGHJ
KLMNPR
STUVWXZ
ab
c
def
ghjkm
n
pr
s
A
B
C
D
E
F
A
B
C
D
E
32-3
4- #16,2-#12,
2- #4, 1- #0
ABC
D
E
F
G
H
J
*Inactive for new design
67www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-STD-1651
Insert Arrangements (Pin Front View)
for MIL-DTL-5015 Connectors
Insert Arrangements Views
– –
32-5*
2- #0
32-7
28- #16,7-#12
32-8*
24- #16,6-#12
32-10*
3- #16, 2- #8,
2- #4
32-15
6- #12, 2- #0
32-17
4- #4
32-22
54- #16
32-63
5- #4
32-73
46- #16
36-3
3- #12,3-#0
36-5
4- #0
A
B
32-6
16- #16, 2- #12,
3- #8, 2- #4
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
A
B
C
D
A
B
C
D
E
F
A
BC
DE
F
G
H
A
B
C
D
E
A
B
C
D
A
B
C
D
G
F
E
AB
CD
EF
G
H
IJ
K
LM
N
P
ORS
T
UV
WX
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
k
AB
CD E
FGH J
XY
KLM
NP
R
O
S
TUVW
Za
bcd ef
ghjk
mnpqr
y
stu
v
wx
zAA
AB
AC
AD
AF AG
AE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
*Inactive for new design
68www.conesys.com sales@aero-electric.com
MIL–DTL– 5015 S III
MIL-STD-1651
Insert Arrangements (Pin Front View)
for MIL-DTL-5015 Connectors
Insert Arrangements Views
– –
36-9
14- #16, 14- #12,
2- #8, 1- #4
36-10
48- #16 40-10
16- #16,9-#8,
4- #4
40-56
85- #16
A
B
C
D
E
H
F
G
I
J
K
L
M
N
O
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
AB
CDEFG
HJKLMN
OPQRSTU
VW X Y Z
a
bc
defghjk
mn
pqrs
tuvw x
yz
A
B
CD
E
F
GH
I
JK
L
MNOPQ
R
ST
U
VWX
Y
Za
b
c
A
BCD
EFH JKLM
NP RSTUVW
XYZ
ab
cdfg
hjkimnpq rs
tuvw xyzAAAB
AC AD AE AF AH AJ AK AL AM AN
AP AR AS AT AU AV AW AX AY
AZ BA BB BC BD BE BF BH
BJ BK BL BM BN BP BR
BS BT BU BV
36-6
4- #4, 2- #0
36-7
40- #16, 7- #12
36-8
46- #16,1-#12
A
B
C
D
E
F
AB
CDE
FG
HIJ
KLMN
OPRS
T
UVWX
YZabc
m
def
g
hjt
k
np
uwv
rs
xzy
A
B
C
DE
F
GH
IJKL
M
NOPR
STUV
WXYZa
bcde
fgh
y
j
k
w
mn
x
p
z
r
st
u
v
69www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482
Features and Application
Series 2
– –
Features and Application
MIL-DTL-26482 Series 2, bayonet coupling, rear-removable
crimp contact connectors were designed as an upgrade to
MIL-DTL-26482 Series 1. Series 2 connectors are inter-
mountable and interchangeable with both solder and
front-release crimp Series 1. They are also identical to the
inactivated MIL-DTL- 83723 Series I connectors.
Series 2 connectors are widely used on commercial, military
and aerospace systems requiring general-purpose, miniature
cylindrical bayonet coupling connectors.
This family of connectors is offered in 4 receptacle-mounting
styles. They include narrow flange wall mounting receptacles,
wide flange wall mounting receptacles, cable connecting
receptacles and jam nut mounting receptacles which incorpo-
rate “O” ring seals, designed for rear panel “D” hole mounting.
Plugs are available in two designs, with and without RFI
grounding.
Thirty-three insert arrangements per MIL-STD-1669 are
tooled and qualified to MIL-DTL-26482 Series 2, utilizing
3 to 61 M39029 contacts. Contacts come in sizes 20, 16 and
12, terminating wire sizes from 24 to 12 gauge.
These connectors are available in wide range of shell
materials and finishes. Aluminum shells are offered in
electroless nickel, olive drab cadmium and black anodic.
Other finishes such as zinc cobalt are available upon request
to commercial callouts only. In addition, we offer passivated
stainless steel shells with standard environment-resisting
inserts (commercial callouts only), and for highly corrosive
environments, nickel-aluminum-bronze shells with standard
environment-resisting inserts (commercial callouts only).
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
Insert Polarization – Alternate insert clocking positions aid
in mating of adjacent connectors having identical insert
arrangement.
Closed-Entry Socket Insert – Hard dielectric socket face
has lead-in chamfers for positive alignment of pins (even
partially bent within pre-established limits) with sockets.
Interfacial Pin Insert Seal – Raised moisture barriers
around each pin, which mate into lead-in chamfers of hard
face socket insert, provide individual contact sealing.
Interfacial seal is never touched by service tools.
Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in
each cavity at the rear of the connector.
Superior Contact Stability – Rear release crimp contact
system features a stamped beryllium-copper retaining clip
captivated by molded-in shoulders of each contact cavity in
the insulator. A rear-inserted M81969 plastic tool expands
the tines beyond the shoulder, releasing the contact.
70www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482
Performance Specifications
Series 2
– –
Performance Specifications
Operating Temperature Range
Classes A, L and S*: -55°C to +200°C (-67°F to +392°F)
Classes W and ZC*: -55°C to +175°C (-67°F to +347°F)
Material and Finish Data (Class)
A – aluminum shell, black anodized finish
L – aluminum shell, electroless nickel finish
W – aluminum shell, olive drab cadmium over nickel base
S* – stainless steel shell, passivated
ZC*– aluminum shell, zinc cobalt finish
Corrosion Resistance
Classes A, S*, W and ZC* withstand 500-hour salt spray.
Class L withstands 48-hour salt spray.
Environmental Seal
Wired, mated connectors with specified accessories
attached, shall meet the altitude-immersion test specified in
MIL-DTL-26482 Series 2.
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808
(lubricating oil), MIL-PRF-23699 (lubricating oil),
MIL-PRF-5606 (hydraulic fluid), M2-V Chevron oil,
Coolanol 25, ASTM D4814 (gasoline), SAE-AMS1424 Type I
(defrosting fluid), MIL-DTL-5624 (JP-5), and solvents
specified in Method 215 of MIL-STD-202.
* Not on QPL, can be supplied to Aero-Electric P/N only.
Durability
Mated connectors withstand a minimum of 250 mating
cycles for RFI plug (MS3475) and 500 cycles for standard
plug (MS3476).
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, coupling
ring shall not loosen, and there shall be no interruption of
electrical continuity longer than one microsecond when
subjected to the following:
Shock
Mated connectors withstand a pulse of approximate half
sine wave of 300 G magnitude with duration of three
milliseconds applied in each direction of the three major axes.
Vibration
Mated connectors withstand the following vibration levels:
●Random vibration per MIL-STD-202, method 214, test
condition II, letter J.
Shielding Effectiveness
RFI attenuation at the specified frequency meets the
requirements of MIL-DTL-26482 Series 2.
●RFI shielding effectiveness of mated connectors with
RFI backshells is measured in a triaxial radio frequency
leakage fixture.
Shell-to-Shell Conductivity
●With RFI spring fingers, the maximum potential drop
shall not exceed 5 millivolts.
●Without spring fingers, the maximum potential drop
shall not exceed 200 millivolts.
Service
Rating
Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft.70,000 Ft.110,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
I600 850 1,500 500 375 200
II 1,000 1,275 2,300 750 500 200
Voltage Rating
** To be used by designer only as a guide.
71www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482
Part Number Development
Series 2
Military and Aero-Electric Part Number Development
– –
* Not on QPL, can be supplied to Aero part number only. Consult factory
for availability.
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 2 to 26 of each contact and two spares for
inserts with 27 or more of each size, and a minimum of one
sealing plug up to 15% of the number of contacts. In addition,
one plastic insetion/removal tool of each size is included.
Note 2: Proper part number marking has no “0” in front of
single digit shell size ( 8) and no “0” after the dash between
shell size and single digit layout. Example of each:
MS3470W8-33P and MS3470W10-6P
. In both “N” for normal
was omitted.
Note 3: Insert layouts 8-2, 8-3 and 8-4 can only be ordered
to Aero-Electric part number. Non standard contacts are
required and to avoid confusion are sold “with contacts”
only. See page 80 for the correct contact part numbers.
Mil. Prefix MS34 70 L12 - 10 P W
Aero Prefix AE7 70 L12 - 10 P W -340
Shell type
70 = Narrow flange receptacle
71 = Cable connecting receptacle
72 = Wide flange receptacle
74 = Jam nut receptacle
75 = RFI grounding plug
76 = Straight plug
Class (Material and Finish)
A= Aluminum shell, black anodized finish (not available in RFI plug)
L= Aluminum shell, electroless nickel finish
W= Aluminum shell, olive drab cadmium over electroless nickel base
S*= Stainless steel shell, passivated (Aero part number only)
ZC* = Aluminum shell, zinc cobalt finish (Aero part number only)
Shell Size
8, 10, 12, 14, 16, 18, 20, 22 or 24
Insert Arrangement
See pages 82 thru 85
Contact Style
P= Pin
S= Socket
A= Pin connector less pins (with intent to use non-std contact)
B= Socket connector less sockets (with intent to use non-std contacts)
Polarization
N= Normal (not included in part number)
W, X,Y or Z= Alternate insert polarizations (see pages 82 thru 83 for position availability)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/31-XXX E-nut
341 = Connector kitted with M85049/52-1-XXX straight clamp
342 = Connector kitted with M85049/51-1-XXX right angle clamp
Consult factory for other modifications
72www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MS3470
Narrow Flange Receptacle
AE770
Bayonet Coupling, Crimp Removable, Rear Release
– –
Page 71 Completed Part Number
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
Note: Maximum grommet O.D. is same as [C MAXon
page 74.
BLUE COLOR BAND
MAX PANEL THICKNESS & SCREWHEAD
.087(2.21) S.S. 8–18
.212(5.38) S.S. 20–24
MAX PANEL
THICKNESS
.125(3.18)
BLUE COLOR BAND
B
4x
[
C
MOUNTING HOLES
MASTER
KEYWAY
[
H
4 MINOR KEYWAYS
3 BAYONET PINS
F
A
MAX
3 ACCESSORY TEETH
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
G
ACCESSORY THREAD
E
.290
(7.37)
MIN
FULL
THREAD
D
MAX
Shell
Size
A B [C D E F G [H
+.016 +.41 Accessory Thread
Maximum (TP) ±.005 ±.13 Maximum ±.016 ±.41 -.015 -.38 Class 2A ±.003 ±.08
inch mm inch mm inch mm inch mm inch mm inch mm inch mm
8.828 21.03 .594 15.09 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 1/2-20UNF .471 11.96
10 .954 24.23 .719 18.26 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 5/8-24UNEF .588 14.94
12 1.047 26.59 .812 20.62 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 3/4-20UNEF .748 19.00
14 1.141 28.98 .906 23.01 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 7/8-20UNEF .873 22.17
16 1.234 31.34 .969 24.61 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 1-20UNEF .998 25.35
18 1.328 33.73 1.062 26.97 .120 3.05 1.215 30.86 .062 1.57 .446 11.33 1-1/16-18UNEF 1.123 28.52
20 1.453 36.91 1.156 29.36 .120 3.05 1.275 32.39 .094 2.39 .571 14.50 1-3/16-18UNEF 1.248 31.70
22 1.578 40.08 1.250 31.75 .120 3.05 1.275 32.39 .094 2.39 .571 14.50 1-5/16-18UNEF 1.373 34.87
24 1.703 43.26 1.375 34.93 .147 3.73 1.275 32.39 .094 2.39 .604 15.34 1-7/16-18UNEF 1.498 38.05
73www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MS3471
Cable Connecting Receptacle
AE771
Bayonet Coupling, Crimp Removable, Rear Release
– –
Note: Maximum grommet O.D. is same as [C MAXon
page 74.
Page 71 Completed Part Number
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
BLUE COLOR BANDS
[ B
MASTER
KEYWAY
A
MAX .290
(7.37)
MIN
FULL
THREAD
4 MINOR KEYWAYS
3 BAYONET PINS
[ F
ED
C
MAX
G ACCESSORY THREAD
3 ACCESSORY TEETH
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
Shell
Size
A[B C D E [F G
+.016 +.41 Accessory Thread
Maximum ±.020 ±.51 Maximum ±.016 ±.41 -.015 -.38 ±.003 ±.08 Class 2A
inch mm inch mm inch mm inch mm inch mm inch mm
8.828 21.03 .938 23.83 1.215 30.86 .062 1.57 .446 11.33 .471 11.96 1/2-20UNF
10 .954 24.23 1.062 26.97 1.215 30.86 .062 1.57 .446 11.33 .588 14.94 5/8-24UNEF
12 1.047 26.59 1.156 29.36 1.215 30.86 .062 1.57 .446 11.33 .748 19.00 3/4-20UNEF
14 1.141 28.98 1.250 31.75 1.215 30.86 .062 1.57 .446 11.33 .873 22.17 7/8-20UNEF
16 1.234 31.34 1.344 34.14 1.215 30.86 .062 1.57 .446 11.33 .998 25.35 1-20UNEF
18 1.328 33.73 1.438 36.53 1.215 30.86 .062 1.57 .446 11.33 1.123 28.52 1-1/16-18UNEF
20 1.453 36.91 1.562 39.67 1.275 32.39 .094 2.39 .571 14.50 1.248 31.70 1-3/16-18UNEF
22 1.578 40.08 1.688 42.88 1.275 32.39 .094 2.39 .571 14.50 1.373 34.87 1-5/16-18UNEF
24 1.703 43.26 1.812 46.02 1.275 32.39 .094 2.39 .604 15.34 1.498 38.05 1-7/16-18UNEF
74www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MS3472
Wide Flange Receptacle
AE772
Bayonet Coupling, Crimp Removable, Rear Release
– –
Page 71 Completed Part Number
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
Shell
Size
A B [CD E F G [H
+.016 +.41 Accessory Thread
Maximum (TP) Maximum Maximum ±.016 ±.41 -.015 -.38 Class 2A ±.003 ±.08
inch mm inch mm inch mm inch mm inch mm inch mm inch mm
81.065 27.05 .734 18.64 .305 7.75 1.215 30.86 .062 1.57 .477 12.12 1/2-20UNF .471 11.96
10 1.141 28.98 .812 20.62 .405 10.29 1.215 30.86 .062 1.57 .477 12.12 5/8-24UNEF .588 14.94
12 1.266 32.16 .938 23.83 .531 13.49 1.215 30.86 .062 1.57 .477 12.12 3/4-20UNEF .748 19.00
14 1.360 34.54 1.031 26.19 .665 16.89 1.215 30.86 .062 1.57 .477 12.12 7/8-20UNEF .873 22.17
16 1.453 36.91 1.125 28.58 .790 20.07 1.215 30.86 .062 1.57 .477 12.12 1-20UNEF .998 25.35
18 1.532 38.91 1.203 30.56 .869 22.07 1.215 30.86 .062 1.57 .477 12.12 1-1/16-18UNEF 1.123 28.52
20 1.688 42.88 1.297 32.94 .994 25.25 1.275 32.39 .094 2.39 .571 14.50 1-3/16-18UNEF 1.248 31.70
22 1.766 44.86 1.375 34.93 1.119 28.42 1.275 32.39 .094 2.39 .571 14.50 1-5/16-18UNEF 1.373 34.87
24 1.891 48.03 1.500 38.10 1.244 31.60 1.275 32.39 .094 2.39 .604 15.34 1-7/16-18UNEF 1.498 38.05
[
.150±.005
(
[
3.81±.13)
MOUNTING HOLES4 MINOR KEYWAYS
3BAYONET PINS
MASTER
KEYWAY
B
A
MAX
[
H
FE
D
MAX
G
ACCESSORY THREAD
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
3 ACCESSORY TEETH
[
C
MAX
GROMMET
.290
(7.37)
MIN
FULL
THREAD
BLUE COLORBAND
MAX PANEL THICKNESS &SCREWHEAD
.118(3.00) S.S. 8–18
.212(5.38) S.S. 20–24
BLUE COLORBAND
MAX PANEL
THICKNESS
.125(3.18)
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
.290(7.37)
MIN
FULL THREAD
[
B
AC
MAX
G
ACCESSORY THREAD
(SAME AS FOR MS3472
ON PREVIOUS PAGE)
H
THREAD
E
D
3X REAR ACCESSORY TEETH
BLUE COLOR BAND
S.S. 8–18
S.S. 20–24
PANEL THICKNESS
.187(4.75)
.062(1.57)
.250(6.35)
.062(1.57)
"O" RING
BLUE COLOR BAND
3 BAYONET PINS
HEX NUT
PER MS3186
EXCEPT FOR THICKNESS
F
FLAT
.125(3.18)
.108(2.74)
MASTER
KEYWAY
75www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MS3474
Jam Nut Receptacle
AE774
Bayonet Coupling, Crimp Removable, Rear Release
– –
Page 71 Completed Part Number
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
Shell
Size
A[B C D E F H
+.000 +.00 +.000 +.00 Flat Jam Nut
-.031 -.79 -.031 -.79 Maximum ±.005 ±.13 Thread
inch mm inch mm inch mm inch mm inch mm inch mm UNEF-2A
8.954 24.23 1.078 27.38 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .525 13.34 9/16-24
10 1.078 27.38 1.203 30.56 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .650 16.51 11/16-24
12 1.266 32.16 1.391 35.33 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .813 20.65 7/8-20
14 1.391 35.33 1.516 38.51 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 .937 23.80 1-20
16 1.516 38.51 1.641 41.68 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 1.061 26.95 1-1/8-18
18 1.641 41.68 1.766 44.86 1.215 30.86 .113/.086 2.87/2.18 .707/.658 17.96/16.71 1.186 30.12 1-1/4-18
20 1.828 46.43 1.954 49.63 1.275 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.311 33.30 1-3/8-18
22 1.954 49.63 2.078 52.78 1.275 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.436 36.47 1-1/2-18
24 2.078 52.78 2.203 55.96 1.275 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.561 39.65 1-5/8-18
Note: Maximum grommet O.D. is same as [E MAXon
page 76.
76www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MS3476
Straight Plug
AE776
Bayonet Coupling, Crimp Removable, Rear Release
– –
Page 71 Completed Part Number
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
BLUE COLOR BAND
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
1.230(31.24)
MAX
.320(8.13)
MIN
.290
(7.37)
MIN
FULL THREAD
MASTER
KEY
4 MINOR KEYS
[
C
MAX
COUPLING NUT
[
A
MAX
INSERT
[
B
D ACCESSORY THREAD
3 ACCESSORY TEETH
EQUALLY SPACED
[
E
MAX
GROMMET
Shell
Size
[A[B[C D [E
Accessory Thread
Maximum ±.003 ±.08 Maximum Class 2A Maximum
inch mm inch mm inch mm inch mm
8.285 7.24 .355 9.02 .782 19.86 1/2-20UNF .305 7.75
10 .402 10.21 .483 12.27 .926 23.52 5/8-24UNEF .405 10.29
12 .516 13.11 .595 15.11 1.043 26.49 3/4-20UNEF .531 13.49
14 .641 16.28 .720 18.29 1.183 30.05 7/8-20UNEF .665 16.89
16 .766 19.46 .845 21.46 1.305 33.15 1-20UNEF .790 20.07
18 .855 21.72 .945 24.00 1.391 35.33 1-1/16-18UNEF .869 22.07
20 .980 24.89 1.070 27.18 1.531 38.89 1-3/16-18UNEF .994 25.25
22 1.105 28.07 1.195 30.35 1.656 42.06 1-5/16-18UNEF 1.119 28.42
24 1.229 31.22 1.320 33.53 1.777 45.14 1-7/16-18UNEF 1.244 31.60
77www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MS3475
RFI Grounding Plug
AE775
Bayonet Coupling, Crimp Removable, Rear Release
– –
Page 71 Completed Part Number
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
RFI STRIP
[
A
MAX
INSERT
[
B
[
C
MAX
COUPLINGNUT
1.230(31.24)
MAX
BLUECOLOR BAND
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
[
E
MAX
GROMMET
.290
(7.37)
MIN
FULL THREAD
D
ACCESSORY THREAD
MASTER
KEY
4MINOR KEYS
3ACCESSORY TEETH
EQUALLY SPACED
.320(8.13)
MIN
Shell
Size
[A[B[C D [E
Accessory Thread
Maximum ±.003 ±.08 Maximum Class 2A Maximum
inch mm inch mm inch mm inch mm
8.285 7.24 .355 9.02 .782 19.86 1/2-20UNF .305 7.75
10 .402 10.21 .483 12.27 .926 23.52 5/8-24UNEF .405 10.29
12 .516 13.11 .595 15.11 1.043 26.49 3/4-20UNEF .531 13.49
14 .641 16.28 .720 18.29 1.183 30.05 7/8-20UNEF .665 16.89
16 .766 19.46 .845 21.46 1.305 33.15 1-20UNEF .790 20.07
18 .855 21.72 .945 24.00 1.391 35.33 1-1/16-18UNEF .869 22.07
20 .980 24.89 1.070 27.18 1.531 38.89 1-3/16-18UNEF .994 25.25
22 1.105 28.07 1.195 30.35 1.656 42.06 1-5/16-18UNEF 1.119 28.42
24 1.229 31.22 1.320 33.53 1.777 45.14 1-7/16-18UNEF 1.244 31.60
78www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
AC3475
Arctic Coupling Nut, RFI Plug
Bayonet Coupling, Crimp Removable, Rear Release
AC3475 – 10- 7 P N
– –
Page 80 Contacts, Sealing Plugs and Tools
Pages 84, 85 Insert Arrangements
Page 70 Performance Specifications
Pages 82, 83 Insert Availability and Contact Information
Page 82 Polarization
Note: AC3475 Arctic Coupling Nut, RFI Plug is available
to Aero-Electric part number only. Mating part is AC3474
which is same as AE774 on page 75. Additional mates are
AC3470 (same as AE770 on page 72), AC3471 (same as
AE771 on page 73)and AC3472 (same as AE772 on page 74).
Shell
Size
[A[B[C D [E
Accessory Thread
Maximum ±.003 ±.08 Maximum Class 2A Maximum
inch mm inch mm inch mm inch mm
8.285 7.24 .355 9.02 .900 22.86 1/2-20UNF .305 7.75
10 .402 10.21 .483 12.27 1.010 25.65 5/8-24UNEF .405 10.29
12 .516 13.11 .595 15.11 1.180 29.97 3/4-20UNEF .531 13.49
14 .641 16.28 .720 18.29 1.310 33.27 7/8-20UNEF .665 16.89
16 .766 19.46 .845 21.46 1.510 38.35 1-20UNEF .790 20.07
18 .855 21.72 .945 24.00 1.620 41.15 1-1/16-18UNEF .869 22.07
20 .980 24.89 1.070 27.18 1.740 44.20 1-3/16-18UNEF .994 25.25
22 1.105 28.07 1.195 30.35 1.850 46.99 1-5/16-18UNEF 1.119 28.42
24 1.229 31.22 1.320 33.53 1.980 50.29 1-7/16-18UNEF 1.244 31.60
RFI STRIP
[
B
[
C
MAX
COUPLING NUT
1.230(31.24)
MAX
.190 (4.83)
.130 (3.30)
GROMMET EXTENSION
[
E
MAX
GROMMET
.290
(7.37)
MIN
FULL THREAD
D
ACCESSORYTHREAD
MASTER KEY
4MINOR KEYS
3ACCESSORY TEETH
EQUALLY SPACED
[
A
MAX
INSERT
Aero Prefix
Class (Material and Finish)
–= Aluminum shell, cadmium olive drab over nickel
ZC = Aluminum shell, zinc cobalt finish
Shell Size
8, 10, 12, 14, 16, 18, 20, 22 or 24
Polarization
N= Normal (N included in part number marking)
A,B,C,D,Eor F(Alternate key positions)
and W, X, Y or Z(Alternate insert clocking positions)
Contact Style
P= Pin
S= Socket
Layout
See pages 82 thru 85
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MIL–DTL– 26482 S 2
MIL-DTL-26482 Series 2
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
Flange and Jam Nut Mounting Dimensions
Note: For [C and [E, MS3470 and MS3472 call out for
tolerance of ±.010 (±.25),however we recommend ±.005 (±.13).
Shell
Size
[AB [C D [E F [G
±.005 ±.13 (TP) ±.010 ±.25 (TP) ±.010 ±.25 ±.005 ±.13 ±.005 ±.13
inch mm inch mm inch mm inch mm inch mm inch mm inch mm
8.568 14.43 .594 15.09 .120 3.05 .734 18.64 .150 3.81 .536 13.61 .572 14.53
10 .685 17.40 .719 18.26 .120 3.05 .812 20.62 .150 3.81 .661 16.79 .697 17.70
12 .864 21.95 .812 20.62 .120 3.05 .938 23.83 .150 3.81 .824 20.93 .895 22.73
14 .989 25.12 .906 23.01 .120 3.05 1.031 26.19 .150 3.81 .948 24.08 1.010 25.65
16 1.113 28.27 .969 24.61 .120 3.05 1.125 28.58 .150 3.81 1.072 27.23 1.135 28.83
18 1.238 31.45 1.062 26.97 .120 3.05 1.203 30.56 .150 3.81 1.197 30.40 1.260 32.00
20 1.363 34.62 1.156 29.36 .120 3.05 1.297 32.94 .150 3.81 1.322 33.58 1.385 35.18
22 1.488 37.80 1.250 31.75 .120 3.05 1.375 34.93 .150 3.81 1.447 36.75 1.510 38.35
24 1.615 41.02 1.375 34.93 .147 3.73 1.500 38.10 .150 3.81 1.572 39.93 1.635 41.53
B
[
G
[
E
D
[
C
[
A
F
[
A
MS3470(AE770) MS3474(AE774) MS3472(AE772)
80www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482
Contacts, Tools and Seal Plugs
Series 2
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
Note: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
* Size 20 contacts for 8–2, 8–3 and 8–4 layouts are only available to
Aero-Electric part numbers. Connectors incorporating these three
layouts are only sold to Aero-Electric callouts (AE770, AE771, AE772,
AE774, AE775, AE776, AC3470, AC3471, AC3472, AC3474 and AC3475).
Standard size 20 contacts M39029/4-110 and M39029/5-115 will not
work in these 3 layouts.
– –
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
20 Power/Signal M39029/4-110 M39029/5-115 MS27488-20-1 M81969/14-11
16 Power/Signal M39029/4-111 M39029/5-116 MS27488-16-1 M81969/14-03
12 Power/Signal M39029/4-113 M39029/5-118 MS27488-12-1 M81969/14-04
20* Power/Signal 5291-022-204H 5091-022-204H MS27488-20-1 M81969/39-01
Contact
Size
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
20 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-205 M81969/8-206
M22520/2-01 M22520/2-02 M22520/2-02
16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-207 M81969/8-208
12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-209 M81969/8-210
20* M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-205 M81969/8-206
M22520/2-01 M22520/2-02 M22520/2-02
Contact
Size
Test Current Voltage Crimp Well Data Wire Range Finished Wire [Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWG mm2inch mm inch mm
20 7.5 55 .049 ±.001 .155 3.94 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .250 6.35 20-16 .52-1.31 .053 1.35 .103 2.62
12 23.0 42 .100 ±.002 .250 6.35 14-12 2.08-3.31 .097 2.46 .158 4.01
81www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482
Contact Installation Instructions
Series 2
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the contact.
Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into
the insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to
removing insertion tool, do not try to reinsert the
insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
damage the inside of the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place the wire into the
extraction tool of the pin or socket.
3. Slowly slide the extraction tool down wire into the contact
cavities until the tool tip bottoms against the contact
shoulder, expanding the clip retaining tines. Hold the wire
firmly in the tool and pull the wired contact and tool
straight out of the rear of the insulator.
Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool
20 M39029/4-110 M39029/5-115 M22520/1-01 M22520/1-02 Red M22520/1-02 Red M81969/14-11
M22520/2-01 M22520/2-02 M22520/2-02
16 M39029/4-111 M39029/5-116 M22520/1-01 M22520/1-02 Blue M22520/1-02 Blue M81969/14-03
12 M39029/4-113 M39029/5-118 M22520/1-01 M22520/1-02 Yellow M22520/1-02 Yellow M81969/14-04
20* 5291-022-204H 5091-022-204H M22520/1-01 M22520/1-02 Red M22520/1-02 Red M81969/39-01
M22520/2-01 M22520/2-02 M22520/2-02
* Aero-Electric proprietary size 20 contacts used in 8-2, 8-3 and 8-4 layouts only.
82www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482 Series 2
Polarization, Insert Availability & Contact Information
per MIL-STD-1669
Insert Availability, Contact Information and Clocking Positions
– –
Polarization (Insert Clocking)
1. In the normal insert clocking position (position N), the
insert centerline coincides with the centerline of the
master keyway (key) of the shell: L = 0°.
2. In the alternate clocking positions (W, X, Y and Z),
the pin insert (viewing from mating side) is rotated
clockwise relative to the centerline of the master
keyway (key) of the shell.
3. The socket insert is rotated counter-clockwise.
4. Plugs have keys; receptacles have keyways.
Note: Be careful with alternate positions. See table below for
position availability on layouts of interest.
*Not qualified to MIL-DTL-26482 Series 2. These layouts were designed
to mate with solder Series 1 connectors using proprietary Aero-Electric
contacts (not QPL’d to M39029) and to avoid confusion are sold only
“with contacts”.
** Non MIL-STD-1669 layouts,available to Aero-Electric part numbers
only and utilize standard M39029 contacts.These layouts were
originally designed for use in AC3475 Artic Coupling RFI plugs and
AC3474 jam nut receptacles.
Insert
Arrangement
Aero-Electric Total Contact Quantity Service Insert Positions
Status No. of By Size In Degrees
QPL'd Tooled Contacts 20 16 12 Rating N W X Y Z
8-2* No Yes 2 2 I 0 58 122 — —
8-3* No Yes 3 3 I 0 60 210 — —
8-4* No Yes 4 4 I 0 45 — — —
8-33 Yes Yes 3 3 I 0 90 — — —
8-98 Yes Yes 3 3 I 0 — — — —
10-6 Yes Yes 6 6 I 0 90 — — —
10-7** N/A Yes 7 7 I 0 90 — — —
12-3 Yes Yes 3 3 II 0 — — 180 —
12-8 Yes Yes 8 8 I 0 90 112 203 292
12-10 Yes Yes 10 10 I 0 60 155 270 295
14-2** N/A Yes 2 2 I 0 — — — —
14-4 Yes Yes 4 4 I 0 45 — — —
14-5 Yes Ye s 5 5 II 0 40 92 184 273
14-9 Yes Yes 9 5 4 I 0 15 90 180 240
14-12 Yes Yes 12 8 4 I 0 43 90 — —
14-15 Yes Yes 15 14 1 I 0 17 110 155 234
14-18 Yes Yes 18 18 I 0 15 90 180 270
14-19 Yes Yes 19 19 I 0 30 165 315 —
PIN INSERT
MATING FACE
(SOCKET INSERT IS OPPOSITE)
INSERT
VERTICAL
CENTERLINE
MASTER
KEYWAY (KEY)
OF A SHELL
L°
83www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-DTL-26482 Series 2
Polarization, Insert Availability & Contact Information
per MIL-STD-1669
Insert Availability, Contact Information and Clocking Positions
– –
Insert
Arrangement
Aero-Electric Total Contact Quantity Service Insert Positions
Status No. of By Size In Degrees
QPL'd Tooled Contacts 20 16 12 Rating N W X Y Z
16-8 Yes Yes 8 8 II 0 54 152 180 331
16-14 Yes Yes 14 8 6 I 0 25 78 180 240
16-23 Yes Yes 23 22 1 I 0 158 270 — —
16-26 Yes Yes 26 26 I 0 60 —275 338
18-8 Yes Yes 8 8 I 0 180 ———
18-11 Yes Yes 11 11 II 0 62 119 241 340
18-30 Yes Yes 30 29 1 I 0 180 193 285 350
18-32 Yes Yes 32 32 I 0 85 138 222 265
20-16 Yes Yes 16 16 II 0 238 318 333 347
20-24 Yes Yes 24 24 I 0 70 145 215 290
20-39 Yes Yes 39 37 2 I 0 63 144 252 333
20-41 Yes Yes 41 41 I 0 45 126 225 —
22-12 Yes Yes 12 12 I 0 — — — —
22-21 Yes Yes 21 21 II 0 16 135 175 349
22-41 Yes Yes 41 27 14 I 0 39 135 264 —
22-55 Yes Yes 55 55 I 0 30 142 226 314
22-95 Yes Yes 32 26 6 I 0 26 180 266 —
24-19 Yes No 19 19 II 0 30 165 315 —
24-31 Yes Yes 31 31 I 0 90 225 255 —
24-61 Yes Yes 61 61 I 0 90 180 270 324
84www.conesys.com sales@aero-electric.com
MIL–DTL– 26482 S 2
MIL-STD-1669
Insert Arrangements (Pin Front View)
for MIL-DTL-26482 Series 2 Connectors
Insert Arrangements Views
– –
* Not on QPL, available to Aero-Electric part number only. ** Non MIL-STD-1669 layout, available in AC3470 through AC3475 shell
styles only.
A
B
C
AB A
BC
DA
B
C
A
B
CA
B
C
D
E
F
A
B
G
C
D
E
FA
B
C
A
HB
C
D
E
F
G
AB
C
D
E
F
G
H
J
K
A
B
C
D
A
B
C
D
E
A
B
C
D
E
F
G
H
J
A
B
C
D
E
F
G
M
H
J
K
L
A
B
RC
D
E
F
G
H
J
K
L
M
N
P
A
B
C
D
E
F
G
H
J
K
L
MN
P
R
S
TU
AB
C
D
E
F
G
H
J
K
L
M
NP
R
S
T
UV
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
J
K
L
M
NP
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
ST
U
V
W
X
Y
Z
ab
c
A
B
C
D
E
F
G
H
A
B
C
D
E
G
H
J
K
L
F
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
J
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
8-3*
3#20, I
8-2*
2#20, I
8-4*
4#20, I
8-33
3#20, I
8-98
3#20, I
10-6
6#20, I
10-7**
7#20,I
12-3
3 # 16, II
12-8
8#20,I
12-10
10 # 20, I
14-4
4#12, I
14-5
5 # 16, II
14-9
5#20,4#12,I
14-12
4#16,8#20,I
14-15
1#16, 14 # 20, I
14-18
18 # 20, I
14-19
19 # 20, I
16-8
8 # 16, II
16-14
8#20,6#12,I
16-23
1#16,22#20, I
16-26
26 # 20, I
18-8
8#12, I
18-11
11 # 16, II
20-16
16 # 16, II
18-32
32 # 20, I
18-30
1#16,29#20,I
A
B
14-2**
2#12, I
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MIL–DTL– 26482 S 2
MIL-STD-1669
Insert Arrangements (Pin Front View)
for MIL-DTL-26482 Series 2 Connectors
Insert Arrangements Views
– –
A
B
C
D
E
F
G
H
J
K
LM
N
P
R
ST
U
V
WX
Y
Z
a
20-24
24#20,I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
VW
XY
Z
a
b
c
d
e
f
g
h
J
k
m
n
P
r
i
q
20-39
2#16, 37 # 20, I
20-41
41#20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
22-21
21 # 16, II
A
B
C
D
E
F
G
H
J
K
L
M
22-12
12 # 12, I
a
b
c
d
e
f
g
H
j
k
m
n
P
r
s
t
A
B
C
D
E
F
G
H
J
K
L
M
N
R
S
T
U
V
W
X
Y
Z
P
i
q
22-41
14 # 16, 27 # 20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
UV
W
X
Y
Z
l
a
b
c
d
e
f
g
h
k
m
n
p
r
s
t
u
v
w
x
y
z
i
q
AA
BB
CC
DD
EE
FF
GG
HH
22-55
55 # 20, I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
YZ
a
b
c
d
e
f
g
h
j
22-95
6#12, 26 # 20, I
AB
C
D
E
F
G
H
J
K
L
M
NP
R
S
T
UV
24-19
19 # 12, II
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
Q
24-31
31 # 16, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
YZ
AA
BB
CC
DD
EE
FF
GG
HH
JJ
LL
KK
MM
NN
PP
abc
d
e
f
g
h
j
k
m
n
p
r
s
t
u
v
w
x
y
z
i
q
24-61
61 # 20, I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
XY
Z
a
b
c
d
e
f
g
h
j
k
m
n
p
r
s
i
q
t
86www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
– –
MIL-DTL-83723 Series III
Features and Application
Bayonet and Threaded Coupling
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Features and Application
MIL-DTL-83723 Series III family offers connectors with
bayonet and threaded coupling including lanyard-release
quick-disconnects. These connectors combine the best features
of MIL-DTL-26500 and NAS 1599 miniature connector
specifications. They are intermateable with both bayonet and
threaded 26500 connectors (exception: shell size 8, threaded
coupling only) and have the added advantage provided by the
rear-release contact retention system.
AE833 connectors are widely used on commercial, military
and aerospace systems requiring general-purpose, miniature
cylindrical bayonet or threaded coupling connectors. In
addition, Series III threaded connectors with self-locking
plugs are well suited for engine applications.
This family of connectors (bayonet as well as threaded) is
offered in wall mount receptacles as well as jam nut mounted
receptacles which incorporate “O” ring seals, designed for rear
panel “D”hole mounting.
Series III bayonet-coupling plugs are available in two designs
- with and without RFI grounding. Threaded coupling plugs
are offered with and without RFI grounding, self-locking
and RFI/self-locking. In addition we offer quick-disconnect
(lanyard release) plugs, which mate with threaded receptacles
via an adapter.
Thirty-one insert arrangements per MIL-STD-1554 are
tooled and qualified to MIL-DTL-83723 Series III, utilizing
2 to 61 M39029 contacts. Contacts come in sizes 20, 16 and
12, terminating wire sizes from 24 to 12 gauge.
These connectors are available in wide range of shell materials
and finishes. Aluminum shells are offered in electroless nickel,
olive drab cadmium and black anodic. Other finishes such as
zinc cobalt are available upon request to commercial callouts
only. In addition, we offer passivated stainless steel shells
with both standard and firewall-rated inserts, and for highly
corrosive environments, nickel-aluminum-bronze shells
with standard environment-resisting inserts (commercial
callouts only).
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
Shell Polarization – Alternate key/keyway positions prevent
cross mating of adjacent connectors having same insert
arrangement.
Closed-Entry Socket Insert – Hard dielectric socket face has
lead-in chamfers for positive alignment of pins (even partially
bent within pre-established limits) with sockets.
Interfacial Pin Insert Seal – Raised moisture barriers around
each pin, which mate into lead-in chamfers of hard face
socket insert, provide individual contact sealing. Interfacial
seal is never touched by service tools.
Elastomer Wire Sealing Grommet – Sealing over a wide
range of wire diameters is assured by a triple wire seal in each
cavity at the rear of the connector.
Superior Contact Stability – Rear release crimp contact
system features a stamped beryllium-copper retaining clip
captivated by molded-in shoulders of each contact cavity in
the insulator. A rear-inserted M81969 plastic tool expands the
tines beyond the shoulder, releasing the contact.
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MIL–DTL– 83723 S III
MIL-DTL-83723 Series III
Performance Specifications
Bayonet and Threaded Coupling
– –
Performance Specifications
Operating Temperature Range
Classes A and R: -65°C to +200°C (-85°F to +392°F)
Class W: -65°C to +175°C (-85°F to +347°F)
Classes G and K: -65°C to +200°C (-85°F to +392°F)
Classes N and S: -65°C to +200°C (-85°F to +392°F)
Material and Finish Data (Class)
A – aluminum shell, black anodized finish
G – stainless steel shell, passivated
K – stainless steel shell, passivated, firewall
R – aluminum shell, electroless nickel finish
S – stainless steel shell, passivated, firewall, and 360° teeth
W– aluminum shell, olive drab cadmium over nickel base
N – stainless steel shell, electrodeposited nickel, firewall, and
360° teeth
Corrosion Resistance
Class W withstands 500-hour salt spray.
Class R withstands 48-hour salt spray.
Environmental Seal
Wired, mated connectors with specified accessories
attached, shall meet the altitude-immersion test specified by
MIL-DTL-83723 Series III.
Fluid Resistance
Connectors resist specified immersions in MIL-PRF-7808
(lubricating oil), MIL-PRF-23699 (lubricating oil),
MIL-PRF-5606 (hydraulic fluid), M2-V Chevron oil,
Coolanol 25, MIL-DTL-83133 (turbine fuel JP-8),
MIL-DTL-5624 (turbine fuels JP-4 and JP-5), SAE-AMS1424
Type I (defrosting fluid), and other solvents and cleaning
agents.
Voltage Rating
Durability
Mated connectors withstand a minimum of 500 mating
cycles for bayonet coupling straight plug (M83723/75, 76);
250 mating cycles for bayonet coupling RFI plug
(M83723/77, 78); and 250 cycles for all threaded coupling
plugs (M83723/86, 87, 91, 92, 95, 96, 97, 98).
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, coupling
ring shall not loosen, and there shall be no interruption of
electrical continuity longer than one microsecond when
subjected to the following:
Shock
Mated connectors withstand a pulse of approximate half
sine wave of 300 G ± 15 percent magnitude with duration
of 3 ± 1 milliseconds applied in three axes.
Vibration
Mated connectors withstand the following vibration levels:
●Random vibration per MIL-STD-1344, method 2005,
test condition VI, letter J.
Shielding Effectiveness
RFI attenuation at the specified frequency meets the
requirements of MIL-DTL-83723 Series III.
●RFI shielding effectiveness of mated connectors with RFI
backshells is measured in a triaxial radio frequency leak-
age fixture.
Shell-to-Shell Conductivity (Except class A)
●With RFI spring fingers, the maximum potential drop
shall not exceed 5 millivolts.
●Without spring fingers, the maximum potential drop
shall not exceed 200 millivolts.
* To be used by designer only as a guide.
Service
Rating
Suggested Operating Voltage* Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft.70,000 Ft.110,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
I600 850 1500 500 375 200
II 900 1250 2300 750 500 200
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MIL–DTL– 83723 S III
MIL-DTL-83723 Series III
Part Number Development
Bayonet Coupling
Military and Aero-Electric Part Number Development
– –
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 2 to 26 of each contact and two spares for
inserts with 27 or more of each size, and a minimum of one
sealing plug up to 15% of the number of contacts of each
size. In addition, one insertion/removal tool of each size is
included.
Note 2: Proper part number marking has no “0” in front of
single digit shell size (8), but it does include the “0” in front
of single digit layout. Examples: M83723/72W803N and
M83723/77G10056. Please note that in this series “N” for
normal is included in part number marking.
Mil. Prefix M83723/ 71 R12 12 N
Aero Prefix AE833 71 R12 12 N-340
Shell type
71 = Wall mount receptacle with socket contacts
72 = Wall mount receptacle with pin contacts
73 = Jam nut receptacle with socket contacts
74 = Jam nut receptacle with pin contacts
75 = Straight plug with socket contacts
76 = Straight plug with pin contacts
77 = RFI grounding plug with socket contacts
78 = RFI grounding plug with pin contacts
Class (Material and Finish)
A= Aluminum shell, black anodized finish (not available in 77 and 78 RFI plugs)
G= Stainless stell shell, passivated
R= Aluminum shell, electroless nickel finish
W= Aluminum shell, olive drab cadmium over electroless nickel finish
Shell Size (SS)
8, 10, 12, 14, 16, 18, 20, 22 or 24
Insert Arrangement
See pages 106 thru 108
Polarization (Keying)
N= Normal
6, 7, 8, 9 or Y(Alternate keyed positions,Y is not availabe in SS 8)
1, 2, 3, 4 or 5(Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in SS 8)
Modification (applies to Aero part numbers only)
01 = Less contacts (Part is bagged and tagged, but not marked with 01)
340 = Connector kitted with M85049/31-XXX E-nut
341 = Connector kitted with M85049/52-1-XXX straight clamp
342 = Connector kitted with M85049/51-1-XXX right angle clamp
Consult factory for other modifications
89www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/71, 72
Wall Mounting Receptacle
AE83371, 72
Bayonet Coupling, Crimp Removable, Rear Release
– –
MASTER
KEYWAY
4x MINOR KEYS
[
D
3x BAYONET PINS
EQUALLY SPACED
4x
[
C
MOUNTING
HOLES
3 ACCESSORY TEETH
EQUALLY SPACED
E
ACCESSORY THREAD
[
F
MAX
GROMMET
.290(7.37) MIN FULL THREAD
A
B
1.300(33.02)
MAX
.728(18.49)
.708(17.98)
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
.072(1.83)
.052(1.32)
BLUE COLOR BANDS
Page 88 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Shell
Size
A B [C[D E [F
+.000 +.00 Accessory Thread
±.005 ±.13 (TP) ±.005 ±.13 -.005 -.13 Class 2A Maximum
inch mm inch mm inch mm inch mm inch mm
8.812 20.62 .594 15.09 .120 3.05 .536 13.61 1/2-20UNF .305 7.75
10 .937 23.80 .719 18.26 .120 3.05 .659 16.74 5/8-24UNEF .405 10.29
12 1.031 26.19 .812 20.62 .120 3.05 .829 21.06 3/4-20UNEF .531 13.49
14 1.125 28.58 .906 23.01 .120 3.05 .898 22.81 7/8-20UNEF .665 16.89
16 1.250 31.75 .969 24.61 .120 3.05 1.025 26.04 1-20UNEF .790 20.07
18 1.343 34.11 1.062 26.97 .120 3.05 1.131 28.73 1-1/16-18UNEF .869 22.07
20 1.437 36.50 1.156 29.36 .120 3.05 1.256 31.90 1-3/16-18UNEF .994 25.25
22 1.562 39.67 1.250 31.75 .120 3.05 1.381 35.08 1-5/16-18UNEF 1.119 28.42
24 1.703 43.26 1.375 34.93 .149 3.78 1.506 38.25 1-7/16-18UNEF 1.244 31.60
90www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/73, 74
Jam Nut Receptacle
AE83373, 74
Bayonet Coupling, Crimp Removable, Rear Release
– –
BLUE COLOR BAND
BLUE COLOR BAND
.781(19.84)
.761(19.33)
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
HEX NUT
PER MS3186
3 ACCESSORY TEETH
EQUALLY SPACED
1.300(33.02)
MAX
4x MINOR KEYWAYS
MASTER
KEYWAY
"O" RING
[
D
E
MOUNTING FLAT
G
ACCESSORY THREAD
F
JAM NUT
THREAD
[
C
MAX
GROMMET
[
B
MAX
A
MAX
PANEL THICKNESS:
.125(3.18)
.062(1.58)
Page 88 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Shell
Size
A[B[C[D E F G
+.000 +.00 Jam Nut Thread Accessory Thread
Maximum Maximum Maximum -.005 -.13 ±.003 ±.08 Class 2A Class 2A
inch mm inch mm inch mm inch mm inch mm
8.979 24.87 1.068 27.13 .305 7.75 .536 13.61 .593 15.06 5/8-20UN 1/2-20UNF
10 1.104 28.04 1.192 30.28 .405 10.29 .659 16.74 .718 18.24 3/4-20UNEF 5/8-24UNEF
12 1.291 32.79 1.380 35.05 .531 13.49 .829 21.06 .905 22.99 15/16-20UNEF 3/4-20UNEF
14 1.391 35.33 1.505 38.23 .665 16.89 .898 22.81 .968 24.59 1-20UNEF 7/8-20UNEF
16 1.516 38.51 1.630 41.40 .790 20.07 1.025 26.04 1.093 27.76 1-1/8-20UN 1-20UNEF
18 1.641 41.68 1.756 44.60 .869 22.07 1.131 28.73 1.217 30.91 1-1/4-18UNEF 1-1/16-18UNEF
20 1.766 44.86 1.860 47.24 .994 25.25 1.256 31.90 1.342 34.09 1-3/8-18UNEF 1-3/16-18UNEF
22 1.954 49.63 2.086 52.98 1.119 28.42 1.381 35.08 1.467 37.26 1-1/2-18UNEF 1-5/16-18UNEF
24 2.079 52.81 2.160 54.86 1.244 31.60 1.506 38.25 1.592 40.44 1-5/8-18UNEF 1-7/16-18UNEF
91www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/75, 76
Straight Plug
AE83375, 76
Bayonet Coupling, Crimp Removable, Rear Release
– –
BLUE COLOR BAND
MASTER KEY
4 MINOR KEYS
3x BAYONET HOLES
EQUALLY SPACED
3 ACCESSORY TEETH
EQUALLY SPACED
H
ACCESSORY THREAD
[
E
MAX
GROMMET
.290(7.37) MIN FULL THREAD
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
[
F
MAX
COUPLING
NUT
[
G
1.230(31.24)
MAX
Page 88 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Shell
Size
[E[F[G H
+.005 +.13 Accessory Thread
Maximum Maximum -.004 -.10 Class 2A
inch mm inch mm inch mm
8.305 7.75 .776 19.71 .419 10.64 1/2-20UNF
10 .405 10.29 .906 23.01 .521 13.23 5/8-24UNEF
12 .531 13.49 1.078 27.38 .691 17.55 3/4-20UNEF
14 .665 16.89 1.141 28.98 .760 19.30 7/8-20UNEF
16 .790 20.07 1.266 32.16 .887 22.53 1-20UNEF
18 .869 22.07 1.375 34.93 .993 25.22 1-1/16-18UNEF
20 .994 25.25 1.510 38.35 1.118 28.40 1-3/16-18UNEF
22 1.119 28.42 1.625 41.28 1.243 31.57 1-5/16-18UNEF
24 1.244 31.60 1.760 44.70 1.368 34.75 1-7/16-18UNEF
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MIL–DTL– 83723 S III
M83723/77, 78
RFI Grounding Plug
AE83377, 78
Bayonet Coupling, Crimp Removable, Rear Release
– –
Page 88 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Shell
Size
[E[F[GH
+.005 +.13 Accessory Thread
Maximum Maximum -.004 -.10 Class 2A
inch mm inch mm inch mm
8.305 7.75 .776 19.71 .419 10.64 1/2-20UNF
10 .405 10.29 .906 23.01 .521 13.23 5/8-24UNEF
12 .531 13.49 1.078 27.38 .691 17.55 3/4-20UNEF
14 .665 16.89 1.141 28.98 .760 19.30 7/8-20UNEF
16 .790 20.07 1.266 32.16 .887 22.53 1-20UNEF
18 .869 22.07 1.375 34.93 .993 25.22 1-1/16-18UNEF
20 .994 25.25 1.510 38.35 1.118 28.40 1-3/16-18UNEF
22 1.119 28.42 1.625 41.28 1.243 31.57 1-5/16-18UNEF
24 1.244 31.60 1.760 44.70 1.368 34.75 1-7/16-18UNEF
3x BAYONET HOLES
EQUALLY SPACED .290(7.37) MIN FULL THREAD
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
BLUE COLOR BAND
R.F.I SPRING
3 ACCESSORY TEETH
EQUALLY SPACED
H
ACCESSORY THREAD
[
E
MAX
GROMMET
[
G
1.230(31.24)
MAX
MASTER KEY
4 MINOR KEYS
[
F
MAX
COUPLING
NUT
93www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-DTL-83723 Series III
Part Number Development
Threaded Coupling
Military and Aero-Electric Part Number Development
– –
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 2 to 26 of each contact and two spares for
inserts with 27 or more of each size, and a minimum of one
sealing plug up to 15% of the number of contacts of each
size. In addition, one insertion/removal tool of each size is
included.
Note 2: Proper part number marking has no “0” in front of
single digit shell size (8), but it does include the “0” in front
of single digit layout. Examples: M83723/95G803N and
M83723/98S10056. Please note that in this series “N” for
normal is included in part number marking.
Note 3: Shell type M83723/70 (AE83370 Receptacle Adapter)
is not listed above, see page 101.
Mil. Prefix M83723/ 95 R12 12 N
Aero Prefix AE833 95 R12 12 N-340
Shell type
82 = Wall mount receptacle with socket contacts
83 = Wall mount receptacle with pin contacts
84 = Jam nut receptacle with socket contacts
85 = Jam nut receptacle with pin contacts
86 = Straight plug with socket contacts
87 = Straight plug with pin contacts
91 = RFI grounding plug with socket contacts
92 = RFI grounding plug with pin contacts
95 = Self-locking plug with socket contacts
96 = Self-locking plug with pin contacts
97 = Self-locking, RFI grounding plug with socket contacts
98 = Self-locking, RFI grounding plug with pin contacts
68 = Lanyard release, quick-disconnect plug, pin (not available in K & S classes)
69 = Lanyard release, quick-disconnect plug, socket (not available in K & S classes)
Class (Material and Finish)
A= Aluminum shell, black anodized finish (Not available in 91, 92, 97 & 98 RFI plugs)
G= Stainless steel shell, passivated (n/a in 97 & 98)
K= Stainless steel shell, passivated, with firewall rated insert (n/a in 91, 92, 97 & 98)
R= Aluminum shell, electroless nickel finish (n/a in 97 & 98 to mil number)
W= Aluminum shell, olive drab cadmium over nickel base (n/a in 97 & 98 to mil number)
S= Stainless steel shell, passivated, full teeth, firewall insert (n/a in 86, 87, 91, 92, 95 & 96)
Shell Size (SS)
8, 10, 12, 14, 16, 18, 20, 22 or 24 (and shell size 28 available in Aero p/n only)
Insert Arrangement
See pages 106-108
Polarization (Keying)
N= Normal
6, 7, 8, 9 or Y(Alternate keyed positions,Y is not availabe in SS 8)
1, 2, 3, 4 or 5(Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in SS 8)
Modification (applies to Aero part numbers only)
01 = Less contacts (Part is bagged and tagged, but not marked with 01)
340 = Connector kitted with M85049/31-XXX E-nut
341 = Connector kitted with M85049/52-1-XXX straight clamp
342 = Connector kitted with M85049/51-1-XXX right angle clamp
Consult factory for other modifications
H
No. OF TEETH
CLASSES: “N” & “S” ONLY
E
ACCESSORY THREAD
.290(7.37) MIN FULL THREAD
.160(4.06) GROMMET
.010(0.25) EXTENSION
1.340(34.04) MAX
CLASSES: “N” & “S” ONLY
E
4 MINOR KEYWAYS
1.248(31.70)
MAX
4x
[
C
MOUNTING HOLES
B
A
D
MATING THREAD
.728(18.49)
.708(17.98)
FULL MATE
INDICATOR
COLOR: RED
[
F
MAX
GROMMET
[
F
MAX
GROMMET
.290(7.37) MIN
FULL THREAD
.072(1.83)
.052(1.32)
.190(4.83) GROMMET
.130(3.30) EXTENSION
ACCESSORY THREAD
MASTER
KEYWAY
BLUE COLOR BANDS
3 ACCESORY TEETH
EQUALLY SPACED
PANEL THICKNESS:
.125(3.18) MAX
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MIL–DTL– 83723 S III
M83723/82, 83
Wall Mounting Receptacle
AE83382, 83
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Shell
Size
A B [C D E [F H
+.005 +.13 Mating Thread Accessory Thread No. of
±.005 ±.13 (TP) -.004 -.10 Class 2A Class 2A Maximum Teeth
inch mm inch mm inch mm inch mm
8.812 20.62 .594 15.09 .120 3.05 9/16-24UNEF 1/2-20UNF .305 7.75 12
10 .937 23.80 .719 18.26 .120 3.05 11/16-24UNEF 5/8-24UNEF .405 10.29 15
12 1.031 26.19 .812 20.62 .120 3.05 7/8-20UNEF 3/4-20UNEF .531 13.49 21
14 1.125 28.58 .906 23.01 .120 3.05 15/16-20UNEF 7/8-20UNEF .665 16.89 24
16 1.250 31.75 .969 24.61 .120 3.05 1-1/16-18UNEF 1-20UNEF .790 20.07 30
18 1.343 34.11 1.062 26.97 .120 3.05 1-3/16-18UNEF 1-1/16-18UNEF .869 22.07 33
20 1.437 36.50 1.156 29.36 .120 3.05 1-5/16-18UNEF 1-3/16-18UNEF .994 25.25 36
22 1.562 39.67 1.250 31.75 .120 3.05 1-7/16-18UNEF 1-5/16-18UNEF 1.119 28.42 39
24 1.703 43.26 1.375 34.93 .149 3.78 1-9/16-18UNEF 1-7/16-18UNEF 1.244 31.60 42
28 2.000 50.80 1.562 39.67 .149 3.78 1-13/16-16UN 1-3/4-18UNS 1.475 37.47 54
H
ACCESSORY THREAD
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
.290(7.37)
MIN FULL THREAD
BLUE COLOR BAND
3 ACCESSORY
TEETH 120°
APART
[
B
4 MINOR KEYWAYS
.781(19.84)
.761(19.33)
D
MATING THREAD
BLUE COLOR BAND
E
JAM NUT
THREAD
MASTER
KEYWAY
G
MOUNTING FLAT
A
FULL MATE
INDICATOR
COLOR: RED
"O" RING
HEX NUT
PER MS3186
1.240(31.50)
MAX
1.340(34.04) MAX
CLASSES: “N” & “S” ONLY
H
ACCESSORY THREAD
F
No. OF TEETH
CLASSES: “N” & “S” ONLY
.160(4.06) GROMMET
.010(0.25) EXTENSION
CLASSES: “N” & “S”
.290(7.37) MIN FULL THREAD
[
C
MAX
GROMMET
[
C
MAX
GROMMET
PANEL THICKNESS:
.125(3.18)
.062(1.57)
95www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/84, 85
Jam Nut Receptacle
AE83384, 85
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Shell
Size
A[B[CD E F G H
+.016 +.41 +.016 +.41 Mating Thread Jam Nut Thread No. of Accessory
-.015 -.38 -.015 -.38 Maximum Class 2A Class 2A Teeth ±.003 ±.08 Thread
inch mm inch mm inch mm inch mm Class 2A
8.964 24.49 1.062 26.97 .305 7.75 9/16-24UNEF 5/8-20UN 12 .593 15.06 1/2-20UNF
10 1.088 27.64 1.176 29.87 .405 10.29 11/16-24UNEF 3/4-20UNEF 15 .718 18.24 5/8-24UNEF
12 1.275 32.39 1.364 34.65 .531 13.49 7/8-20UNEF 15/16-20UNEF 21 .905 22.99 3/4-20UNEF
14 1.375 34.93 1.545 39.24 .665 16.89 15/16-20UNEF 1-20UNEF 24 .968 24.59 7/8-20UNEF
16 1.500 38.10 1.625 41.28 .790 20.07 1-1/16-18UNEF 1-1/8-18UNEF 30 1.093 27.76 1-20UNEF
18 1.625 41.28 1.750 44.45 .869 22.07 1-3/16-18UNEF 1-1/4-18UNEF 33 1.217 30.91 1-1/16-18UNEF
20 1.750 44.45 1.938 49.23 .994 25.25 1-5/16-18UNEF 1-3/8-18UNEF 36 1.342 34.09 1-3/16-18UNEF
22 1.938 49.23 2.062 52.37 1.119 28.42 1-7/16-18UNEF 1-1/2-18UNEF 39 1.467 37.26 1-5/16-18UNEF
24 2.063 52.40 2.166 55.02 1.244 31.60 1-9/16-18UNEF 1-5/8-18UNEF 42 1.592 40.44 1-7/16-18UNEF
28 2.314 58.78 2.428 61.67 1.475 37.47 1-13/16-16UN 1-7/8-20UN 54 1.840 46.74 1-3/4-18UNS
96www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/86, 87
Straight Plug
AE83386, 87
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
[
B
MAX
COUPLING NUT .290(7.37)
MIN
FULL
THREAD
4 MINOR KEYS
MASTER KEY
D
MATING THREAD
[
A
BLUE COLOR BAND
3x
[
.035(.89)
SAFETY WIRE HOLES
1.180(29.97)
MAX
3 ACCESSORY TEETH
EQUALLY SPACED
E
ACCESSORY THREAD
[
C
MAX GROMMET
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
Shell
Size
[A[ B[ C D E
+.005 +.13 Mating Thread Accessory Thread
-.004 -.10 Maximum Maximum Class 2B Class 2A
inch mm inch mm inch mm
8.400 10.16 .776 19.71 .305 7.75 9/16-24UNEF 1/2-20UNF
10 .521 13.23 .906 23.01 .405 10.29 11/16-24UNEF 5/8-24UNEF
12 .691 17.55 1.078 27.38 .531 13.49 7/8-20UNEF 3/4-20UNEF
14 .760 19.30 1.141 28.98 .665 16.89 15/16-20UNEF 7/8-20UNEF
16 .887 22.53 1.266 32.16 .790 20.07 1-1/16-18UNEF 1-20UNEF
18 .993 25.22 1.375 34.93 .869 22.07 1-3/16-18UNEF 1-1/16-18UNEF
20 1.118 28.40 1.510 38.35 .994 25.25 1-5/16-18UNEF 1-3/16-18UNEF
22 1.243 31.57 1.625 41.28 1.119 28.42 1-7/16-18UNEF 1-5/16-18UNEF
24 1.368 34.75 1.760 44.70 1.244 31.60 1-9/16-18UNEF 1-7/16-18UNEF
28 1.618 41.10 2.050 52.07 1.475 37.47 1-13/16-16UN 1-3/4-18UNS
97www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/91, 92
RFI Grounding Plug
AE83391, 92
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
4 MINOR KEYS
MASTER KEY
BLUE COLOR BAND
1.180(29.97)
MAX
RFI STRIP
[
B
MAX
COUPLING NUT
[
C
MAX
GROMMET
[
A
D
MATING THREAD
E
ACCESSORY THREAD
3 ACCESSORY TEETH
EQUALLY SPACED
3X
[
.035(.89)
SAFETY WIRE HOLES .290(7.37)
MIN
FULL
THREAD
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
Shell
Size
[A[B[C D E
+.005 +.13 Mating Thread Accessory Thread
-.004 -.10 Maximum Maximum Class 2B Class 2A
inch mm inch mm inch mm
8.400 10.16 .776 19.71 .305 7.75 9/16-24UNEF 1/2-20UNF
10 .521 13.23 .906 23.01 .405 10.29 11/16-24UNEF 5/8-24UNEF
12 .691 17.55 1.078 27.38 .531 13.49 7/8-20UNEF 3/4-20UNEF
14 .760 19.30 1.141 28.98 .665 16.89 15/16-20UNEF 7/8-20UNEF
16 .887 22.53 1.266 32.16 .790 20.07 1-1/16-18UNEF 1-20UNEF
18 .993 25.22 1.375 34.93 .869 22.07 1-3/16-18UNEF 1-1/16-18UNEF
20 1.118 28.40 1.510 38.35 .994 25.25 1-5/16-18UNEF 1-3/16-18UNEF
22 1.243 31.57 1.625 41.28 1.119 28.42 1-7/16-18UNEF 1-5/16-18UNEF
24 1.368 34.75 1.760 44.70 1.244 31.60 1-9/16-18UNEF 1-7/16-18UNEF
28 1.618 41.10 2.050 52.07 1.475 37.47 1-13/16-16UN 1-3/4-18UNS
98www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/95, 96
Self-Locking Plug
AE83395, 96
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
BLUE COLOR BAND
1.180(29.97)
MAX
[
C
MAX
COUPLING NUT
D
MATING THREAD
[
A
E
ACCESSORY THREAD
3 ACCESSORY TEETH
EQUALLY SPACED
[
B
MAX
GROMMET
.190(4.83)
.130(3.30)
GROMMET
EXTENSION
.290(7.37)
MIN
FULL
THREAD
4 MINOR KEYS
MASTER KEY
Shell
Size
[A[B[C D E
+.005 +.13 Mating Thread Accessory Thread
-.004 -.10 Maximum Maximum Class 2B Class 2A
inch mm inch mm inch mm
8.400 10.16 .305 7.75 .832 21.13 9/16-24UNEF 1/2-20UNF
10 .521 13.23 .405 10.29 .959 24.36 11/16-24UNEF 5/8-24UNEF
12 .691 17.55 .531 13.49 1.097 27.86 7/8-20UNEF 3/4-20UNEF
14 .760 19.30 .665 16.89 1.236 31.39 15/16-20UNEF 7/8-20UNEF
16 .887 22.53 .790 20.07 1.360 34.54 1-1/16-18UNEF 1-20UNEF
18 .993 25.22 .869 22.07 1.473 37.41 1-3/16-18UNEF 1-1/16-18UNEF
20 1.118 28.40 .994 25.25 1.586 40.28 1-5/16-18UNEF 1-3/16-18UNEF
22 1.243 31.57 1.119 28.42 1.703 43.26 1-7/16-18UNEF 1-5/16-18UNEF
24 1.368 34.75 1.244 31.60 1.846 46.89 1-9/16-18UNEF 1-7/16-18UNEF
28 1.618 41.10 1.475 37.47 2.278 57.86 1-13/16-16UN 1-3/4-18UNS
99www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/97, 98
Self-Locking, RFI Grounding Plug
AE83397, 98
Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
.160(4.06)
.010(0.25)
GROMMET
EXTENSION
4 MINOR KEYS
BLUE COLOR BAND
F
ACCESSORY THREAD
B
NUMBER OF TEETH
1.280(32.51)
MAX
MASTER KEY
RFI STRIP
[
D
MAX
COUPLING NUT
E
MATING THREAD
[
A
[
C
MAX
GROMMET
.290(7.37)
MIN
FULL
THREAD
Shell
Size
[A B [C[D E F
+.005 +.13 No. of Mating Thread Accessory Thread
-.004 -.10 Teeth Maximum Maximum Class 2B Class 2A
inch mm inch mm inch mm
8.400 10.16 12 .305 7.75 .967 24.56 9/16-24UNEF 1/2-20UNF
10 .521 13.23 15 .405 10.29 1.093 27.76 11/16-24UNEF 5/8-24UNEF
12 .691 17.55 21 .531 13.49 1.170 29.72 7/8-20UNEF 3/4-20UNEF
14 .760 19.30 24 .665 16.89 1.310 33.27 15/16-20UNEF 7/8-20UNEF
16 .887 22.53 30 .790 20.07 1.500 38.10 1-1/16-18UNEF 1-20UNEF
18 .993 25.22 33 .869 22.07 1.562 39.67 1-3/16-18UNEF 1-1/16-18UNEF
20 1.118 28.40 36 .994 25.25 1.710 43.43 1-5/16-18UNEF 1-3/16-18UNEF
22 1.243 31.57 39 1.119 28.42 1.812 46.02 1-7/16-18UNEF 1-5/16-18UNEF
24 1.368 34.75 42 1.244 31.60 1.948 49.48 1-9/16-18UNEF 1-7/16-18UNEF
28 1.618 41.10 54 1.475 37.47 2.278 57.86 1-13/16-16UN 1-3/4-18UNS
100www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/68, 69
Lanyard Release, Quick-Disconnect Plug
AE83368, 69
Quick-Disconnect, Threaded Coupling, Crimp Removable, Rear Release
– –
Page 93 Completed Part Number
Page 104 Contacts,Sealing Plugs and Tools
Pages 107, 108 Insert Arrangements
Page 87 Performance Specifications
Page 106 Insert Availability and Contact Information
Page 102 Polarization
Note 1: M83723/70 receptacle adapter (page 101) is required
to mate the Quick-Disconnect Plug with a receptacle.
Note 2: Not available in shell size 8.
C ACCESSORY THREAD
7.500(190.50)
MAX
[ A
MAX
[ D
MASTER
KEY
1.180(29.97)
MAX
.190(4.83)
.130(3.30)GROMMET EXTENSION
BLUE COLOR BAND
[ B
MAX GROMMET
3 ACCESSORY TEETH
EQUALLY SPACED
LENGTH TO BE MEASURED WITH A
[
.750(19.05)±.060(1.52) BAR TO PULL
LANYARD TAUT
4 MINOR KEYS
Shell
Size
[A[B C [D
Accessory Thread
Maximum Maximum Class 2A
inch mm inch mm inch mm
10 1.240 31.50 .405 10.29 5/8-24UNEF .526/.517 13.36/13.13
12 1.432 36.37 .531 13.49 3/4-20UNEF .696/.687 17.68/17.45
14 1.490 37.85 .665 16.89 7/8-20UNEF .765/.756 19.43/19.20
16 1.711 43.46 .790 20.07 1-20UNEF .892/.883 22.66/22.43
18 1.815 46.10 .869 22.07 1-1/16-18UNEF .998/.989 25.35/25.12
20 1.962 49.83 .994 25.25 1-3/16-18UNEF 1.123/1.114 28.52/28.30
22 2.070 52.58 1.119 28.42 1-5/16-18UNEF 1.248/1.239 31.70/31.47
24 2.195 55.75 1.244 31.60 1-7/16-18UNEF 1.373/1.364 34.87/34.65
101www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
M83723/70
Receptacle Adapter, Quick-Disconnect
AE83370
Quick-Disconnect (Push-Pull) Receptacle Adapter
– –
COLOR BAND
D
THREAD
[
B
[
A
[
C
[
E
.442(11.23)
±.005(.13)
Note: The adapter is required to mate the Lanyard Release
and Push-Pull Quick-Disconnect plugs (M83723/66 thru 69)
with M83723/82, 83, 84, 85, 88, 89 and 90 threaded coupling
receptacles. Use compatible thread seizing compound to
permanently secure to the receptacle.
Shell
Size
D[A[B[C[E
Coupling Thread
Class 2B ±.002 ±.05 ±.002 ±.05 ±.002 ±.05 ±.005 ±.13
inch mm inch mm inch mm inch mm
89/16-24UNEF .605 15.37 .577 14.66 .687 17.45 .525 13.34
10 11/16-24UNEF .730 18.54 .712 18.08 .812 20.62 .650 16.51
12 7/8-20UNEF .917 23.29 .892 22.66 .999 25.37 .840 21.34
14 15/16-20UNEF .980 24.89 .952 24.18 1.062 26.97 .900 22.86
16 1-1/16-18UNEF 1.105 28.07 1.077 27.36 1.187 30.15 1.025 26.04
18 1-3/16-18UNEF 1.230 31.24 1.202 30.53 1.328 33.73 1.150 29.21
20 1-5/16-18UNEF 1.355 34.42 1.327 33.71 1.453 36.91 1.275 32.39
22 1-7/16-18UNEF 1.480 37.59 1.452 36.88 1.578 40.08 1.400 35.56
24 1-9/16-18UNEF 1.605 40.77 1.577 40.06 1.703 43.26 1.525 38.74
Mil Prefix M83723/ 70 W10
Aero Prefix AE833 70 W10
Specification Sheet (Shell type)
70 = Receptacle adapter, quick-disconnect
Class (Material and Finish)
A= Aluminum shell, black anodized finsih
G= Stainless steel shell, passivated
R= Aluminum shell, elctroless nickel finish
W= Aluminum shell, cadmium olive drab over nickel base
Shell Size
8, 10, 12, 14, 16, 18, 20, 22 or 24
102www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-DTL-83723 Series III
Polarization (Shell Keying, Insert Clocking)
Bayonet and Threaded
Shell Keying Insert Clocking
– –
Notes:
1. In the normal position (N), the insert centerline coin-
cides with the centerline of the master keyway (key) of
the shell. E = 0°.
2. In the alternate keying positions (6, 7, 8, 9 and Y), the
minor keyways (keys) are positioned with reference to
master keyway (key) as indicated in the keying position
table below.
3. In the alternate insert clocking positions (1, 2, 3, 4 and
5), the pin insert (viewing from the mating side) is
rotated counter-clockwise relative to the centerline of the
master keyway (key) of the shell. The socket insert is
rotated clockwise.
* Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and
5 are not available in shell size 8.
** Shell size 28 is not from military standard. It is only availabe in
threaded family to Aero-Electric part number.
† Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new
design.
Note: Alternate positions “Z” and “10” are cancelled and
superseded by Position “Y”.
Shell
Size
Polarizing Key/Keyway Positions Insert Position
Position A° B° C° D° E°
8*, 10
N105 140 215 265 0
6102 132 248 320 0
780 118 230 312 0
835 140 205 275 0
964 155 234 304 0
10 only Y25 115 220 270 0
12 thru 24, 28**
N105 140 215 265 0
618 149 192 259 0
792 152 222 342 0
884 152 204 334 0
924 135 189 240 0
Y98 152 268 338 0
10 thru 24
1† 105 140 215 265 10
2† 105 140 215 265 20
3† 105 140 215 265 30
4† 105 140 215 265 40
5† 105 140 215 265 50
INSERT
VERTICAL
CENTERLINE
PIN INSERT
MATING FACE
(SOCKET INSERT IS OPPOSITE)
ENGAGING FACE VIEW FOR
RECEPTACLE SHELL KEYWAYS
(PLUG SHELL KEYS, OPPOSITE)
MASTER
KEYWAY(KEY)
OF SHELL
E°
C°
B°
D°
A°
MASTER
KEYWAY
103www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-DTL-83723 Series III, Bayonet and Threaded
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
L
[
LL
[
J
S
[
Z
Flange and Jam Nut Mounting Dimensions
Panel Thickness
* Includes screw-head
Receptacle Type Rear Mounting Front Mounting
inch mm inch mm
Wall Mount Receptacle, Bayonet .250 max* 6.36 max* .125 max 3.18 max
Wall Mount Receptacle,Threaded .125 max 3.18 max .125 max 3.18 max
Jam Nut Mount (Bayonet & Threaded) .062/.125 1.57/3.18 ——
Shell
Size
L[J[J[LL S[Z
For Back Mounting For Front Mounting +.000 +.00
(TP) Minimum Minimum -.009 -.23 ±.005 ±.13 ±.005 ±.13
inch mm inch mm inch mm inch mm inch mm inch mm
8.594 15.09 .620 15.75 .510 12.95 .125 3.18 .605 15.37 .635 16.13
10 .719 18.26 .748 19.00 .635 16.13 .125 3.18 .730 18.54 .760 19.30
12 .812 20.62 .918 23.32 .760 19.30 .125 3.18 .917 23.29 .947 24.05
14 .906 23.01 .988 25.10 .885 22.48 .125 3.18 .980 24.89 1.010 25.65
16 .969 24.61 1.114 28.30 1.010 25.65 .125 3.18 1.105 28.07 1.135 28.83
18 1.062 26.97 1.220 30.99 1.072 27.23 .125 3.18 1.229 31.22 1.260 32.00
20 1.156 29.36 1.346 34.19 1.197 30.40 .125 3.18 1.354 34.39 1.385 35.18
22 1.250 31.75 1.470 37.34 1.322 33.58 .125 3.18 1.479 37.57 1.510 38.35
24 1.375 34.93 1.596 40.54 1.442 36.63 .154 3.91 1.604 40.74 1.635 41.53
104www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-DTL-83723
Contacts, Tools and Seal Plugs
Series III
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
– –
Note: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
20 Power/Signal M39029/4-110 M39029/5-115 MS27488-20-1 M81969/14-11
16 Power/Signal M39029/4-111 M39029/5-116 MS27488-16-1 M81969/14-03
12 Power/Signal M39029/4-113 M39029/5-118 MS27488-12-1 M81969/14-04
Contact
Size
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
20 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-205 M81969/8-206
M22520/2-01 M22520/2-02 M22520/2-02
16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-207 M81969/8-208
12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/8-209 M81969/8-210
Contact
Size
Test Current Voltage Crimp Well Data Wire Range Finished Wire [Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWGmm2inch mm inch mm
20 7.5 55 .049 ±.001 .155 3.94 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .250 6.35 20-16 .52-1.31 .053 1.35 .103 2.62
12 23.0 42 .100 ±.002 .250 6.35 14-12 2.08-3.31 .097 2.46 .158 4.01
105www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-DTL-83723 Series III
Contact Installation Instructions
Bayonet and Threaded Coupling
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the contact.
Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into the
insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to
removing insertion tool, do not try to reinsert the
insertion tool. Instead, remove the contact and try
again; otherwise reinserting the insertion tool may
damage the inside of the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place the wire into the
extraction tool of the pin or socket.
3. Slowly slide the extraction tool down wire into the
contact cavities until the tool tip bottoms against the
contact shoulder, expanding the clip retaining tines. Hold
the wire firmly in the tool and pull the wired contact and
tool straight out of the rear of the insulator.
Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool
20 M39029/4-110 M39029/5-115 M22520/1-01 M22520/1-02 Red M22520/1-02 Red M81969/14-11
M22520/2-01 M22520/2-02 M22520/2-02
16 M39029/4-111 M39029/5-116 M22520/1-01 M22520/1-02 Blue M22520/1-02 Blue M81969/14-03
12 M39029/4-113 M39029/5-118 M22520/1-01 M22520/1-02 Yellow M22520/1-02 Yellow M81969/14-04
106www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-DTL-83723 Series III
Insert Availability and Contact Information
per MIL-STD-1554
Insert Availability and Contact Information
– –
* Non MIL-STD-1554 layout, available to Aero-Electric part number only.
D Consult factory for pin insert availablility.
** Alternate clocking positions (1, 2, 3, 4, and 5) are for interchangeability
use only. Inactive for new design per MIL-STD-1554.
Insert
Arrangement
Aero-Electric Total Quantity of Contacts Service Alternate Positions**
Status No. of (by Size) (Insert Rotation in Degrees)
QPL'd Tooled Contacts 20 16 12 # 8coax Rating 1 2 3 4 5
8-2DYes Yes 2 2 I N/A N/A N/A N/A N/A
8-3 Yes Yes 3 3 I N/A N/A N/A N/A N/A
8-98 Yes Yes 3 3 I N/A N/A N/A N/A N/A
10-2 Yes Yes 2 2 I 10 20 30 40 50
10-5 Yes Yes 5 5 I 10 20 30 40 50
10-6 Yes Yes 6 6 I 10 20 30 40 50
10-20 Yes Yes 2 2 I 10 20 30 40 50
12-3 Ye s Yes 3 3 I 10 20 30 40 50
12-12 Yes Ye s 12 12 I10 20 30 40 50
14-4 Ye s Yes 4 4 I 10 20 30 40 50
14-7 Yes Yes 7 7 I 10 20 30 40 50
14-12 Yes Yes 12 9 3 I 10 20 30 40 50
14-15 Yes Yes 15 15 I10 20 30 40 50
16-10 Yes Yes 10 10 I10 20 30 40 50
16-24 Yes Yes 24 24 I10 20 30 40 50
18-8 Ye s Yes 8 8 I 10 20 30 40 50
18-14 Yes Ye s 14 14 I10 20 30 40 50
18-31 Yes Ye s 31 31 I10 20 30 40 50
20-16 Yes Yes 16 16 I10 20 30 40 50
20-25 Yes Yes 25 19 6 I 10 20 30 40 50
20-28 Yes Yes 28 24 4 I 10 20 30 40 50
20-39 Yes Yes 39 37 2 I 10 20 30 40 50
20-41 Yes Yes 41 41 I10 20 30 40 50
22-12 Yes Yes 12 12 I10 20 30 40 50
22-19 Yes Yes 19 19 I10 20 30 40 50
22-32 Yes Yes 32 26 6 I 10 20 30 40 50
22-55 Yes Yes 55 55 I10 20 30 40 50
24-19 Yes Yes 19 19 I10 20 30 40 50
24-29* N/A Yes 29 29 I10 20 30 40 50
24-30* N/A Yes 30 30 I10 20 30 40 50
24-43 Yes Yes 43 23 20 I10 20 30 40 50
24-57 Yes Yes 57 55 2 I 10 20 30 40 50
24-61 Ye s Yes 61 61 I10 20 30 40 50
28-42* N/A Yes 42 42 I10 20 30 40 50
2
1
3
2
1
1
2
1
2
34
5
6
2
1
802*
2#20
I
803
3#20
I
898
3#20
I
1002
2#20
I
1005
5#20
I
1006
6#20
I
1020
2#16
I
1203
3#16
I
1212
12#20
I
1404
4#1
2
I
1407
7#16
I
1412
9#20, 3#16
I
1814
14#16
I
1831
31#20
I
2016
16#16
I
2025
19 # 20,6#12
I
2028
24 # 20, 4 # 12
I
2039
37 # 20, 2 # 16
I
2041
41#20
I
2212
12#12
I
1
31
1
25
1
3
1
5
1
23
1
4
1
7
1808
8#12
I
1
8
1
12
1
12
1415
15#20
I
1
15
1610
10#16
I
1
10
1
14
1
12
1
39
1624
24#20
I
1
24
1
16
1
28
1
41
107www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-STD-1554
Insert Arrangements (Socket Front View)
for MIL-DTL-83723 Series III Connectors
Insert Arrangements Views
– –
*Consult factory for pin insert availability.
108www.conesys.com sales@aero-electric.com
MIL–DTL– 83723 S III
MIL-STD-1554
Insert Arrangements (Socket Front View)
for MIL-DTL-83723 Series III Connectors
Insert Arrangements Views
– –
2219
19#16
I
2419
19#12
I
2232
26#20,6#12
I
2443
23 # 20, 20#16
I
2430D
30#16
I
2429D
29#16
I
2255
55 #20
I
2457
55 # 20, 2 # 12
I
2461
61#20
I
2842D
42#16
I
19
11
32
1
43
29
1130
1
55
1
61
1
57
1
42
1
19
DNon MIL-STD-1554 layout, available to Aero-Electric part number only.
109www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
– –109
MIL-DTL-26500
Features and Application
MS2426*/AE66*
www.conesys.com sales@aero-electric.com
Connector Sealing – A pressure seal at the connector
interface is accomplished through the aid of a coupling
device which compresses the front resilient insulators and
thus offers a seal around each contact preventing the
passage of moisture through the contact cavity. Rear resilient
insulators are designed with a triple wire seal in each cavity
to offer positive sealing and prevent wicking of moisture
through the connector without the use of external clamping
devices or adapters. In addition, a dynamic O’ring seal in
the receptacles engages the front of the plug shell when
connectors are mated and offers yet another barrier to
moisture and contaminants.
Superior Contact Stability - Front release crimp contact
system features a beryllium-copper retaining clip completely
encased in a tough dielectric wafer, thus protecting the clip
tines from damage.
Closed Entry Socket Contacts
Closed-entry socket contacts facilitate positive mating.
Features and Application
MIL-DTL-26500 family offers connectors with bayonet
coupling as well as threaded coupling. These connectors are
intermateable with correspondingly coupled MIL-DTL-83723
Series III connectors (except shell size 8, threaded coupling
only).
AE66 connectors are widely used on commercial, military
and aerospace systems requiring general-purpose, miniature
cylindrical bayonet or threaded coupling connectors.
This family (bayonet as well as threaded) of connectors
is offered in wall mount receptacles, jam nut mounted
receptacles which incorporate O’ring seals, designed for
rear panel “D” hole mounting, and straight plugs.
Twenty-one insert arrangements per MIL-STD-1554 are
tooled and qualified to MIL-DTL-26500, utilizing 3 to 57
M39029 contacts. Contacts come in sizes 20, 16 and 12,
terminating wire sizes from 24 to 12 gauge.
These connectors are only available in aluminum shells
with anodic plating to the MS number. In addition, we offer
connectors with passivated stainless steel shells to commercial
callouts only.
Insert Polarization
Alternate insert positions documented in the original
specification, positions 1 through 5, are still available
(except in shell size 8), but are not approved for new design.
These alternate insert clocking positions aid in mating of
adjacent connectors having identical insert arrangement.
Shell Polarization – Alternate key/keyway positions prevent
cross mating of adjacent connectors having same insert
arrangement.
110www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-DTL-26500
Performance Specifications
MS2426*/AE66*
– –
Performance Specifications
Operating Temperature Range
Class R: -55°C to +200°C (-67°F to +392°F)
Class E*: -55°C to +200°C (-67°F to +392°F)
Material and Finish Data (Class)
R – aluminum shell, black anodized finish
E*– stainless steel shell, passivated
Corrosion Resistance
Classes R and E* withstand 48-hour salt spray.
Environmental Seal
Wired, mated connectors shall meet the altitude-immersion
test specified by MIL-DTL-26500.
Fluid Resistance
Unmated connectors resist specified immersions in
MIL-PRF-5606 (hydraulic fluid), MIL-PRF-23699 (lubricating
oil), MIL-PRF-7808 (lubricating oil), MIL-DTL-5624 (JP-5)
and glycol.
Durability
Bayonet Coupling – 500 cycles
Threaded Coupling – 200 cycles
Voltage Rating
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, coupling
ring shall not loosen, and there shall be no interruption of
electrical continuity longer than one microsecond when
subjected to the following:
Shock
Mated connectors withstand a pulse of approximate
half sine wave of 100 G magnitude with duration of
6 milliseconds applied in each of the three major axes.
Vibration
Mated connectors withstand the following vibration levels:
●Vibration per EIA-364, test procedure 28 conducted at a
low temperature ambient of -55°C (-67°F) and high
ambient of +200°C (392°F).
Shell-to-Shell Conductivity
●Class R is non-conductive.
●Maximum potential drop shall not exceed 200 millivolts
for class E*.
* Class E only available to commercial callouts. Consult factory for
drawings. Pages 112 thru 117 apply to class R only.
** To be used by designer only as a guide.
Service
Rating
Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
I600 850 1500 450 275 200
111www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-DTL-26500
Part Number Development
Bayonet & Threaded Coupling
– –
Part Number Development
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: Two spare contacts
for each size contact utilized and at least 15% of the number
of contacts but no less than three sealing plugs are provided.
No insertion/removal tools are provided. No spares are
required for shielded contacts.
Note 2: Proper part number marking has no “0” in front of
single digit shell size (8), and no “0” in front of single digit
layouts. Example: MS24264R8B3SN and MS24264R18B8P6.
Please note that in this series “N” for normal is included in
part number marking.
Mil. Prefix MS 24266 R12 T12 P N
Aero Prefix AE 666 R12 T12 P N -340
Shell type
24264 = Wall mount receptacle = 664 (Aero p/n)
24265 = Jam nut receptacle = 665 (Aero p/n)
24266 = Straight plug = 666 (Aero p/n)
Class (Material and Finish)
R= Aluminum shell, black anodized finish
E* = Stainless steel shell, passivated
Shell Size (SS)
8, 10, 12, 14, 16, 18, 20, 22 or 24
Coupling Mechanism
B= Bayonet Coupling
T= Threaded Coupling
Insert Arrangement
See pages 122, 123
Contact Style
P= Pin
S= Socket
Polarization (Keying)
N= Normal
6, 7, 8, 9 or Y(Alternate keyed positions,Y is not availabe in SS 8)
1, 2, 3, 4 or 5(Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in SS 8)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
341 = Connector kitted with MS27291-XX straight clamp
Consult factory for other modifications
*Class E only available to commercial callouts. Consult factory for
drawings. Pages 112 thru 117 apply to class R only.
1.421(36.09)
MAX
4x
[
C
MOUNTING
HOLES
3 ORANGE COLOR STRIPES
EQUALLY SPACED
PANEL THICKNESS:
.125(3.18)MAX
[
D
KEYWAY
MASTER
B
.728(18.49)
.708(17.98)
A
E
ACCESSORY THREAD
[
F
MAX
GROMMET
.072(1.83)
.052(1.32)
.306(7.77) MIN FULL THREAD
4 MINORKEYWAYS
112www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MS24264R**B
Wall Mounting Receptacle
AE664R**B
Bayonet Coupling, Crimp Removable, Front Release
– –
Page 111 Completed Part Number
Page 120 Contacts,Sealing Plugs and Tools
Page 123 Insert Arrangements
Page 110 Performance Specifications
Page 122 Insert Availability and Contact Information
Page 118 Polarization
Shell
Size
A B [C[D E [F
+.000 +.00 +.000 +.00 Accessory Thread
±.005 ±.13 (TP) -.009 -.23 -.005 -.13 Class 2A Maximum
inch mm inch mm inch mm inch mm inch mm
8.812 20.62 .594 15.09 .125 3.18 .536 13.61 7/16-28UNEF .328 8.33
10 .937 23.80 .719 18.26 .125 3.18 .659 16.74 9/16-24UNEF .420 10.67
12 1.031 26.19 .812 20.62 .125 3.18 .829 21.06 3/4-20UNEF .580 14.73
14 1.125 28.58 .906 23.01 .125 3.18 .898 22.81 13/16-20UNEF .664 16.87
16 1.250 31.75 .969 24.61 .125 3.18 1.025 26.04 15/16-20UNEF .769 19.53
18 1.343 34.11 1.062 26.97 .125 3.18 1.131 28.73 1-1/16-18UNEF .902 22.91
20 1.437 36.50 1.156 29.36 .125 3.18 1.256 31.90 1-3/16-18UNEF 1.033 26.24
22 1.562 39.67 1.250 31.75 .125 3.18 1.381 35.08 1-5/16-18UNEF 1.152 29.26
24 1.703 43.26 1.375 34.93 .154 3.91 1.506 38.25 1-7/16-18UNEF 1.282 32.56
MOUNTING
FLAT
3 ORANGE COLOR STRIPES
EQUALLY SPACED
E
ACCESSORY THREAD
JAM-NUT THREAD
G
HEX NUT WITH
3 TEFLON PLUGS
EQUALLY SPACED
"O" RING
PANEL THICKNESS:
.125(3.18) MAX
[
F
MAX
GROMMET
[
D
.781(19.84)
.761(19.33)
1.421(36.09)
MAX
.306(7.77)
MIN FULL THREAD
[
A
MAX
B
C
MASTER
KEYWAY
113www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MS24265R**B
Jam Nut Receptacle
AE665R**B
Bayonet Coupling, Crimp Removable, Front Release
– –
Page 111 Completed Part Number
Page 120 Contacts,Sealing Plugs and Tools
Page 123 Insert Arrangements
Page 110 Performance Specifications
Page 122 Insert Availability and Contact Information
Page 118 Polarization
Shell
Size
[A B C [D E [F G
+.000 +.00 Accessory Thread Jam Nut Thread
Maximum ±.005 ±.13 ±.003 ±.08 -.005 -.13 Class 2A Maximum Class 2A
inch mm inch mm inch mm inch mm inch mm
81.068 27.13 .979 24.87 .593 15.06 .536 13.61 7/16-28UNEF .328 8.33 5/8-20UN
10 1.192 30.28 1.104 28.04 .718 18.24 .659 16.74 9/16-24UNEF .420 10.67 3/4-20UNEF
12 1.380 35.05 1.291 32.79 .905 22.99 .829 21.06 3/4-20UNEF .580 14.73 15/16-20UNEF
14 1.505 38.23 1.391 35.33 .968 24.59 .898 22.81 13/16-20UNEF .664 16.87 1-20UNEF
16 1.630 41.40 1.516 38.51 1.093 27.76 1.025 26.04 15/16-20UNEF .769 19.53 1-1/8-20UN
18 1.740 44.20 1.641 41.68 1.217 30.91 1.131 28.73 1-1/16-18UNEF .902 22.91 1-1/4-20UN
20 1.860 47.24 1.766 44.86 1.342 34.09 1.256 31.90 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF
22 2.040 51.82 1.954 49.63 1.467 37.26 1.381 35.08 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN
24 2.160 54.86 2.079 52.81 1.592 40.44 1.506 38.25 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF
114www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MS24266R**B
Straight Plug
AE666R**B
Bayonet Coupling, Crimp Removable, Front Release
– –
Page 111 Completed Part Number
Page 120 Contacts,Sealing Plugs and Tools
Page 123 Insert Arrangements
Page 110 Performance Specifications
Page 122 Insert Availability and Contact Information
Page 118 Polarization
D
ACCESSORY THREAD
3 ORANGE STRIPES
EQUALLY SPACED
.306(7.77)
MIN FULL THREAD
[
B
[
C
MAX
GROMMET
[
A
MAX COUPLING NUT 1.375(34.93)
MAX
4 MINOR KEYS
MASTER KEY
Shell
Size
[A[B[C D
+.000 +.00 Accessory Thread
Maximum -.005 -.13 Maximum Class 2A
inch mm inch mm inch mm
8.776 19.71 .424 10.77 .328 8.33 7/16-28UNEF
10 .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF
12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF
14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF
16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF
18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF
20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF
22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF
24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF
FULL MATE
INDICATOR
COLOR: ORANGE
4x
[
C
MOUNTING
HOLES
D
MATING THREAD
E
ACCESSORY THREAD
MASTER
KEYWAY
[
F
MAX
GROMMET
A
B
1.421(36.09)
MAX
.728(18.49)
.708(17.98)
.306(7.77) MIN FULL THREAD
.072(1.83)
.052(1.32)
4 MINOR KEYWAYS
PANEL THICKNESS:
.125(3.18) MAX
115www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MS24264R**T
Wall Mounting Receptacle
AE664R**T
Threaded Coupling, Crimp Removable, Front Release
– –
Page 111 Completed Part Number
Page 120 Contacts,Sealing Plugs and Tools
Page 123 Insert Arrangements
Page 110 Performance Specifications
Page 122 Insert Availability and Contact Information
Page 118 Polarization
Shell
Size
A B [C D E [F
+.000 +.00 Mating Thread Accessory Thread
±.005 ±.13 (TP) -.009 -.23 Class 2A Class 2A Maximum
inch mm inch mm inch mm inch mm
8.812 20.62 .594 15.09 .125 3.18 9/16-24UNEF 7/16-28UNEF .328 8.33
10 .937 23.80 .719 18.26 .125 3.18 11/16-24UNEF 9/16-24UNEF .420 10.67
12 1.031 26.19 .812 20.62 .125 3.18 7/8-20UNEF 3/4-20UNEF .580 14.73
14 1.125 28.58 .906 23.01 .125 3.18 15/16-20UNEF 13/16-20UNEF .664 16.87
16 1.250 31.75 .969 24.61 .125 3.18 1-1/16-18UNEF 15/16-20UNEF .769 19.53
18 1.343 34.11 1.062 26.97 .125 3.18 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91
20 1.437 36.50 1.156 29.36 .125 3.18 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24
22 1.562 39.67 1.250 31.75 .125 3.18 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26
24 1.703 43.26 1.375 34.93 .154 3.91 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56
E
ACCESSORY THREAD
D
MATING THREAD
FULL MATE
INDICATOR
COLOR: ORANGE
HEX NUT WITH
3 TEFLON PLUGS
EQUALLY SPACED
"O" RING
[
F
MAX
GROMMET
G
JAM-NUT THREAD
[
A
MAX
B
C
MOUNTING
FLAT
.306(7.77)
MIN FULL THREAD
1.421(36.09)
MAX
.781(19.84)
.761(19.33)
PANEL THICKNESS:
.125(3.18) MAX
MASTER
KEYWAY
116www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MS24265R**T
Jam Nut Receptacle
AE665R**T
Threaded Coupling, Crimp Removable, Front Release
– –
Page 111 Completed Part Number
Page 120 Contacts,Sealing Plugs and Tools
Page 123 Insert Arrangements
Page 110 Performance Specifications
Page 122 Insert Availability and Contact Information
Page 118 Polarization
Shell
Size
[AB C D E [FG
Mating Thread Accessory Thread Jam Nut Thread
Maximum ±.005 ±.13 ±.003 ±.08 Class 2A Class 2A Maximum Class 2A
inch mm inch mm inch mm inch mm
81.068 27.13 .979 24.87 .593 15.06 9/16-24UNEF 7/16-28UNEF .328 8.33 5/8-20UN
10 1.192 30.28 1.104 28.04 .718 18.24 11/16-24UNEF 9/16-24UNEF .420 10.67 3/4-20UNEF
12 1.380 35.05 1.291 32.79 .905 22.99 7/8-20UNEF 3/4-20UNEF .580 14.73 15/16-20UNEF
14 1.505 38.23 1.391 35.33 .968 24.59 15/16-20UNEF 13/16-20UNEF .664 16.87 1-20UNEF
16 1.630 41.40 1.516 38.51 1.093 27.76 1-1/16-18UNEF 15/16-20UNEF .769 19.53 1-1/8-20UN
18 1.740 44.20 1.641 41.68 1.217 30.91 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91 1-1/4-20UN
20 1.860 47.24 1.766 44.86 1.342 34.09 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF
22 2.040 51.82 1.954 49.63 1.467 37.26 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN
24 2.160 54.86 2.079 52.81 1.592 40.44 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF
117www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MS24266R**T
Straight Plug
AE666R**T
Threaded Coupling, Crimp Removable, Front Release
– –
Page 111 Completed Part Number
Page 120 Contacts,Sealing Plugs and Tools
Page 123 Insert Arrangements
Page 110 Performance Specifications
Page 122 Insert Availability and Contact Information
Page 118 Polarization
1.375(34.93)
MAX
[
A
MAX COUPLING NUT
[
B
D ACCESSORY THREAD
[
C
MAX
GROMMET
.306(7.77)
MIN FULL THREAD
E MATING THREAD
4 MINOR KEYS
MASTER KEY
Shell
Size
[A[B[C D E
+.000 +.00 Accessory Thread Mating Thread
Maximum -.005 -.13 Maximum Class 2A Class 2B
inch mm inch mm inch mm
8.776 19.71 .424 10.77 .328 8.33 7/16-28UNEF 9/16-24UNEF
10 .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF 11/16-24UNEF
12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF 7/8-20UNEF
14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF 15/16-20UNEF
16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF 1-1/16-18UNEF
18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF 1-3/16-18UNEF
20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF 1-5/16-18UNEF
22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF 1-7/16-18UNEF
24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF 1-9/16-18UNEF
118www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-DTL-26500
Polarization (Shell Keying, Insert Clocking)
Bayonet and Threaded
Shell Keying Insert Clocking
– –
Notes:
1. In the normal position (N), the insert centerline
coincides with the centerline of the master keyway (key)
of the shell: E = 0°.
2. In the alternate keying positions (6, 7, 8, 9 and Y), the
minor keyways (keys) are positioned with reference to
master key/keyway as indicated in the keying position
table below.
3. In the alternate insert clocking positions (1, 2, 3, 4 and
5), the pin insert (viewing from the mating side) is
rotated counter-clockwise relative to the centerline of the
master keyway (key) of the shell. The socket insert is
rotated clockwise.
*Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5
are not available in shell size 8.
** Alterate positions “Z” and “10”are cancelled and superseded by Position “Y”.
†Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design.
Shell
Size
Polarizing Key/Keyway Positions Insert Position
Position A° B° C° D° E°
8*, 10
N105 140 215 265 0
6102 132 248 320 0
780 118 230 312 0
835 140 205 275 0
964 155 234 304 0
10 only Y** 25 115 220 270 0
12 thru 24
N105 140 215 265 0
618 149 192 259 0
792 152 222 342 0
884 152 204 334 0
924 135 189 240 0
Y** 98 152 268 338 0
10 thru 24
1† 105 140 215 265 10
2† 105 140 215 265 20
3† 105 140 215 265 30
4† 105 140 215 265 40
5† 105 140 215 265 50
INSERT
VERTICAL
CENTERLINE
PIN INSERT
MATING FACE
(SOCKET INSERT IS OPPOSITE)
ENGAGING FACE VIEW FOR
RECEPTACLE SHELL KEYWAYS
(PLUG SHELL KEYS, OPPOSITE)
MASTER
KEYWAY(KEY)
OF SHELL
E°
C°
B°
D°
A°
MASTER
KEYWAY
119www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-DTL-26500 Bayonet and Threaded
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
– –
Note: Maximum panel thickness of .125 inch (3.18 mm).
Flange and Jam Nut Mounting Dimensions
L
S
[
LL
[
J
[
Z
Shell
Size
L[J[J[LL S[Z
For Back Mounting For Front Mounting +.000 +.00
(TP) Minimum Minimum -.009 -.23 ±.005 ±.13 ±.005 ±.13
inch mm inch mm inch mm inch mm inch mm inch mm
8.594 15.09 .620 15.75 .447 11.35 .125 3.18 .605 15.37 .635 16.13
10 .719 18.26 .748 19.00 .572 14.53 .125 3.18 .730 18.54 .760 19.30
12 .812 20.62 .913 23.19 .760 19.30 .125 3.18 .917 23.29 .947 24.05
14 .906 23.01 .980 24.89 .822 20.88 .125 3.18 .980 24.89 1.010 25.65
16 .969 24.61 1.107 28.12 .948 24.08 .125 3.18 1.105 28.07 1.135 28.83
18 1.062 26.97 1.209 30.71 1.072 27.23 .125 3.18 1.225 31.12 1.260 32.00
20 1.156 29.36 1.337 33.96 1.192 30.28 .125 3.18 1.350 34.29 1.385 35.18
22 1.250 31.75 1.452 36.88 1.322 33.58 .125 3.18 1.475 37.47 1.510 38.35
24 1.375 34.93 1.577 40.06 1.442 36.63 .154 3.91 1.600 40.64 1.635 41.53
120www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-DTL-26500
Contacts, Tools and Seal Plugs
MS2426*/AE66*
– –
Note 1: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
Note 2: No plastic Insertion/Removal tools are supplied as part
of contact packages when ordering 26500 connectors. Metal
insertion and extraction tools must be ordered separately.
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
20 Power/Signal M39029/31-241 M39029/32-260 MS27488-20-1 N/A
16 Power/Signal M39029/31-229 M39029/32-248 MS27488-16-1 N/A
12 Power/Signal M39029/31-235 M39029/32-254 MS27488-12-1 N/A
8 Coax Coax M39029/54-343 M39029/55-345 MS27488-8-1 N/A
Contact
Size/Type
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
20 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-03 M81969/19-07
M22520/2-01 M22520/2-02 M22520/2-02
16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-04 M81969/19-08
12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-05 M81969/19-09
8 Coax Inner M22520/2-01 M22520/2-24 M22520/2-24 M81969/17-06 M81969/19-03
8 Coax Outer M22520/5-01 M22520/5-10 M22520/5-10
Contact
Size
Test Current Potential Crimp Well Data Wire Range Finished Wire [Range
DC Test Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWGmm2inch mm inch mm
20 7.5 55 .049 ±.001 .267 6.78 24-20 .20-.52 .040 1.02 .090 2.29
16 13.0 49 .067 ±.001 .236 5.99 20-16 .52-1.31 .068 1.73 .130 3.30
12 23.0 42 .100 ±.002 .236 5.99 14-12 2.08-3.31 .106 2.69 .170 4.32
121www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-DTL-26500
Contact Installation Instructions
MS2426*/AE66*
– –
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end first, into the tool.
5. Insert the stripped wire into the hollow end of the
contact. Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly after all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive film. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
firmly.
4. Beginning with a center cavity, insert the contact into the
insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1If contacts are not inserted all the way prior to removing
insertion tool, do not try to reinsert the insertion tool.
Instead, remove the contact and try again; otherwise
reinserting the insertion tool may damage the inside of
the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
After all the cavities have been filled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place tool over the contact
on mating side and insert into the cavity.
3. Exert nominal force axially to release retention clip.
Spacer sleeve will shoulder at face of insulation when
tool is inserted to proper depth.
4. Push extraction plunger to force the contact out of the
rear of the insert.
5. Grasp contact or wire and pull the wired contact out of
the rear of the insulator.
6. Remove extraction tool axially.
7. After using the extraction tool, the spacer sleeve should
be set forward in the last notch to protect the end of the
plunger guide.
Size Pin Contact Socket Contact Basic Crimp Tool Positioner Insertion Tool Removal Tool
20 M39029/31-241 M39029/32-260 M22520/1-01 M22520/1-02 Red M81969/17-03 M81969/19-07
M22520/2-01 M22520/2-02
16 M39029/31-229 M39029/32-248 M22520/1-01 M22520/1-02 Blue M81969/17-04 M81969/19-08
12 M39029/31-235 M39029/32-254 M22520/1-01 M22520/1-02 Yellow M81969/17-05 M81969/19-09
MIL-DTL-26500 Bayonet and Threaded
Insert Availability and Contact Information
per MIL-STD-1554
Insert Availability and Contact Information
– – sales@aero-electric.comwww.conesys.com 122
MIL–DTL– 26500
Insert
Arrangement
Aero-Electric Total Quantity of Contacts Service Alternate Positions
Status No. of (by Size) (Insert Rotation in Degrees)
QPL’d Tooled Contacts 20 16 12 # 8 Coax Rating 1* 2* 3* 4* 5*
8-3 Yes Yes 3 3 I N/A N/A N/A N/A N/A
10-5 Ye s Yes 5 5 I 10 20 30 40 50
12-3 Ye s Yes 3 3 I 10 20 30 40 50
12-12 Yes Yes 12 12 I10 20 30 40 50
14-7 Yes Yes 7 7 I 10 20 30 40 50
14-12 Yes Ye s 12 9 3 I 10 20 30 40 50
14-15 Yes Yes 15 15 I10 20 30 40 50
16-10 Yes Yes 10 10 I10 20 30 40 50
16-24 Yes Yes 24 24 I10 20 30 40 50
18-8 Yes Yes 8 8 I 10 20 30 40 50
18-11 Yes Yes 11 10 1 I 10 20 30 40 50
18-14 Yes Yes 14 14 I10 20 30 40 50
18-31 Yes Yes 31 31 I10 20 30 40 50
20-16 Yes Yes 16 16 I10 20 30 40 50
20-25 Yes Yes 25 19 6 I 10 20 30 40 50
20-39 Yes Yes 39 37 2 I 10 20 30 40 50
20-41 Yes Yes 41 41 I10 20 30 40 50
22-19 Yes Yes 19 19 I10 20 30 40 50
22-55 Yes Yes 55 55 I10 20 30 40 50
24-30** N/A Yes 30 30 I10 20 30 40 50
24-43 Yes Yes 43 23 20 I10 20 30 40 50
24-57 Yes Yes 57 55 2 I 10 20 30 40 50
* Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Non MIL-STD-1554 layout, available to Aero-Electric part number only.
8-3
3#20
I
1
3
10-5
5#20
I
1
5
12-3
3#16
I
1
23
14-7
7#16
I
1
7
18-8
8#12
I
1
8
12-12
12#20
I
1
12
14-12
9#20,3#16
I
1
12
14-15
15#20
I
1
15
16-10
10#16
I
1
10
18-14
14#16
I
1
14
18-31
31#20
I
1
31
20-39
37 # 20, 2#16
I
1
39
16-24
24#20
I
1
24
20-16
16#16
I
1
16
20-25
19 # 20, 6#12
I
1
25
20-41
41#20
I
1
41
18-11
10 # 16, 1 # 8 Coax.
I
1
11
22-19
19#16
I
19
1
22-55
55#20
I
1
55
24-43
23 # 20, 20#16
I
1
43
24-57
55 # 20, 2#12
I
1
57
130
24-30D
30#16
I
123www.conesys.com sales@aero-electric.com
MIL–DTL– 26500
MIL-STD-1554
Insert Arrangements (Socket Front View)
for MIL-DTL-26500 Connectors
– –
Insert Arrangements Views
DNon MIL-STD-1554 layout, available to Aero-Electric part number only.
124www.conesys.com sales@aero-electric.com
Part Number Cross Reference
Part Number Cross Reference, Status and Availability
– –
* Active – recommended for new design; Inactive – not recommended for
new design; Canceled – must use superseding part.
** Equivalent part from newer Series/Spec is intermateable and intermount-
able; some differences in accessory threads and contact release may exist.
Note: Aero-Electric manufactures MIL-DTL- 26482 Series 2,
MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500,
MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and
III. Only part numbers covered by these specifications are listed.
Military Available Description Contact Military Status* Superseding Available
Part from Shell Type Style Specification & Series of Equivalent** from
Number Aero (MIL-DTL-) Document MS Number Aero
D38999/20 Ye s Wall Mount Receptacle P & S 38999 Series III Active — —
D38999/21 No Box Mount Receptacle, Hermetic C,P,X 38999 Series III Active — —
D38999/22 No Dummy Receptacle — 38999 Series III Active — —
D38999/23 No Jam Nut Receptacle, Hermetic C,P,X 38999 Series III Active — —
D38999/24 Ye s Jam Nut Receptacle P & S 38999 Series III Active — —
D38999/25 No Solder Mount Receptacle, Hermetic C,P,X 38999 Series III Active — —
D38999/26 Ye s RFI Grounding Plug P & S 38999 Series III Active — —
D38999/27 No Weld Mount Receptacle, Hermetic C,P,X 38999 Series III Active — —
D38999/28 No Hex Mounting Nut (Jam Nut) — 38999 Series III, IV Active — —
D38999/29 No Lanyard Release Plug, Pin Contact P 38999 Series III Active — —
D38999/30 No Lanyard Release Plug, Socket Contact S 38999 Series III Active — —
D38999/31 No Lanyard Release Plug, SS 25, Pin P 38999 Series III Active — —
D38999/32 No Metal Protective Cover, Plug — 38999 Series III Active — —
D38999/33 No Metal Protective Cover, Receptacle — 38999 Series III Active — —
M38999/1 No Grommet Nut (E-Nut) — 38999 Series I, II Canceled, Superseded by M85049/27 No
M38999/2 No Boot Adapter — 38999 Series I, II Canceled, Superseded by M85049/62 No
M38999/3 No EMI/RFI Crimp Ring Adapter — 38999 Series I, II Canceled, Superseded by M85049/33-2 No
M38999/4 No Individual Shield Termination Backshell — 38999 Series I, II Canceled, Superseded by M85049/30 No
M38999/5 No Straight Backshell, EMI, Environmental — 38999 Series I, II Canceled, Superseded byM85049/17 No
M38999/6 No Straight Backshell, Non Environmental — 38999 Series I, II Canceled, Superseded by M85049/29 No
M38999/7 No Straight Backshell, EMI/RFI — 38999 Series I, II Canceled, Superseded by M85049/36 No
M38999/8 No 90º Split Backshell, EMI/RFI —38999 Series I, II Canceled, Superseded by M85049/37 No
M38999/9 No Dummy Receptacle — 38999 Series I Active — —
M38999/10 No Dummy Receptacle — 38999 Series II Active — —
M83723/1 No Narrow Flange Mount Receptacle S 83723 Series I Canceled, Superseded by MS3470 Ye s
M83723/2 No Narrow Flange Mount Receptacle P 83723 Series I Canceled, Superseded by MS3470 Yes
M83723/3 NoWide Flange Mount Receptacle S83723 Series I Canceled,Superseded by MS3472 Y
es
M83723/4 No Wide Flange Mount Receptacle P 83723 Series I Canceled, Superseded by MS3472 Ye s
M83723/5 No Jam Nut Receptacle S 83723 Series I Canceled, Superseded by MS3474 Ye s
M83723/6 NoJam Nut Receptacle P83723 Series I Canceled, Superseded by MS3474 Y
es
M83723/7 No Cable Connecting Receptacle S 83723 Series I Canceled, Superseded by MS3471 Ye s
M83723/8 NoCable Connecting Receptacle P83723 Series I Canceled, Superseded by MS3471 Y
es
M83723/9 No Narrow Flange Mt. Recept., Hermetic P 83723 Series I Canceled, Superseded by MS3440 No
M83723/10 No Wide Flange Mt. Recept., Hermetic P 83723 Series I Canceled, Superseded by MS3442 No
M83723/11 NoSolder Mount Receptacle, Hermetic P83723 Series I Canceled,Superseded by MS3443 No
M83723/12 No Jam Nut Receptacle, Hermetic P 83723 Series I Canceled, Superseded by MS3449 No
M83723/13 No Straight Plug S 83723 Series I Canceled, Superseded by MS3476 Ye s
M83723/14 No Straight Plug P 83723 Series I Canceled, Superseded by MS3476 Ye s
M83723/15A No 90º Strain Relief — 83723 Series I, III Canceled, Superseded by M85049/51 No
M83723/15N No Grommet Nut (E-Nut) — 83723 Series I, III Canceled, Superseded by M85049/31 No
M83723/15S NoStraight Strain Relief —83723 Series I, III Canceled, Superseded by M85049/52 No
M83723/16A No 90º Heat Shrink Boot — 83723 Series I Active — —
M83723/16M No Boot Adapter — 83723 Series I Active M85049/60-2 No
M83723/16S NoStraight Heat Shrink Boot —83723 Series I Active— —
125www.conesys.com sales@aero-electric.com
Part Number Cross Reference
Part Number Cross Reference, Status and Availability
– –
* Active – recommended for new design; Inactive – not recommended for
new design; Canceled – must use superseding part.
** Equivalent part from newer Series/Spec is intermateable and intermount-
able; some differences in accessory threads and contact release may exist.
Note: Aero-Electric manufactures MIL-DTL- 26482 Series 2,
MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500,
MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and
III. Only part numbers covered by these specifications are listed.
Military Available Description Contact Military Status* Superseding Available
Part from Shell Type Style Specification &
Series of Equivalent** from
Number Aero (MIL-DTL-) Document MS Number Aero
M83723/17 No Cable Connecting Receptacle S 83723 Series II Inactive, Use MS3451 Ye s
M83723/18 No Cable Connecting Receptacle P 83723 Series II Inactive, Use MS3451 Ye s
M83723/19 No Wall Mount Receptacle S 83723 Series II Inactive, Use MS3450 Ye s
M83723/20 No Wall Mount Receptacle P 83723 Series II Inactive, Use MS3450 Ye s
M83723/21 No Box Mount Receptacle S 83723 Series II Inactive, Use MS3452 Ye s
M83723/22 No Box Mount Receptacle P 83723 Series II Inactive, Use MS3452 Ye s
M83723/23 No Straight Plug S 83723 Series II Inactive, Use MS3456 Ye s
M83723/24 No Straight Plug P 83723 Series II Inactive, Use MS3456 Ye s
M83723/25 No Wall Mount Receptacle, Hermetic P 83723 Series II Canceled, Superseded by MS3142 No
M83723/26 No Solder Mount Receptacle, Hermetic P 83723 Series II Canceled, Superseded by MS3143 No
M83723/27A No 90º Heat Shrink Boot — 83723 Series II Inactive — —
M83723/27M No Boot Adapter — 83723 Series II Inactive — —
M83723/27S No Straight Heat Shrink Boot — 83723 Series II Inactive — —
M83723/28 No Seal Plugs — 83723 Series I, III Canceled, Superseded by MS27488 Ye s
M83723/29 No Pin Contacts (0 thru 16) P 83723 Series II Canceled, Superseded by M39029/29 Ye s
M83723/30 No Socket Contacts (0 thru 16) S 83723 Series II Canceled, Superseded by M39029/30 Ye s
M83723/31 No Insertion/Extraction Tools (20, 16, 12) — 83723 Series I, III Canceled, Superseded byM81969/14 Yes
M83723/32 No Insertion/Extraction Tools (0, 4, 8) —83723 Series II Canceled, Superseded byM81969/14 Yes
M83723/33 No Pin Contacts (20, 16, 12) P 83723 Series I, III Canceled, Superseded by M39029/4 Ye s
M83723/34 No Socket Contacts (20, 16, 12) S 83723 Series I, III Canceled, Superseded by M39029/5 Yes
M83723/35A No 90º Backshell with Cable Clamp —83723 Series II Inactive — —
M83723/35N No Grommet Nut (E-Nut) —83723 Series II Inactive — —
M83723/35S No Straight Backshell with Cable Clamp —83723 Series II Inactive — —
M83723/36 No Pre-wired Plug for 8-2, 8-3, 8-4 Layouts only P 83723 Series I Canceled — —
M83723/37 Ye s Pre-wired Plug for 8-2, 8-3, 8-4 Layouts only S 83723 Series I Inactive — —
M83723/38 No Pre-wired Narrow Flange Receptacle for
8-2, 8-3, 8-4 Layouts only P 83723 Series I Canceled — —
M83723/39 No Pre-wired Narrow Flange Receptacle for
8-2, 8-3, 8-4 Layouts S 83723 Series I Canceled — —
M83723/40 No Pre-wired Wide Flange Receptacle
for 8-2, 8-3, 8-4 Layouts P 83723 Series I Canceled — —
M83723/41 No Pre-wired Wide Flange Receptacle
for 8-2, 8-3, 8-4 Layouts S 83723 Series I Canceled — —
M83723/42 No RFI Grounding Plug P 83723 Series I Canceled, Superseded by MS3475 Ye s
M83723/43 No RFI Grounding Plug S 83723 Series I Canceled, Superseded by MS3475 Ye s
M83723/44 No Metal Protective Cover, Receptacle — 83723 Series I Canceled, Superseded by MS3181 No
M83723/45 No Dummy Receptacle — 83723 Series I Canceled, Superseded by MS3115 No
M83723/46 No Metal Protective Cover, Plug — 83723 Series I Canceled, Superseded by MS3180 No
M83723/47 No Shield Termination l, RFI Grounding — 83723 Series I Canceled, M85049/26 No
M83723/48 No Pre-wired RFI Plug for 8-2, 8-3, 8-4 Layouts only P 83723 Series I Canceled — —
M83723/49 No Pre-wired RFI Plug for 8-2, 8-3, 8-4 Layouts only S 83723 Series I Canceled — —
126www.conesys.com sales@aero-electric.com
Part Number Cross Reference
Part Number Cross Reference, Status and Availability
– –
* Active – recommended for new design; Inactive – not recommended
for new design; Canceled – must use superseding part.
Note 1: M83723/59, 60, 61 metal plug and receptacle covers
and dummy receptacle can be used on MIL-DTL-26500
connectors.
** Equivalent part from newer Series/Spec is intermateable and intermount-
able; some differences in accessory threads and contact release may exist.
Note 2: Aero-Electric manufactures MIL-DTL- 26482 Series 2,
MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500,
MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and
III. Only part numbers covered by these specifications are listed.
Military Available Description Contact Military Status* Superseding Available
Part from Shell Type Style Specification & Series of Equivalent** from
Number Aero (MIL-DTL-) Document MS Number Aero
M83723/50A No 90º Cable Tie Strain Relief — 83723 Series II Inactive — —
M83723/50B No 45º Cable Tie Strain Relief — 83723 Series II Inactive — —
M83723/50R No Straight Cable Tie Strain Relief — 83723 Series II Inactive — —
M83723/51A No Environmental 90º Backshell — 83723 Series II Canceled — —
M83723/51B No Environmental 45º Backshell — 83723 Series II Canceled — —
M83723/51R No Environmental Straight Backshell — 83723 Series II Canceled — —
M83723/52 No Self Locking Plug, Firewall P 83723 Series II Canceled, Superseded by MS3459 Ye s
M83723/53 No Self Locking Plug, Firewall S 83723 Series II Canceled, Superseded by MS3459 Ye s
M83723/59 No Metal Protective Cover, Plug — 83723 SIII, Bay & Thr Active — —
M83723/60 No Metal Protective Cover, Receptacle — 83723 SIII, Bay & Thr Active — —
M83723/61 No Dummy Receptacle — 83723 SIII, Bay & Thr Active — —
M83723/65 No Jam Nut Receptacle, Hermetic P 83723 Series III, Bay Active — —
M83723/66 No Quick-Disconnect Plug, Less Lanyard P 83723 Series III, Thr Active — —
M83723/67 No Quick-Disconnect Plug, Less Lanyard S 83723 Series III, Thr Active — —
M83723/68 Ye s Quick-Disconnect Plug, With Lanyard P 83723 Series III, Thr Active — —
M83723/69 Ye s Quick-Disconnect Plug, With Lanyard S 83723 Series III, Thr Active — —
M83723/70 Ye s Recept. Adapter for Quick-Dis. Plugs — 83723 Series III, Thr Active — —
M83723/71 Ye s Wall Mount Receptacle S 83723 Series III, Bay Active — —
M83723/72 Ye s Wall Mount Receptacle P 83723 Series III, Bay Active — —
M83723/73 Ye s Jam Nut Receptacle S 83723 Series III, Bay Active — —
M83723/74 Yes Jam Nut Receptacle P 83723 Series III, Bay Active — —
M83723/75 Yes Straight Plug S 83723 Series III, Bay Active — —
M83723/76 Yes Straight Plug P 83723 Series III, Bay Active — —
M83723/77 Yes RFI Grounding Plug S83723 Series III, Bay Active — —
M83723/78 Yes RFI Grounding Plug P83723 Series III, Bay Active — —
M83723/79 No Wall Mount Receptacle, Hermetic P 83723 Series III, Bay Active — —
M83723/80 No Solder Mount Receptacle, Hermetic P 83723 Series III, Bay Active — —
M83723/81 No Jam Nut Receptacle, Hermetic P 83723 Series III, Bay Active — —
M83723/82 Ye s Wall Mount Receptacle S 83723 Series III, Thr Active — —
M83723/83 Ye s Wall Mount Receptacle P 83723 Series III, Thr Active — —
M83723/84 Y
es Jam Nut Receptacle S83723 Series III,Thr Active — —
M83723/85 Y
es Jam Nut Receptacle P83723 Series III, Thr Active — —
M83723/86 Y
es Straight Plug S83723 Series III, Thr Active — —
M83723/87 Ye s Straight Plug P 83723 Series III, Thr Active — —
M83723/88 No Wall Mount Receptacle, Hermetic P 83723 Series III, Thr Active — —
M83723/89 No Jam Nut Receptacle, Hermetic P 83723 Series III, Thr Active — —
M83723/90 No Solder Mount Receptacle, Hermetic P 83723 Series III, Thr Active — —
M83723/91 Ye s RFI Grounding Plug S 83723 Series III, Thr Active — —
M83723/92 Ye s RFI Grounding Plug P 83723 Series III, Thr Active — —
M83723/93 No Solder Mount Receptacle, Hermetic P 83723 Series III, Bay Active — —
M83723/94 No Jam Nut Receptacle, Hermetic P 83723 Series III, Bay Active — —
M83723/95 Ye s Self Locking Plug S 83723 Series III, Thr Active — —
M83723/96 Ye s Self Locking Plug P 83723 Series III, Thr Active — —
127www.conesys.com sales@aero-electric.com
Part Number Cross Reference
Part Number Cross Reference, Status and Availability
– –
* Active – recommended for new design; Inactive – not recommended
for new design; Canceled – must use superseding part.
Note 1: MS24264 “T”, MS24265 “T” and MS24266 “T”
equivalents (M83723/82 thru 87) listed above do not apply
for shell size 8.
** Equivalent part from newer Series/Spec is intermateable and intermount-
able; some differences in accessory threads and contact release may exist.
Note 2: Aero-Electric manufactures MIL-DTL- 26482 Series 2,
MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500,
MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and
III. Only part numbers covered by these specifications are listed.
Military Available Description Contact Mil Connector Status* Superseding Available
Part from Shell Type Style Specification & Series of Equivalent** from
Number Aero (MIL-DTL-) Document MS Number Aero
M83723/97 Ye s RFI Grounding, Self Locking Plug S 83723 Series III, Thr Active — —
M83723/98 Ye s RFI Grounding, Self Locking Plug P 83723 Series III, Thr Active — —
MS24264 “B” Ye s Wall Mount Receptacle P & S 26500 Bayonet Inactive, Can Use M83723/72,71 Ye s
MS24264 “T” Ye s Wall Mount Receptacle P & S 26500 Threaded Inactive, Can Use M83723/83,82 Ye s
MS24265 “B” Ye s Jam Nut Mount Receptacle P & S 26500 Bayonet Inactive, Can Use M83723/74,73 Ye s
MS24265 “T” Ye s Jam Nut Mount Receptacle P & S 26500 Threaded Inactive, Can Use M83723/85,84 Ye s
MS24266 “B” Ye s Straight Plug P & S 26500 Bayonet Inactive, Can Use M83723/76,75 Ye s
MS24266 “T” Ye s Straight Plug P & S 26500 Threaded Inactive, Can Use M83723/87,86 Ye s
MS25042 No Metal Protective Cover, Plug — 5015 Series I, II, III Active — —
MS25043 No Metal Protective Cover, Receptacle — 5015 Series I, II, III Active — —
MS25183 No Straight Plug, Potting Seal, Solder P & S 5015 Series I (Solder) Inactive, Can Use MS3456 Ye s
MS27034 No Solder Mount Receptacle, Hermetic C, E 26500 Bay & Thr Inactive, Use M83723/93,90 No
MS27291 No Straight Clamp — 26500 Bay & Thr Inactive — —
MS27466 Ye s Front Wall Mount Receptacle P & S 38999 Series I Active — —
MS27467 Ye s RFI Grounding Plug P & S 38999 Series I Active — —
MS27468 Ye s Jam Nut Receptacle P & S 38999 Series I Active — —
MS27469 No Wall Mount Receptacle, Hermetic C,P,X 38999 Series I Active — —
MS27470 No Jam Nut Receptacle, Hermetic C,P,X 38999 Series I Active — —
MS27471 No Solder Mount Receptacle, Hermetic C,P,X 38999 Series I Active — —
MS27472 Ye s Front Wall Mount Receptacle P & S 38999 Series II Active — —
MS27473 Yes Straight Plug P & S 38999 Series II Active — —
MS27474 Yes Jam Nut Receptacle P & S 38999 Series II Active — —
MS27475 No Wall Mount Receptacle, Hermetic C, P, X 38999 Series II Active — —
MS27476 No Box Mount Receptacle, Hermetic C, P, X 38999 Series II Active — —
MS27477 No Jam Nut Receptacle, Hermetic C, P, X 38999 Series II Active — —
MS27478 No Solder Mount Receptacle, Hermetic C,P,X 38999 Series II Active — —
MS27479 No Wall Mount Receptacle P & S 38999 Series II Active — —
MS27480 No Straight Plug P & S 38999 Series II Active — —
MS27481 No Jam Nut Receptacle P & S 38999 Series II Active — —
MS27482 No Wall Mount Receptacle, Hermetic P 38999 Series II Canceled, Superseded by MS27475 No
MS27483 NoJam Nut Receptacle, Hermetic P38999 Series II Canceled, Superseded by MS27477 No
MS27484 Y
es RFI Grounding Plug P & S 38999 Series II Active — —
MS27485 NoPotting Boot Ring —38999 Series II Canceled, Superseded by M85049/58 No
MS27486 No Potting Boot — 38999 Series I, II Canceled, Superseded by M85049/75 No
MS27487 No Straight and 90º Adapter — 38999 Series I, II Active — —
MS27488 Ye s Seal Plug (22, 20, 16, 12, 8, 4, 0) — All Active — —
MS27489 No Adapter Reducer — 38999 Series I, II Active — —
MS27496 Ye s Front Box Mount Receptacle P & S 38999 Series I Active — —
MS27497 Ye s Rear Wall Mount Receptacle P & S 38999 Series II Active — —
MS27498 No RFI Plug with 90º Clamp P & S 38999 Series I Canceled, Superseded by MS27467 Ye s
MS27499 Ye s Front Box Mount Receptacle P & S 38999 Series II Active — —
MS27500 Ye s Straight Plug with 90º Strain Relief P & S 38999 Series II Active — —
MS27501 No Metal Protective Cover, Plug — 38999 Series I Active — —
128www.conesys.com sales@aero-electric.com
Part Number Cross Reference
Part Number Cross Reference, Status and Availability
– –
* Active – recommended for new design; Inactive – not recommended
for new design; Canceled – must use superseding part.
** Equivalent part from newer Series/Spec is intermateable and inter-
mountable; some differences in accessory threads and contact release
may exist.
D“Bayonet Coupling” equivalents do not exist.
Note 1: MS27615 standard threaded plug equivalent =
M83723/87, 86 in K class.
Note 2: Aero-Electric manufactures MIL-DTL- 26482 Series 2,
MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500,
MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and
III. Only part numbers covered by these specifications are listed.
Military Available Description Contact Mil Connector Status* Superseding Available
Part from Shell Type Style Specification & Series of Equivalent** from
Number Aero (MIL-DTL-) Document MS Number Aero
MS27502 No Metal Protective Cover, Receptacle — 38999 Series I Active — —
MS27504 No Box Mount Receptacle P & S 38999 Series II Active — —
MS27505 Ye s Rear Box Mount Receptacle P & S 38999 Series I Active — —
MS27506 No Straight Strain Relief — 38999 Series I, II Canceled, Superseded by M85049/49 No
MS27507 No 90º Strain Relief — 38999 Series I, II Canceled, Superseded by M85049/47 No
MS27508 Ye s Rear Box Mount Receptacle P & S 38999 Series II Active — —
MS27510 No Metal Protective Cover, Plug — 38999 Series II Active — —
MS27511 No Metal Protective Cover, Receptacle — 38999 Series II Active — —
MS27512 No Hex Mounting Nut (Jam Nut) — 38999 Series II Inactive, Use MS3186 No
MS27513 Ye s Front Box Mt. Receptacle, Long Grommet P & S 38999 Series II Active — —
MS27515 No Rear Wall Mount Receptacle P & S 38999 Series I Inactive, Use MS27656 Ye s
MS27534 No Insertion/Removal Tools — 38999 Series I, II Inactive, Use M81969/14 Ye s
MS27535 No Size 8 Coax Contact, Socket S 38999 Series I Inactive, Use M39029/59 Ye s
MS27536 No Size 8 Coax Contact, Pin P 38999 Series I Inactive, Use M39029/60 Yes
MS27558 No 90º Cable Support, Closed — 26500 Bay & Thr Inactive — —
MS27559 No 90º Cable Clamp — 26500 Bay & Thr Inactive — —
MS27613∆No Wall Mount Receptacle, Firewall P & S 26500 Bay & Thr Inactive, Use M83723/83, 82 Ye s
MS27614∆No Jam Nut Receptacle, Firewall P & S 26500 Bay & Thr Inactive, Use M83723/85, 84 Ye s
MS27615∆No Ratchet Lock & Standard Plug, Firewall P & S 26500 Bay & Thr Inactive, Use M83723/96, 95 Ye s
MS27652 No Wall Mount Receptacle P & S 38999 Series I Inactive, Use MS27466 Yes
MS27653 No Straight Plug P & S 38999 Series I Inactive, Use MS27467 Ye s
MS27654 No Rear Wall Mount Receptacle P & S 38999 Series I Inactive, Use MS27656 Ye s
MS27656 Ye s Rear Wall Mount Receptacle P & S 38999 Series I Active — —
MS27657 No Short Cable Support for Classes E, K — 26500 Bay & Thr Inactive — —
MS27661 No Lanyard Release Plug P & S 38999 Series I Active — —
MS27662 No Thru-Bulkhead Mounting Receptacle C 38999 Series I Active — —
MS27663-1 No Straight Non-Metallic Strain Relief — 38999 Series I, II Canceled, Superseded by M85049/45 No
MS27663-2 No 90º Non-Metallic Strain Relief — 38999 Series I, II Canceled, Superseded by M85049/46 No
MS27664 No Rear Wall Mount Receptacle P & S 38999 Series II Canceled, Use MS27497 Ye s
MS27667 NoThru-Bulkhead Mounting Receptacle C38999 Series II Canceled — —
MS27668 No Straight Cable Tie Strain Relief — 38999 Series I, II Canceled, Superseded by M85049/56 No
MS27669 No45º Cable Tie Strain Relief —38999 Series I, II Canceled,Superseded by M85049/57 No
MS27670 No 90º Cable Tie Strain Relief — 38999 Series I, II Canceled, Superseded by M85049/63 No
MS3100 No Wall Mount Receptacle P & S 5015 Series I (Solder) Inactive MS3450 Ye s
MS3101 No Cable Connecting Receptacle P & S 5015 Series I (Solder) Inactive MS3451 Ye s
MS3102 No Box Mount Recptacle P & S 5015 Series I (Solder) Inactive MS3452 Ye s
MS3103 No Flange Mount Receptacle, Potting Seal P & S 5015 Series I (Solder) Inactive — —
MS3105 NoDummy Receptacle —5015 Series I (Solder) Inactive— —
MS3106 No Straight Plug P & S 5015 Series I (Solder) Inactive MS3456 Ye s
MS3107 NoQuick Disconnect Plug P & S 5015 Series I (Solder) Inactive— —
MS3108 No 90º Plug P & S 5015 Series I (Solder) Inactive MS3456 & B/S Ye s
MS3110 NoWall Mount Receptacle P & S 26482 Series 1 Solder Inactive,Can Use MS3470 Y
es
129www.conesys.com sales@aero-electric.com
Part Number Cross Reference
Part Number Cross Reference, Status and Availability
– –
* Active – recommended for new design; Inactive – not recommended
for new design; Canceled – must use superseding part.
** Equivalent part from newer Series/Spec is intermateable and inter-
mountable; some differences in accessory threads and contact release
may exist.
Note: Aero-Electric manufactures MIL-DTL- 26482 Series 2,
MIL-DTL-5015 Series III (Rear Release), MIL-DTL-26500,
MIL-DTL-83723 Series III and MIL-DTL-38999 Series I, II and
III. Only part numbers covered by these specifications are listed.
Military Available Description Contact Mil Connector Status* Superseding Available
Part from Shell Type Style Specification & Series of Equivalent** from
Number Aero (MIL-DTL-) Document MS Number Aero
MS3111 No Cable Connecting Receptacle P & S 26482 Series 1 Solder Inactive, Can Use MS3471 Ye s
MS3112 No Box Mount Receptacle P & S 26482 Series 1 Solder Inactive, Can Use MS3470 Ye s
MS3113 No Solder Mount Receptacle P 26482 Series 1 Solder Inactive, Use MS3443 —
MS3114 No Jam Nut Receptacle P & S 26482 Series 1 Solder Inactive, Use MS3474 Ye s
MS3115 No Dummy Receptacle — 26482 Series 1, 2 Inactive — —
MS3116 No Straight Plug P & S 26482 Series 1 Solder Inactive, Can Use MS3476 Ye s
MS3119 No Thru-Bulkhead Mounting Receptacle S to P 26482 Series 1 Solder Inactive — —
MS3120 No Wall Mount Receptacle P & S 26482 Series 1 Crimp Inactive, Can Use MS3470 Ye s
MS3121 No Cable Connecting Receptacle P & S 26482 Series 1 Crimp Inactive, Can Use MS3471 Ye s
MS3122 NoBox Mount Receptacle P & S 26482 Series 1 Crimp Inactive, Can Use MS3470 Y
es
MS3124 No Jam Nut Receptacle P & S 26482 Series 1 Crimp Inactive, MS3474 Ye s
MS3126 No Straight Plug P & S 26482 Series 1 Crimp Inactive, Use MS3476 Ye s
MS3127 No Box Mount Receptacle P & S 26482 Series 1 Crimp Inactive, Can Use MS3470 Ye s
MS3128 No Wall Mount Receptacle P & S 26482 Series 1 Crimp Inactive, Can Use MS3470 Yes
MS3180 No Metal Protective Cover, Plug — 26482 Series 1, 2Inactive — —
MS3181 No Metal Protective Cover, Recepacle — 26482 Series 1, 2 Inactive — —
MS3400 No Wall Mount Receptacle P & S 5015 SII (Front Rel) Active MS3450 Ye s
MS3401 No Cable Connecting Receptacle P & S 5015 SII (Front Rel) Active MS3451 Yes
MS3402 No Box Mount Receptacle P & S 5015 SII (Front Rel) Active MS3452 Ye s
MS3404 No Jam Nut Receptacle P & S 5015 SII (Front Rel) Active MS3454 Ye s
MS3406 No Straight Plug P & S 5015 SII (Front Rel) Active MS3456 Ye s
MS3408 No 90º Plug P & S 5015 SII (Front Rel) Active MS456 & B/S Ye s
MS3409 No 45º Plug P & S 5015 SII (Front Rel) Active MS456 & B/S Ye s
MS3412 No Wall Mount Receptacle P & S 5015 SII (Front Rel) Active MS3450 Ye s
MS3436 No RFI Plug, Utility (20-4 layout only) P & S 5015 Series I (Solder) Inactive — —
MS3440 No Narrow Flange Mt. Receptacle, Hermetic P 26482 Series 2 Inactive — —
MS3442 No Wide Flange Mt. Receptacle, Hermetic P 26482 Series 2 Inactive — —
MS3443 No Solder Mount Receptacle, Hermetic P 26482 Series 2 Inactive — —
MS3449 No Jam Nut Receptacle, Hermetic P 26482 Series 2 Inactive — —
MS3450 Y
es Wall Mount Receptacle P & S 5015 SIII (Rear Rel) Active — —
MS3451 Ye s Cable Connecting Receptacle P & S 5015 SIII (Rear Rel) Active — —
MS3452 Y
es Box Mount Receptacle P & S 5015 SIII (Rear Rel) Active— —
MS3454 Ye s Jam Nut Receptacle P & S 5015 SIII (Rear Rel) Active — —
MS3456 Ye s Straight Plug P & S 5015 SIII (Rear Rel) Active — —
MS3459 Y
es Self locking Plug P & S 5015 SIII (Rear Rel) Active— —
MS3470 Ye s Wall Mount Receptacle P & S 26482 Series 2 Inactive — —
MS3471 Y
es Cable Connecting Receptacle P & S 26482 Series 2 Inactive— —
MS3472 Ye s Wide Flange Mount Receptacle P & S 26482 Series 2 Inactive — —
MS3473 NoSolder Mount Receptacle, Hermetic P26482 Series 2 Inactive— —
MS3474 Y
es Jam Nut Receptacle P & S 26482 Series 2 Inactive— —
MS3475 Ye s RFI Grounding Plug P & S 26482 Series 2 Inactive — —
MS3476 Y
es Straight Plug P & S 26482 Series 2 Inactive— —
MS3477 No Box Mount Receptacle, Hermetic P 26482 Series 2 Inactive — —
MS3479 NoJam Nut Receptacle, Hermetic P26482 Series 2 Inactive — —
MS3507 NoQuick Disconnect Plug (20-4 layout only) P5015 Series I (Solder) Active — —
130www.conesys.com sales@aero-electric.com
Glossary of Terms
– –
A
accessories Sometimes referred to as “Rear Accessories” or
“Backshells” are mechanical devices such as strain reliefs,
cable clamps, adapters, potting boots, etc., which are threaded
onto the rear connector accessory threads of plug or recep-
tacle connectors to make up the total connector assembly.
adapter A threaded ring device screwed onto the threads of
an 83723 Series III threaded receptacle to accept a quick
disconnect plug.
B
back mounted Rear mounted – a connector with its
mounting flange mounted inside of a panel or box.
bayonet coupling A quick coupling mechanism for mating
a plug onto a receptacle utilizing three equally spaced pins
protruding from the receptacle shell which engage corre-
sponding ramps milled into the coupling nut of the mating
plug. Mating and unmating is accomplished by rotating the
coupling nut.
BIN code Basic identification number - color bands on the
wire barrel end of a contact to identify contact part number.
Each BIN number corresponds to one and only one slash
sheet (XX) thus identifying the complete M39029/XX-BIN
part number.
boot A form placed onto the boot adapter used to environ-
mentally seal and/or strain-relieve a cable assembly.
boot adapter A mechanical device with one side threaded
onto the accessory thread of a connector (plug or receptacle)
and the other side used to accept a boot.
braid Braided wire – flexible conductor made of woven or
braided assembly of wires.
bussing The joining of two or more circuits.
C
cable clamp A mechanical device attached to the accessory
threads at the rear of a plug or receptacle to support the
cable or wire bundle, to provide strain relief and absorb
vibration and shock which would otherwise be transmitted
by the cable to the contact or wire crimp area.
coaxial contact A contact with two conductive surfaces – a
center contact and a surrounding coaxial sleeve.
color coding A system of identification of contact
insertion/extraction tools. Colors green, red, orange, blue,
yellow and white indicate the proper tool to use for either
insertion or extraction of appropriate contact size.
connector A mechanical device, either a plug or a receptacle,
used to terminate or connect electrical conductors (pin and
socket contacts) of a cable and its individual wires and provide
a means to continue or terminate these conductors to a
mating connector which may be mounted on electrical
equipment panels, thru bulkheads, printed circuit boards, etc.
contact Pin or socket – the conductive element of a
connector which actually makes contact for the purpose of
conducting electrical current. This is the heart of the
connector.
contact area The actual area in contact (touching)
between two conductors (pin and socket) permitting the
flow of electrical current.
contact arrangement The number of contacts, their size
and spacing in a connector.
contact engagement/separation force The force necessary
to engage or separate pin and socket contacts.
contact resistance The electrical resistance on a mated
pair of contacts (pin and socket). Resistance is measure in
ohms or millivolt drop at a specified current over the
engaged contacts.
contact retainer Contact retention clip – a device captivated
in the hard plastic of the connector body (insert) which
retains the contact in the insert.
contact retention The axial load in either direction (push
or pull) which a contact can withstand without being dis-
lodged from its normal position within the insert of the
connector.
contact sizeA specific number indicating the size (or gauge)
of the engaging end of the contact; examples: size 20, size 16,
size 8, etc.
contact shoulder The flanged portion around the body of
a contact which limits its forward travel into the insert and
prevents it from being pushed forward out of the insert.
coupling nut/ring The movable portion of a connector
plug which aids in the coupling and uncoupling of a plug
and a receptacle and locks the plug and receptacle together.
crimp The physical compression (uniformed deformation)
of a contact wire barrel around the conductor in order to
captivate the conductor and make an electrical connection.
crimping A pressure method using a tool to mechanically
secure a contact (pin or socket) to a conductor (wire).
crimp contact A contact, pin or socket, whose back portion
(wire barrel) is a hollow cylinder into which a stripped wire
(conductor) is inserted. The sidewalls of the wire barrel are
then mechanically compressed (uniformly deformed) using
a crimping tool to captivate the conductor.
crimp die Portion of the crimp tool that shapes the crimp
on the wire barrel.
crimp tool Mechanical device that holds the crimp die and
is used to perform the crimping function.
D
depth of crimp The distance the crimp die indenter
penetrates into the wire barrel.
131www.conesys.com sales@aero-electric.com
Glossary of Terms
– –
die closure The distance between the crimp die indenters
when the crimp tool handle is at full closure. This is usually
checked using a Go/No Go gauge.
dielectric A material having electrical insulating properties.
E
environmental sealing Designed in a connector using
grommets, interfacial seals, peripheral seals, gaskets or potting
material to keep contaminants such as dirt and moisture out
of the connector.
extraction tool Removal tool – a tool used to remove
contacts from a connector.
F
filter contact A contact which provides filtering of EMI
signals without altering its normal function.
filter connector A connector using filtered contacts or filtered
discs to filter EMI signals without altering its normal function.
front mounting A connector mounted with its mounting
flange outside of a box or panel.
front release A term indicating the direction the contact
removal tool must enter the connector to allow for the
removal of contacts. On a front release connector, the contact
removal tool must be inserted in the contact cavity from the
front or face of the connector to release the contact retention
clip. Whether front release or rear release, the contacts are
inserted from the rear of the connector.
G
grommet A resilient elastomeric seal bonded to the rear
of a connector. It is designed with internal sealing barriers
that grasp and seal on the wire's insulation to prevent
contaminants from entering into the rear of the connector.
grounding fingers Grounding spring – a metal band with
spring fingers attached to the plug shell to ensure positive
shell-to-shell grounding before the contacts engage during
mating and when they disengage during unmating. They are
also used t improve EMI/RFI performance.
I
insert The insulating core of the connector designed to posi-
tion, retain, support and provide separation for the contacts.
insertion tool A tool used to insert contacts into a connector.
inspection hole A hole at the bottom of the contact wire
barrel to permit visual inspection to ensure that the wire has
been inserted to the proper depth in the wire barrel prior to
crimping.
insulation Jacket – insulating material around a wire or cable.
interface The two surfaces on the contact side of a mating
plug and receptacle. The surfaces will face each other and
interface when mated.
interfacial seal The sealing of mating connectors over the
entire area of the interface and around each contact. This is
accomplished when resilient material, with raised barriers
around each cavity on the pin interface, displaces into the
hard recessed (chamfered) cavities on the socket interface.
This creates what is commonly called “cork and bottle seal.”
J
jacket Insulation – insulating material around a wire or cable.
K
key A rectangular projection on plug connector shell
designed to slide into the rectangular slot or keyway in the
mating receptacle connector to properly align and guide the
two mating halves together. Generally used to obtain proper
polarization.
L
lanyard A sturdy wire attached to plugs of certain
connectors which allows unmating and separation of plug
and receptacle by a pull on the wire (lanyard).
locator Positioner or Turret head – a mechanical device
attached to a crimp tool with multiple locators to position
different size contacts for crimping. It is indexed to a proper
position by rotating.
M
mate The joining of two connectors.
mated pair A plug and receptacle joined or to be joined
together.
millivolt drop Voltage loss due to resistance created by a
crimp joint.
O
“O” ring Also referred to as peripheral seal is used around
the periphery of a connector shell and is compressed
internally between the plug and receptacle shells when
mated to prevent contaminants from entering the connector.
P
pin contact A “male” contact with the engagement end
that enters into the socket contact.
plating The overlaying of a thin coating of metal on
connector shells and contacts to prevent corrosion, improve
conductivity or provide for easy soldering.
plug The “free to move” or “unmounted” member of a mated
pair of connectors which contains the coupling ring/nut for
132www.conesys.com sales@aero-electric.com
Glossary of Terms
– –
coupling and locking the connectors together.
polarization Also known as clocking or keying – the
mechanical arrangement of inserts or rectangular keys
(projections) and keyways (slots) to ensure proper mating.
It eliminates errors when mating identical connectors
mounted beside each other.
positioner Locator or Turret head – a device attached to a
crimp tool with multiple locators to position different size
contacts for crimping. It is indexed to a proper position by
rotating.
potting The permanent sealing of the back of a connector,
after the wires have been inserted, with a material to keep
out the contaminants and/or provide strain relief.
potting boot a form fitted onto the potting ring , which is
threaded onto the back of connector, to environmentally
seal/strain relive a cable assembly.
pull out force The force necessary to separate a wire from
the contact crimped to it or the force necessary to pull a
properly seated contact from a connector by pulling.
pull test Tensile test – a controlled pull test on the contact
crimp joint to determine its mechanical strength.
R
range Wire range – the acceptable sizes of wires
accommodated by a particular contact wire barrel size.
Also the acceptable diameter of wires accommodated by a
sealing grommet.
rear accessories Referred to as backshells, they are
mechanical devices that screw onto the accessory threads on
the rear of the connector. Includes strain reliefs, clamps,
adapters, potting boots, etc.
rear mounted Back mounted – a connector with its
mounting flange mounted inside of a panel or box.
rear release A term indicating the direction the contact
removal tool must enter the connector to allow removal of
the contacts. On a rear release connector the contact
removal tool must be inserted into the contact cavity from
the back or rear of the connector to release the contact
retention clip. Whether rear release or front release, contacts
are inserted through the rear of the connector.
receptacle The fixed or mounted member of a mated pair
of connectors designed to be mounted to a box, panel or
bulkhead.
removal tool A device used to remove contacts from a
connector.
S
safety wire A means of putting wire through holes drilled
in the coupling ring/nut of a connector plug, and securing
the wire to a panel of bulkhead to prevent the plug from loos-
ening or decoupling from the receptacle during vibration.
scoop proof A term to describe a longer shell design on
the pin half (plug or receptacle) of a connector. The longer
shell allows the pin contacts, which protrude from the face
of the connector, to be recessed sufficiently so as not to be
damaged if the mating shell is “scooped” into it during mating
process. This prevents pins from being bent and/or contacts
from being electrically shorted during mating. This is espe-
cially important when using size 22 contacts, which because
of their small size, bend easily.
sealing plug A small plastic plug (MS27488-**-1, head first)
inserted into the rear grommet of a connector, especially an
environmental connector, to seal and prevent the entry of
contaminants into any unused (unwired) cavities.
selective plating The applying of plating material to a
limited area of a contact, especially areas susceptible to wear.
service rating The maximum amount of voltage or current
a connector is designed to continuously carry.
shell The outside case of a connector which holds the
dielectric insert and contacts.
shielded contact A contact shielded from unwanted signals
(EMI/RFI) by one or more outer (protective) conductors.
These contacts are not generally matched to the impedance
of the cable they terminate.
socket contactA contact whose engaging end is designed
to accept the entry of a pin contact.
solder contactA pin or socket contact that accepts a
conductor (wire) which is soldered onto the “solder cup,”
not crimped into the wire barrel.
spliceWire splice – a device used to join two or more
conductors (wires).
strip To remove insulation from a conductor. Generally for
inserting the conductor into the wire barrel/solder cup of a
contact for a crimping/soldering operation.
T
tensile test Pull test – a controlled pull test on the contact
crimp joint to determine its mechanical strength.
thermocouple contact A contact made of special material,
used in connectors in high temperature applications as a
means of measuring temperature electrically. Materials often
used for these contacts are alumel, chromel, constantan,
iron and copper.
threaded coupling A means of coupling a mating pair of
connectors by engaging threads on the exterior of a receptacle
with interior threads of the plug.
turret head Locator or Positioner - a device attached to a
crimp tool with multiple locators to position different size
contacts for crimping. It is indexed to a proper position by
rotating.
