Aero-Electric Connector, Inc. Table of Contents Mil Spec Catalog (AE101) 5015 S III 26482 S 2 83723 S III 26500 sales@aero-electric.com 38999 S III - 1 - 38999 S II www.conesys.com 38999 S I 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 90 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 MIL-DTL-38999 Features and Application Series I MIL-DTL- 38999 S I Features and Application 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. MIL-DTL-38999 Series I is a bayonet coupling subminiature configuration with high contact density, ideal for smaller wire gauge, general-purpose applications. These environmentresisting 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. 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. 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. 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. Standard plugs provide RFI protection by incorporating a continuous strip of attached grounding fingers attenuating interference up to 1 GHz. Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having identical insert arrangement. 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. www.conesys.com - 2 - sales@aero-electric.com MIL-DTL-38999 Performance Specifications Series I 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. Operating Temperature Range Finish B: -65C to +175C (-85F to +347F) Finish F: -65C to +200C (-85F to +392F Finish A: -65C to +150C (-85F to +302F) 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 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: Corrosion Resistance Finishes A and B withstand 500-hour salt spray. Finish F withstands 48-hour salt spray. 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. 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. 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. 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. 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. Shell-to-Shell Conductivity Finish F = 1.0 millivolt maximum potential drop Finishes A and B = 2.5 millivolts maximum potential drop Voltage 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. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS M 400 550 1300 550 350 200 N 300 450 1000 400 260 200 I 600 850 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 www.conesys.com exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 3 - sales@aero-electric.com MIL-DTL- 38999 S I Performance Specifications MIL-DTL-38999 Part Number Development Series I MIL-DTL- 38999 S I Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS AE 27467 167 T T 13 13 B B 35 35 P P A 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 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. www.conesys.com 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. - 4 - sales@aero-electric.com MS27466 Front, Wall Mounting Receptacle AE166 MIL-DTL- 38999 S I Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.323(33.60) MAX A MASTER KEYWAY D F B .219(5.56) MIN. FULL THREAD .060(1.52) MAX GROMMET EXTENSION [H [E MAX GROMMET J ACCESSORY TEETH G ACCESSORY THREAD 4X MINOR KEYWAYS 4x [ C BLUE COLOR BAND Page 4 Page 13 Pages 17-19 Page 3 Pages 15, 16 Page 11 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C [E F G +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 Accessory Thread [H J Maximum No. of Teeth Shell Size .020 .51 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 www.conesys.com (TP) D +.010 -.005 - 5 - sales@aero-electric.com MS27656 Rear, Wall Mounting Receptacle AE156 MIL-DTL- 38999 S I Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.350 (34.29) MAX A MASTER KEYWAY D F .219 (5.56) MIN FULL THREAD B .060 (1.52) MAX GROMMET EXTENSION [H [E MAX GROMMET J ACCESSORY TEETH G ACCESSORY THREAD 4X MINOR KEYWAYS 4x [ C BLUE COLOR BAND Page 4 Page 13 Pages 17-19 Page 3 Pages 15, 16 Page 11 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C D [E F G +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 Accessory Thread [H J Maximum No. of Teeth Shell Size .020 .51 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 www.conesys.com (TP) Note: See page 12 for panel thickness. - 6 - sales@aero-electric.com MS27496 Front, Box Mounting Receptacle AE196 MIL-DTL- 38999 S I Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.104(28.04) MAX A MASTER KEYWAY D F B .060(1.52) MAX GROMMET EXTENSION [H [G MAX GROMMET MAX [E .312(7.93) MAX 4X MINOR KEYWAYS 4x [ C BLUE COLOR BAND Page 4 Page 13 Pages 17-19 Page 3 Pages 15, 16 Page 11 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C [E F [G +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 [H Shell Size .020 .51 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 www.conesys.com (TP) D +.010 -.005 - 7 - Maximum Maximum sales@aero-electric.com MS27505 Rear, Box Mounting Receptacle AE105 MIL-DTL- 38999 S I Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.100(27.94) MAX A MASTER KEYWAY D F B .060(1.52) MAX GROMMET EXTENSION [H [E [G MAX MAX GROMMET 4X MINOR KEYWAYS 4x [ C BLUE COLOR BAND Page 4 Page 13 Pages 17-19 Page 3 Pages 15, 16 Page 11 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C D [E F [G +.010 -.005 +.25 -.13 +.000 -.005 +.00 -.13 +.001 -.005 +.03 -.13 +.015 -.000 +.38 -.00 [H Shell Size .020 .51 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 www.conesys.com (TP) Note: See page 12 for panel thickness. - 8 - Maximum Maximum sales@aero-electric.com MS27468 Jam Nut Receptacle AE168 MIL-DTL- 38999 S I Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof E 1.308 (33.22) MAX B .920 (23.37) .910 (23.11) .615 (15.62) .598 (15.19) MASTER KEYWAY .060 (1.52) MAX GROMMET EXTENSION K [C [A FLAT MAX GROMMET G No. OF TEETH [D F ACCESSORY THREAD 4X MINOR KEYWAYS BLUE COLOR BAND 3X BAYONET PINS EQUALLY SPACED "O"-RING J THREAD BLUE COLOR BAND HEX NUT PER MS3186 Page 4 Page 13 Pages 17-19 Page 3 Pages 15, 16 Page 11 PANEL THICKNESS .125(3.18) .062(1.57) Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A B [C [D E F G J K +.001 -.005 +.03 -.13 +.011 -.010 +.28 -.25 .016 .41 .016 .41 Accessory Thread 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 Shell Size www.conesys.com Maximum - 9 - No. of Jam Nut Thread Flat Teeth Class 2A .005 .13 sales@aero-electric.com MS27467 RFI Grounding Plug AE167 MIL-DTL- 38999 S I Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof 1.294 (32.87) MAX [ F MAX. COUPLING NUT MASTER KEY E ACCESSORY THREAD RFI STRIP .060(1.52) GROMMET MAX EXTENSION [A [C MIN MAX GROMMET D No. OF TEETH .219(5.56) MIN FULL THREAD 4 MINOR KEYS BLUE COLOR BAND Page 4 Page 13 Pages 17-19 Page 3 Pages 15, 16 Page 11 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A Minimum [C D E Maximum No. of Teeth Accessory Thread Class 2A Shell Size inch mm inch mm 9 .417 10.59 .299 7.59 12 11 .545 13.84 .427 10.85 13 .657 16.69 .541 15 .782 19.86 .666 17 .907 23.04 19 1.012 25.70 21 1.137 23 25 [F Maximum inch mm 7/16-28UNEF .859 21.82 16 9/16-24UNEF .984 24.99 13.74 20 11/16-24UNEF 1.156 29.36 16.92 24 13/16-20UNEF 1.281 32.54 .791 20.09 28 15/16-20UNEF 1.406 35.71 .897 22.78 32 1-1/16-18UNEF 1.516 38.51 28.88 1.022 25.96 36 1-3/16-18UNEF 1.641 41.68 1.262 32.05 1.147 29.13 40 1-5/16-18UNEF 1.766 44.86 1.387 35.23 1.272 32.31 44 1-7/16-18UNEF 1.891 48.03 www.conesys.com - 10 - sales@aero-electric.com MIL-DTL-38999 Polarization Series I MIL-DTL- 38999 S I Keying Positions NORMAL C N MASTER KEYWAY A B D 5 DATUM F 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). Keying Positions BSC Shell Size 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 www.conesys.com - 11 - sales@aero-electric.com MIL-DTL-38999 Series I Flange and Jam Nut Receptacles Panel Cutouts MIL-DTL- 38999 S I Panel Cutouts JAM NUT FLANGE MOUNT D MAX PANEL THICKNESS 4x [ C .125(3.18) .062(1.57) PANEL THICKNESS [B MIN E [F A Note 1: Flange Mounting Dimensions ([ B cutout and D MAX) listed only for back of panel mounting (MS27505 and MS27656). Note 2: D MAX includes mounting hardware. Flange and Jam Nut Mounting Dimensions A [B (TP) [C Minimum .005 D .13 E Maximum +.000 -.010 [F +.00 -.25 +.010 -.000 +.25 -.00 Shell Size 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 www.conesys.com - 12 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series I Contact Size 22D 22M* 22* 20 16 12 12 Coax 12 Coax 8 Coax 8 Twinax Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Power/Signal Power/Signal Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Coax Twinax Military No. M39029/58-360 M39029/58-361 M39029/58-362 M39029/58-363 M39029/58-364 M39029/58-365 M39029/28-211 M39029/102-558 M39029/60-367 M39029/90-529 Military No. M39029/56-348 M39029/56-349 M39029/56-350 M39029/56-351 M39029/56-352 M39029/56-353 M39029/75-416 M39029/103-559 M39029/59-366 M39029/91-530 Military No. Plastic Military No. M81969/14-01 MS27488-22-1 MS27488-20-1 MS27488-16-1 -- M81969/14-10 M81969/14-03 MS27488-12-1 M81969/14-04 MS27488-8-1 MS27488-8-1 M81969/14-06 M81969/14-12 Crimping and Metal Insertion/Extraction Tools Crimp Tool Positioner Positioner Insertion Tool Extraction Tool For Socket Contacts Military No. M22520/2-07 M22520/2-07 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 Metal Military No. M81969/8-01 M81969/8-03 Metal Military No. M81969/8-02 M81969/8-04 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M81969/8-13** M81969/8-14 16 12 12 Coax Inner 12 Coax Outer 8 Coax Inner Military No. M22520/2-01 M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 M22520/2-01 8 Coax Outer M22520/5-01 8 Twinax Center M22520/2-01 For Pin Contacts Military No. M22520/2-09 M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 8 Twinax Outer & Intermediate M22520/5-01 M22520/5-200 Contact Size/Type 22D, 22M* 22* 20 -- M22520/5-200 -- Contact and Wire Data Test Current Voltage Contact Size 22D 22M* 22* 20 16 12 DC Test Amps 5.0 3.0 5.0 7.5 13.0 23.0 Max. Drop Millivolts 73 45 73 55 49 42 Crimp Well Data AWG 28-22 28-24 26-22 24-20 20-16 14-12 mm2 .08-.33 .08-.20 .13-.33 .20-.52 .52-1.31 2.08-3.31 Finished Wire [ Range Minimum inch mm .030 .76 .030 .76 .034 .86 .040 1.02 .065 1.65 .097 2.46 Maximum inch mm .054 1.37 .050 1.27 .060 1.52 .083 2.11 .109 2.77 .142 3.61 Note 2: Size 12 coax contacts purchased in bulk. * Inactive for new design ** Insertion tool is not required. 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. Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com Wire Range Well Dia. Minimum Well Dept inch inch mm .0345 .0010 .141 3.58 .028 .001 .141 3.58 .0365 .0010 .141 3.58 .047 .001 .209 5.31 .067 .001 .209 5.31 .100 .002 .209 5.31 - 13 - sales@aero-electric.com MIL-DTL- 38999 S I Contacts, Plastic Insertion/Removal Tools and Seal Plugs MIL-DTL-38999 Contact Installation Instructions Series I MIL-DTL- 38999 S I Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 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. 4.1 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. 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. 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. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 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. 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. 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. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool 22D 22M 22 M39029/58-360 M39029/58-361 M39029/58-362 M39029/56-348 M39029/56-349 M39029/56-350 M39029/58-363 M39029/56-351 20 12 M39029/58-364 M39029/58-365 M39029/56-352 M39029/56-353 M22520/2-09 M22520/2-09 M22520/2-09 M22520/1-04 Red M22520/2-10 M22520/1-04 Blue M22520/1-04 Yellow M22520/2-07 M22520/2-07 M22520/2-07 M22520/1-04 Red M22520/2-10 M22520/1-04 Blue M22520/1-04 Yellow M81969/14-01 M81969/14-01 M81969/14-01 20 M22520/2-01 M22520/2-01 M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 M81969/14-10 M81969/14-03 M81969/14-04 For coax and twinax contacts refer to instructions that are supplied with contacts. www.conesys.com - 14 - sales@aero-electric.com MIL-DTL-38999 Series I, II and III Insert Availability and Contact Information per MIL-STD-1560 Aero-Electric Service Total Status Insert Arrangement Quantity of Contacts No. of Series III QPL'd Tooled Rating Contacts 9-6* 9-35 9-98 11-2 11-4 11-5 11-13* 11-35 11-98 11-99 -- 13-4 13-8 13-22* 13-35 13-98 15-5 15-15 15-18 15-19 15-35 15-37* 15-97 17-6 17-8 17-26 17-35 17-55* 17-99 19-11 19-28 19-30 19-32 19-35 -- 19-66* 8-6* 8-35 8-98 -- -- 10-5 10-13* 10 -35 10-98 10-99 12-3 12-4 12-8 12-22* 12-35 12-98 14-5 14-15 14-18 -- 14-35 14-37* 14-97 16-6 16 -8 16 -26 16 -35 16-55* 16-99 18-11 18-28 18-30 18-32 18-35 18-53** 18-66* -- A35 A98 B2 B4 B5 -- B35 B98 B99 -- C4 C8 -- C35 C98 D5 D15 D18 D19 D35 -- D97 E6 E8 E26 E35 -- E99 F11 F28 F30 F32 F35 -- -- Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M M I I I I M M I I II I I M M I II I I I M M I I II I M M I II I I I M M M 6 6 3 2 4 5 13 13 6 7 3 4 8 22 22 10 5 15 18 19 37 37 12 6 8 26 55 55 23 11 28 30 32 66 53 66 Please see next page for Shell Sizes 21/20/G thru 25/24/J layouts. (by Size) 22D 22M 22 20 16 12 10 8 6 6 3 2 4 5 13 13 6 7 3 4 38999 S III Series II 38999 S II Series I 8 22 22 10 14 18 19 5 1 37 37 8 4 6 8 26 55 55 21 26 29 32 2 11 2 1 66 53 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. www.conesys.com - 15 - MIL-DTL- 38999 S I Insert Availability and Contact Information sales@aero-electric.com MIL-DTL-38999 Series I, II and III Insert Availability and Contact Information per MIL-STD-1560 MIL-DTL- 38999 S I Insert Availability and Contact Information (continued) Aero-Electric Service Total Status Insert Arrangement No. of 38999 S II 38999 S III Series I Series II Series III QPL'd Tooled Rating Contacts 21-1* 21-11 21-16 21-35 21-39 21-41 21-48** 21-75 23-1* 23-2*** 23-21 23-32 23-35 23-53 23-55 25-1* 25-4 -- -- 25-19 -- 25-24 25-29 25-35 25-43 25-46 25-61 -- 20-1* -- 20-16 20-35 20-39 20-41 -- -- 22-1* 22-2*** 22-21 22-32 22-35 22-53 22-55 24-1* 24-4 -- -- 24-19 -- 24-24 24-29 24-35 -- -- 24-61 -- -- G11 G16 G35 G39 G41 G48** G75 -- -- H21 H32 H35 H53 H55 -- J4 J8 J11 J19 J20 J24 J29 J35 J43 J46**** J61 J90 Yes Yes Yes Yes Yes Yes N/A Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M I II M I I I Twinax M M II I M I I M I Twinax N I N, Coax, Twinax I I M I I, Coax I I, Twinax 79 11 16 79 39 41 4 4 100 85 21 32 100 53 55 128 56 8 11 19 30 24 29 128 43 46 61 46 (by Size) 22D 22M 22 20 16 12 10 8 79 11 16 79 37 41 2 4 (Power) 4 (Twinax) 100 85 21 32 100 53 55 128 48 8 8 (Twinax) 2 9 19 4 (Coax) 12 10 13 12 29 3 (Twinax) 23 40 61 40 20 4 2 (Coax) 4 2 (Twinax) 128 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. * 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. 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. *** 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). 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. -- above means "not available" for that series www.conesys.com Quantity of Contacts - 16 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I, II and III Connectors MIL-DTL- 38999 S I Insert Arrangements Views C 5 4 3 1 D A B 1 6 A E A A 10 B 2 B C B D 9-35/8-35 A35, 6 # 22D, M 9-98/8-98 A98, 3 # 20, I 11-5/10-5 B5, 5 # 20, I C F B E C K L K B R J B H D K M D E 15 N C J D P T H E G C 13-8/12-8 C8, 8 # 20, I A U S G A B N P 13-35/12-35 C35, 22 # 22D, M 1 C 31 K C P R F M L B N M C D 13-4/12-4 C4, 4 # 16, I 3 # 16, II A C J F 1 U J D T S H E G 21 D R V 38999 S III 12-3 11-99/10-99 B99, 7 # 20, I E 5 22 C B G 14 B L A A 6 4 B B H 7 21 H F D 11-98/10-98 B98, 6 # 20, I 12 11-35/10-35 B35, 13 # 22D, M A B D E C G A A G 13 38999 S II A A F D 11-4 B4, 4 # 20, I 11-2 B2, 2 # 16, I 3 8 C E 2 11 9 E F F 13-98/12-98 C98, 10 # 20, I K 15-18/14-18 D18, 18 # 20, I G B D H F G T C M L E 15-97/14-97 D97, 4 # 16, 8 # 20, I www.conesys.com 17-6/16-6 E6, 6 # 12, I E D Z V c X 17-8/16-8 E8, 8 # 16, II - 17 - E F W J 32 40 47 D U K C 25 1 Y F 17 4 C b N H 10 B S a B F D A R P B C M 15-35/14-35 D35, 37 # 22D, M 15-19 D19, 19 # 20, I A A E A L J 15-15/14-15 D15, 1 # 16, 14 # 20, I 15-5/14-5 D5, 5 # 16, II G H 17-26/16-26 E26, 26 # 20, I 53 55 3 52 9 16 24 31 46 39 17-35/16-35 E35, 55 # 22D, M sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I, II and III Connectors MIL-DTL- 38999 S I Insert Arrangements Views T S C P Y Z d K H B G E G J H 38999 S II 17 34 43 H K B G 53 38999 S III 52 3 L 66 Z K J C 9 G 63 24 50 E 19-35/18-35 F35, 66 #22D, M 53 #22, M M 51 U 31 N h C 79 71 q p M 21-35/20-35 G35, 79 # 22D, M S f P N M 29 39 b c d e 21-39/20-39 G39, 2 # 16, 37 # 20, I 20 p q R K G H J K L 21-41/20-41 G41, 41 # 20, I 48 N 58 67 12 F n r g G E a t J L m s h H d e F 21-16/20-16 G16, 16 # 16, II F c f 11 b D Z k T E C Y j i a n N 41 D B X U m P 61 E Z r g D G Y k V C S R 21 P R j A W B X i T S A W V B 21-11 G11, 11 # 12, I 18-53* A K D 11 42 1 L F 31 57 16 H 19-32/18-32 F32, 32 # 20, I H A 51 33 J J F a L 19-30/18-30 F30, 1 # 16, 29 # 20, I 64 E Y b G H 21 1 h c M F 58 X N J 1 51 E X Y J D g W Z C W f j 25 D f K 19-28/18-28 F28, 2 # 16, 26 # 20, I 4 V e d L G K 10 B U g F L C V a Z 19-11/18-11 F11, 11 # 16, II A T R Y U e M E a E 17-99/16-99 E99, 2 # 16, 21 # 20, I S X M D F T b D L F d c N W e N C W K C b M L V c V X B P P D A R B U R U N P S A J B S A T A R M 5 A A B P 75 D L 82 1 W R A C X B D C 11 C 81 19 28 38 47 66 57 23-2*/22-2* 21-75 G75, 4 # 8 Twinax, Twinax S 85 4 21-48** G48**, 4 # 8 Power, I V K B 85 # 22, M 74 U J D T E H G F 23-21/22-21 H21, 21 # 16, II * Inactive for new design. ** Not MIL-STD-1560 layout (not QPL'd.). www.conesys.com - 18 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series I, II and III Connectors MIL-DTL- 38999 S I Insert Arrangements Views N M A 25 16 P b 46 35 56 S 67 77 8 B R h S c g 4 97 98 K D Y f e X 7 H 24 34 G a Z X u t z JJ U EE r T KK CC p R n m N M C D 2 G J J20 10 # 20,13 # 16, 4 # 12, 3 # 8 Twinax, N / Coax / Twinax Y Z n A W V m p w U a k D q x T V C b h u X C Y v q a d s R n g f J K N M L 25-43 J43, 20 # 16, 23 # 20, I www.conesys.com k N F h M g L K R H KK m - 19 - M H i j k L J K 25-61/24-61 J61, 61 # 20, I B u X C Y AA v Z q D a p S E z F R b w n c m G h AA BB n N 25-46 J46, 40 # 20, 4 # 16, 2 # 8 Coax, I / Coax E g z LL P J f y MM DD P 81 93 r T D EE q T CC G e f JJ PP S d x y e x s U C w NN r c m H e P w d HH U V B v FF V E P R D 104 A W t A c s Z 47 5870 25-35/24-35 J35, 128 # 22D, M b GG 11 4 35 u t W b t Z a Y B v G S 24 H 25-29/24-29 J29, 29# 16, I X z 121 14 G J p S 7 X Y K A AA E F G u r T F c r s U E W t 125 W 25-24/24-24 J24, 12 # 12, 12 # 16, I B 122 4 e Z F H V L V J d M U K 115 1 D f E W H X N T a 105 U c a X L K b D V W T C S 94 8 P Z F L C 71 82 36 48 59 25 B S Y M G 15 R R E U F 25-19/24-19 J19, 19 # 12, I A B D T 6 X E S J11 9 # 10, 2 # 20, N A P 1 3 M D R H E J8 8 # 8 Twinax, Twinax N 7 C V T J F E B 4 P U D C Y N K K L F A 5 B G K R Z N J C 25-4/24-4 J4, 8 # 16, 48 # 20, I P A L H L S 23-55/22-55 H55, 55 # 20, I J k P G H J M H h BB c d e L B G AA DD u f g LL q S G F b v 23-53/22-53 H53, 53 # 20, I E F E t f H H e y w g D Z a EE K d HH s c B D FF FF Y 38999 S III W V J 85 G CC s A C x GG a HH x b A B c v 76 55 v d r DD i N H M Z u w e 23-35/22-35 H35, 100 # 22D, M A b w 66 Y t BB y P F GG j C X q 38999 S II 23-32/22-32 H32, 32 # 20, I 45 E DD EE f 93 z R W p AA D X s x L K 15 F Y CC FF y 10 0 E V W W r HH M 99 6 J GG g 5 U q m S k B V n C V BB h N p AA z 96 U m P k 95 3 T d i 2 C Z 94 A T B n 1 a L U A T R 86 P k N F d x y h M g L K G e f H J J90, 40 # 20, 4 # 16, 2 # 8 Twinax, I / Twinax sales@aero-electric.com MIL-DTL-38999 Features and Application Series II Features and Application 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. MIL-DTL- 38999 S II MIL-DTL-38999 Series II connectors feature a bayonet coupling mechanism with lower profile design and rear-removable crimp contact retention system. 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. These connectors were designed for military and commercial applications where the prime requirements are lower profile and lighter weight. 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. 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 general 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). 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. 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. www.conesys.com - 20 - sales@aero-electric.com MIL-DTL-38999 Performance Specifications Series II Performance Specifications Operating Temperature Range Finish B: -65C to +175C (-85F to +347F) Finishes C and F: -65C to +200C (-85F to +392F) Finish A: -65C to +150C (-85F to 302F) 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 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. Corrosion Resistance Finishes A, B and C withstand 500-hour salt spray. Finish F withstands 48-hour salt spray. 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: Durability Mated connectors withstand a minimum of 250 mating cycles for RFI plug (MS27484) and 500 cycles for MS27473 and MS27500 plugs. Standard Shock Mated connectors withstand a pulse of approximate half sine wave of 300 G magnitude with duration of three milliseconds applied in three axes per MIL-STD-1344, method 2004. 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. Vibration Mated connectors withstand the following vibration levels: Random vibration per MIL-STD-1344, method 205 test condition VI, Letter "J". Voltage 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. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS M 400 550 1300 550 350 200 N 300 450 1000 400 260 200 I 600 850 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 www.conesys.com exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 21 - sales@aero-electric.com MIL-DTL- 38999 S II 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. MIL-DTL-38999 Part Number Development Series II Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS AE 27473 273 T T 12 12 B B 35 35 P P A A -340 MIL-DTL- 38999 S II 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. www.conesys.com 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. - 22 - sales@aero-electric.com MS27472 Front, Wall Mounting Receptacle AE272 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight D MAX A MIL-DTL- 38999 S II .069(1.75) .058(1.47) .322(8.18) .317(8.05) MAX B MASTER KEYWAY .219(5.56) MIN FULL THREAD K GROMMET EXTENSION [H [E MAX GROMMET G NO. OF TEETH BLUE COLOR BAND 4x [ C Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 F ACCESSORY THREAD 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C [E F G No. of Teeth Shell Size .003 .08 inch mm inch mm inch mm inch mm inch mm UNEF-2A 8 .828 21.03 .594 15.09 .120 3.05 .932 23.67 .471 11.96 7/16-28 10 .954 24.23 .719 18.26 .120 3.05 .932 23.67 .588 14.94 12 1.047 26.59 .812 20.62 .120 3.05 .932 23.67 .748 14 1.141 28.98 .906 23.01 .120 3.05 .932 23.67 .873 16 1.234 31.34 .969 24.61 .120 3.05 .932 23.67 .998 25.35 15/16-20 18 1.328 33.73 1.062 26.97 .120 3.05 .932 23.67 1.123 28.52 1-1/16-18 20 1.453 36.91 1.156 29.36 .120 3.05 .932 23.67 1.248 31.70 1-3/16-18 22 1.578 40.08 1.250 31.75 .120 3.05 .932 23.67 1.373 34.87 24 1.703 43.26 1.375 34.93 .147 3.73 1.000 25.40 1.498 38.05 www.conesys.com (TP) +.25 -.13 D Accessory Thread Maximum +.010 -.005 Maximum - 23 - [H K Maximum Grommet Extension inch mm inch mm 12 .299 7.59 .150/.090 3.81/2.29 9/16-24 16 .427 10.85 .150/.090 3.81/2.29 19.00 11/16-24 20 .541 13.74 .150/.090 3.81/2.29 22.17 13/16-20 24 .666 16.92 .150/.090 3.81/2.29 28 .791 20.09 .150/.090 3.81/2.29 32 .897 22.78 .150/.090 3.81/2.29 36 1.022 25.96 .150/.090 3.81/2.29 1-5/16-18 40 1.147 29.13 .150/.090 3.81/2.29 1-7/16-18 44 1.272 32.31 .140/.040 3.56/1.02 sales@aero-electric.com MS27497 Rear, Wall Mounting Receptacle AE297 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight D MAX A .447(11.35) .442(11.23) MAX MIL-DTL- 38999 S II .069(1.75) .058(1.47) B MASTER KEYWAY .219(5.56) MIN FULL THREAD K GROMMET EXTENSION [H [E MAX GROMMET MAX G NO. OF TEETH BLUE COLOR BAND 4x [ C F ACCESSORY THREAD 4 MINOR KEYWAYS Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C Maximum (TP) +.010 -.005 +.25 -.13 Note: See page 33 for panel thickness. D [E F G [H K Maximum Maximum Accessory Thread No. of Teeth Maximum Grommet Extension Shell Size 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 www.conesys.com - 24 - sales@aero-electric.com MS27499 Front, Box Mounting Receptacle AE299 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight .763(19.38) MAX A MAX .069(1.75) .058(1.47) .322(8.18) .317(8.05) MIL-DTL- 38999 S II B MASTER KEYWAY .312(7.92) MAX .060(1.52) MAX GROMMET EXTENSION [H [E 4x [ C Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 [F MAX MAX GROMMET BLUE COLOR BAND 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum [C +.25 -.13 [F [H Shell Size .003 .08 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 www.conesys.com (TP) [E +.010 -.005 - 25 - Maximum Maximum sales@aero-electric.com MS27508 Rear, Box Mounting Receptacle AE208 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight .757(19.23) MAX A .447(11.35) .442(11.23) MAX MIL-DTL- 38999 S II .250(6.35) MAX B MASTER KEYWAY .069(1.75) .058(1.47) .322(8.18) .317(8.05) [F .060(1.52) MAX GROMMET EXTENSION [H [E MAX [F GROMMET MAX MAX 4x [ C Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 BLUE COLOR BAND 4 MINOR KEYWAYS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum Note: See page 33 for panel thickness. [C +.25 -.13 [F [H Shell Size .003 .08 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 www.conesys.com (TP) [E +.010 -.005 - 26 - Maximum Maximum sales@aero-electric.com MS27513 Long Grommet, Front, Box Mount Receptacle AE213 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight .907(23.04) MAX A MAX .516(13.11) MAX MASTER KEYWAY .322(8.18) .317(8.05) .312(7.92) MAX [H [E MAX GROMMET MIL-DTL- 38999 S II .069(1.75) .058(1.47) B [F MAX BLUE COLOR BAND 4x [ C 4 MINOR KEYWAYS Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Maximum [C +.25 -.13 [F [H Shell Size .003 .08 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 www.conesys.com (TP) [E +.010 -.005 - 27 - Maximum Maximum sales@aero-electric.com MS27474 Jam Nut Receptacle AE274 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight D G MAX. MASTER KEYWAY A MIL-DTL- 38999 S II .105(2.67) .084(2.13) "O" RING SS 8-22 .150(3.81) .090(2.29) GROMMET SS 24 .140(3.56) EXTENSION .040(1.02) B [J [F MAX GROMMET FLAT H NO. OF TEETH M ACCESSORY THREAD HEX NUT PER MS3186 E THREAD 3 BAYONET PINS 4 MINOR KEYWAYS BLUE COLOR BAND PANEL THICKNESS .109(2.77) .062(1.57) Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B D [F G H Maximum No. of Teeth Shell Size .005 .13 .016 .41 Jam Nut Thread Class 2A .003 inch mm inch mm inch mm inch mm inch mm 8 .438 11.13 .817 20.75 1.250 31.75 7/8-20UNEF .471 11.96 .937 23.80 10 .438 11.13 .941 23.90 1.375 34.93 1-20UNEF .588 14.94 .937 12 .438 11.13 1.065 27.05 1.500 38.10 1-1/8-18UNEF .748 19.00 14 .438 11.13 1.190 30.23 1.625 41.28 1-1/4-18UNEF .873 22.17 16 .438 11.13 1.320 33.53 1.781 45.24 1-3/8-18UNEF .998 18 .438 11.13 1.440 36.58 1.890 48.01 1-1/2-18UNEF 1.123 20 .464 11.79 1.565 39.75 2.016 51.21 1-5/8-18UNEF 22 .464 11.79 1.690 42.93 2.140 54.36 24 .464 11.79 1.815 46.10 2.265 57.53 www.conesys.com +.03 -.15 E +.001 -.006 .08 [J M Maximum Accessory Thread inch mm UNEF-2A 12 .299 7.59 7/16-28 23.80 16 .427 10.85 9/16-24 .937 23.80 20 .541 13.74 11/16-24 .937 23.80 24 .666 16.92 13/16-20 25.35 .937 23.80 28 .791 20.09 15/16-20 28.52 .937 23.80 32 .897 22.78 1-1/16-18 1.248 31.70 .931 23.65 36 1.022 25.96 1-3/16-18 1-3/4-18UNS 1.373 34.87 .931 23.65 40 1.147 29.13 1-5/16-18 1-7/8-16UN 1.498 38.05 .984 24.99 44 1.272 32.31 1-7/16-18 - 28 - sales@aero-electric.com MS27473 Straight Plug AE273 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight G [ F MAX COUPLING NUT MAX MASTER KEY E ACCESSORY THREAD BLUE COLOR BAND MIL-DTL- 38999 S II H GROMMET EXTENSION [A [C MIN SHELL MAX GROMMET D NO. OF TEETH 4 MINOR KEYS Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A Minimum [C D E Maximum No of Teeth Accessory Thread Shell Size inch mm inch mm 8 .337 8.56 .299 7.59 10 .465 11.81 .427 12 .557 14.15 14 .702 17.83 16 .827 18 .927 20 [F Maximum G H Maximum Grommet Extension UNEF-2A inch mm inch mm inch mm 12 7/16-28 .750 19.05 .916 23.27 .150/.090 3.81/2.29 10.85 16 9/16-24 .859 21.82 .916 23.27 .150/.090 3.81/2.29 .541 13.74 20 11/16-24 1.031 26.19 .916 23.27 .150/.090 3.81/2.29 .666 16.92 24 13/16-20 1.156 29.36 .916 23.27 .150/.090 3.81/2.29 21.01 .791 20.09 28 15/16-20 1.281 32.54 .916 23.27 .150/.090 3.81/2.29 23.55 .897 22.78 32 1-1/16-18 1.406 35.71 .916 23.27 .150/.090 3.81/2.29 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 www.conesys.com - 29 - sales@aero-electric.com MS27484 RFI Grounding Plug AE284 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight G [ F MAX MAX COUPLING NUT E ACCESSORY THREAD BLUE COLOR BAND RFI STRIP MASTER KEY MIL-DTL- 38999 S II H GROMMET EXTENSION [A [C MIN SHELL MAX GROMMET D NO. OF TEETH 4 MINOR KEYS Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A Minimum [C D E Maximum No of Teeth Accessory Thread Shell Size inch mm inch mm 8 .337 8.56 .299 7.59 10 .465 11.81 .427 12 .557 14.15 14 .702 17.83 16 .827 18 .927 20 [F Maximum G H Maximum Grommet Extension UNEF-2A inch mm inch mm inch mm 12 7/16-28 .750 19.05 .916 23.27 .150/.090 3.81/2.29 10.85 16 9/16-24 .859 21.82 .916 23.27 .150/.090 3.81/2.29 .541 13.74 20 11/16-24 1.031 26.19 .916 23.27 .150/.090 3.81/2.29 .666 16.92 24 13/16-20 1.156 29.36 .916 23.27 .150/.090 3.81/2.29 21.01 .791 20.09 28 15/16-20 1.281 32.54 .916 23.27 .150/.090 3.81/2.29 23.55 .897 22.78 32 1-1/16-18 1.406 35.71 .916 23.27 .150/.090 3.81/2.29 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 www.conesys.com - 30 - sales@aero-electric.com MS27500 Plug with 90 Backshell AE200 Bayonet Coupling, Crimp Removable, Rear Release, Low Profile/Light Weight [ F MAX COUPLING NUT BLUE COLOR BAND MASTER KEY MIL-DTL- 38999 S II [A MIN SHELL Y MAX W MAX 4 MINOR KEYS L MAX Page 22 Page 34 Pages 17-19 Page 21 Pages 15, 16 Page 32 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A [F Minimum L Maximum W Maximum Y Maximum Maximum Shell Size 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 www.conesys.com - 31 - sales@aero-electric.com MIL-DTL-38999 Polarization Series II Keying Positions MIL-DTL- 38999 S II NORMAL C N A MASTER KEYWAY B D 10 DATUM F 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). Keying Positions BSC Shell Size 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 www.conesys.com - 32 - sales@aero-electric.com MIL-DTL-38999 Series II Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts JAM NUT FLANGE MOUNT D MAX PANEL THICKNESS MIL-DTL- 38999 S II 4x [ C .109(2.77) .062(1.57) PANEL THICKNESS [B MIN F [E A Note 1: Flange Mounting Dimensions ([ B cutout and D MAX) listed only for back of panel mounting (MS27497 and MS27508). Note 2: D MAX includes mounting hardware. Flange and Jam Nut Mounting Dimensions A [B (TP) [C Minimum .005 D .13 [E Maximum +.010 -.000 F +.25 -.00 +.000 -.010 +.00 -.25 Shell Size 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 www.conesys.com - 33 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series II Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Military No. Military No. Military No. Military No. 22D Power/Signal M39029/58-360 M39029/57-354 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 16 Power/Signal M39029/58-364 M39029/57-358 Coax M39029/76-424 M39029/78-432 Power/Signal M39029/58-365 Plastic Contact Size MIL-DTL- 38999 S II 16 Coax 12 M81969/14-01 MS27488-22-1 -- MS27488-20-1 M81969/14-10 MS27488-16-1 M81969/14-03 M39029/57-359 MS27488-12-1 M81969/14-04 Positioner Positioner Insertion Tool Extraction Tool Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size/Type 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 M81969/8-03 M81969/8-04 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 22* M22520/2-01 M22520/2-09 M22520/2-06 M22520/1-01 M22520/1-04 M22520/1-04 M22520/2-01 M22520/2-10 M22520/2-10 16 M22520/1-01 M22520/1-04 M22520/1-04 16 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 20 Contact and Wire Data Crimp Well Data Wire Range Finished Wire [ Range Test Current Voltage DC Test Max. Drop Well Dia. Amps Millivolts inch inch mm AWG mm2 inch 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 Contact Size Minimum Well Dept Minimum Maximum * Inactive for new design Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com Note 2: Size 16 coax contacts purchased in bulk. - 34 - sales@aero-electric.com MIL-DTL-38999 Contact Installation Instructions Series II Contact Installation Instructions 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. 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. 4.1 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. 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. 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. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 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. 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. 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. 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 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 M81969/14-10 For coax contacts refer to instructions supplied with contacts. www.conesys.com - 35 - sales@aero-electric.com MIL-DTL- 38999 S II Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. MIL-DTL-38999 Features and Application Series III Features and Application Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. MIL-DTL-38999 Series III is the newest cylindrical connector designed for highest performance capabilities used in both general purpose and severe environment applications. 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. MIL-DTL- 38999 S III 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. 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. Elongated mounting holes permit the Series III Connector to intermount with various existing Mil-spec flange mounted receptacles, giving it a design replacement advantage. 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. 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. 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. 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 (commercial callouts only). Metric Accessory Thread - Metric thread results in additional wall thickness giving greater strength and shock resistance. 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. www.conesys.com - 36 - sales@aero-electric.com MIL-DTL-38999 Performance Specifications Series III Performance Specifications Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-38999. Operating Temperature Range Classes F, K, S and BZ*: -65C to +200C (-85F to +392F) Classes W and ZC*: -65C to +175C (-85F to +347F) 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: Corrosion Resistance Classes K, W, BZ* and ZC* withstand 500-hour salt spray. Classes F and S withstand 48-hour salt spray. Shock Pulse of approximate half sine wave of 300 G 15 percent magnitude with duration of 3 1 milliseconds applied in three axes. Durability Minimum of 500 mating cycles. 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. 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. 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. Voltage Rating * Not on QPL, can be supplied to Aero-Electric part number only. Service Rating M N I II Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level V RMS 1300 1000 1800 2300 50,000 Ft. V RMS 550 400 600 800 70,000 Ft. V RMS 350 260 400 500 100,000 Ft. V RMS 200 200 200 200 AC (RMS) 400 300 600 900 DC 550 450 850 1250 Note: The establishment of electrical safety factors is left entirely to the designer, as he is in the best position to know www.conesys.com exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 37 - sales@aero-electric.com MIL-DTL- 38999 S III 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 MIL-DTL-38999 Part Number Development Series III Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix D38999/ AE3 20 20 W W C C 35 35 P P N N -340 Shell Type (Specification Sheet Number) 20 = Wall mount receptacle 24 = Jam nut receptacle 26 = Self-locking, RFI grounding plug MIL-DTL- 38999 S III 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, H or 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 * 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. www.conesys.com 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. - 38 - sales@aero-electric.com D38999/20 Wall Mounting Receptacle AE320 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof 31.50(1.240) MAX A G MASTER KEYWAY H MAX MAX 7.11(.280) MIN FULL THREAD 2.16(.085) MAX GROMMET EXTENSION D [L MIL-DTL- 38999 S III MAX GROMMET J NUMBER OF TEETH F E MATING THREAD 4 MINOR KEYWAYS LOCKING INDICATOR BAND COLOR: RED C BLUE COLOR BAND (REAR RELEASE) K ACCESSORY THREAD B Page 38 Page 44 Pages 17-19 Page 37 Pages 15, 16 Page 42 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information 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). A B C (TP) D (TP) E G Maximum H J Maximum No. of Teeth Shell Size .012 .30 .008 .20 .008 .20 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 B 1.031 26.20 .812 20.62 .719 18.26 .194 4.93 .128 3.25 .820 20.83 .098 [L Maximum inch mm 12 .299 7.59 2.50 16 .427 10.85 C 1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 3.25 .820 20.83 .098 2.50 20 .541 13.74 D 1.220 31.00 .969 24.61 .906 23.01 .173 4.39 .128 3.25 .820 20.83 .098 2.50 24 .666 16.92 E 1.311 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 F 1.437 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 G 1.563 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 H 1.689 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 J 1.811 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 www.conesys.com - 39 - sales@aero-electric.com D38999/24 Jam Nut Receptacle AE324 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof A D 32.50 (1.280) MAX BLUE COLOR BAND (REAR RELEASE) G LOCKING INDICATOR BAND COLOR: RED MASTER KEYWAY 2.16(.085) MAX GROMMET EXTENSION [H B MAX GROMMET MIL-DTL- 38999 S III FLAT C F NUMBER OF TEETH K ACCESSORY THREAD E MATING THREAD J THREAD 4 MINOR KEYWAYS "O" RING SEAL HEX NUT PER D38999/28 PANEL THICKNESS 3.20(.126) 1.58(.062) Page 38 Page 44 Pages 17-19 Page 37 Pages 15, 16 Page 42 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information 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). A B C +.10 -.15 D F +.024 -.000 +.60 -.00 No. of Teeth G [H J Maximum Jam Nut Thread Shell Size .016 .40 +.004 -.006 +.035 -.004 +.90 -.10 inch mm inch mm inch mm inch mm inch mm inch mm 0.100R A 1.063 27.00 .651 16.53 .945/.859 24.00/21.82 .555 14.10 12 .087 2.20 .299 7.59 M17x1-6g B 1.252 31.80 .751 19.07 1.063/.984 27.00/24.99 .555 14.10 16 .087 2.20 .427 10.85 M20x1-6g C 1.374 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 D 1.500 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 E 1.626 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 F 1.811 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 G 1.937 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 H 2.063 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 J 2.189 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 www.conesys.com - 40 - sales@aero-electric.com D38999/26 Self-Locking, RFI Grounding Plug AE326 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof 31.00(1.220) MAX [ A BLUE COLOR BAND LOCATION OPTIONAL (REAR RELEASE) MASTER KEY MAX COUPLING NUT 2.16(.085) MAX GROMMET EXTENSION 7.11(.280) MIN FULL THREAD [ B RFI STRIP MIL-DTL- 38999 S III MAX GROMMET T NUMBER OF TEETH E MATING THREAD 4 MINOR KEYS Page 38 Page 44 Pages 17-19 Page 37 Pages 15, 16 Page 42 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A Maximum D ACCESSORY THREAD Note : Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). [B D E T Maximum Accessory Thread Metric Mating Thread Class 2B No. of Teeth Shell Size 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 C 1.157 29.40 .541 13.74 M18x1.0-6g 0.100R .8750-0.1P-0.3L 20 D 1.280 32.50 .666 16.92 M22x1.0-6g 0.100R 1.0000-0.1P-0.3L 24 E 1.406 35.70 .791 20.09 M25x1.0-6g 0.100R 1.1875-0.1P-0.3L 28 F 1.516 38.50 .897 22.78 M28x1.0-6g 0.100R 1.2500-0.1P-0.3L 32 G 1.642 41.70 1.022 25.96 M31x1.0-6g 0.100R 1.3750-0.1P-0.3L 36 H 1.768 44.90 1.147 29.13 M34x1.0-6g 0.100R 1.5000-0.1P-0.3L 40 J 1.890 48.00 1.272 32.31 M37x1.0-6g 0.100R 1.6250-0.1P-0.3L 44 www.conesys.com - 41 - sales@aero-electric.com MIL-DTL-38999 Polarization Series III Keying Positions D NORMAL MASTER KEYWAY A B C MIL-DTL- 38999 S III 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). Key/Keyway Shell Size Key/Keyway Positions BSC Identification Letter N A B C D E A 105 102 80 35 64 91 B 140 132 118 140 155 131 C 215 248 230 205 234 197 D 265 320 312 275 304 240 B (11) C (13) D (15) N A B C D E 95 113 90 53 119 51 141 156 145 156 146 141 208 182 195 220 176 184 236 292 252 255 298 242 E (17) F (19) G (21) H (23) J (25) N A B C D E 80 135 49 66 62 79 142 170 169 140 145 153 196 200 200 200 180 197 293 310 244 257 280 272 A (9) www.conesys.com - 42 - sales@aero-electric.com MIL-DTL-38999 Series III Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts JAM NUT FLANGE MOUNT 3.20(.126) 1.58(.062) PANEL THICKNESS 4x [ C [B MIN MIL-DTL- 38999 S III D [E A Note: Diameter B cutout dimensions are listed separately for back and front of panel mounting. A [B [B (TP) For Back Mounting Minimum For Front Mounting Minimum [C D [E .13 +.000 -.010 inch mm inch mm inch mm .128 3.25 .670 17.02 .700 17.78 15.88 .128 3.25 .771 19.59 .825 20.96 Shell Size inch mm inch mm inch mm A (9) .719 18.26 .656 16.66 .516 13.11 B (11) .812 20.62 .796 20.22 .625 .005 +.00 -.25 +.010 -.000 +.25 -.00 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 www.conesys.com - 43 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series III Contacts, Plastic Insertion/Removal Tools and Seal Plugs Contact Size MIL-DTL- 38999 S III 22D 20 16 12 12 Coax 12 Coax 10 (Power) 8 Coax 8 Twinax Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Power Coax Twinax Military No. M39029/58-360 M39029/58-363 M39029/58-364 M39029/58-365 M39029/28-211 M39029/102-558 M39029/58-528 M39029/60-367 M39029/90-529 Military No. M39029/56-348 M39029/56-351 M39029/56-352 M39029/56-353 M39029/75-416 M39029/103-559 M39029/56-527 M39029/59-366 M39029/91-530 Military No. MS27488-22-1 MS27488-20 -1 MS27488-16 -1 Plastic Military No. M81969/14-01 M81969/14-10 M81969/14-03 MS27488-12-1 M81969/14-04 M85049/81-10*** MS27488-8-1 MS27488-8-1 M81969/14-05 M81969/14- 06 M81969/14-12 Positioner Positioner Insertion Tool Extraction Tool For Socket Contacts Military No. M22520/2-07 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 -- M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 Metal Military No. M81969/8-01 Metal Military No. M81969/8-02 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M81969/8-11 M81969/8-12 M81969/8-13** M81969/8-14 M22520/5-200 -- -- Crimping and Metal Insertion/Extraction Tools Crimp Tool 16 12 12 Coax Inner 12 Coax Outer 10 ( Power) 8 Coax Inner Military No. M22520/2- 01 M22520/1- 01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 -- M22520/2-01 8 Coax Outer M22520/5-01 8 Twinax Center M22520/2-01 For Pin Contacts Military No. M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 -- M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 8 Twinax Outer & Intermediate M22520/5-01 M22520/5-200 Contact Size/Type 22D 20 Contact and Wire Data Contact Size 22D 20 16 12 10 Test Current* Voltage* DC Test Amps 5.0 7.5 13.0 23.0 33.0 Max. Drop Millivolts 73 55 49 42 33 Crimp Well Data Well Dia. inch .0345 .0010 .047 .001 .067 .001 .100 .002 .137 .003 Minimum Well Dept inch mm .141 3.58 .209 5.31 .209 5.31 .209 5.31 .355 9.02 AWG 28-22 24-20 20-16 14-12 12-10 mm2 .08-.33 .20-.52 .52-1.31 2.08-3.31 3.31-5.26 Finished Wire [ Range Minimum inch mm .030 .76 .040 1.02 .065 1.65 .097 2.46 .135 3.42 Maximum inch mm .054 1.37 .083 2.11 .109 2.77 .142 3.61 .162 4.12 Note: Size 8 coax contacts are used with M17/095-RG180 cable, while size 8 Twinax contacts are used with M17/176-00002 cable. 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. www.conesys.com Wire Range - 44 - sales@aero-electric.com MIL-DTL-38999 Contact Installation Instructions Series III Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 2. Cycle the tool to be sure the indentors are open. 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. 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. 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. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 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. 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. 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. 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 M22520/1-01 M22520/2-09 M22520/07 M81969/14-01 M22520/1-04 Red M22520/1-04 red M22520/2-01 M22520/2-10 M22520/2-10 20 M39029/58-363 M39029/56-351 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. www.conesys.com M81969/14-10 * Contact Daniels Manufacturing for crimp tool/positioner. - 45 - sales@aero-electric.com MIL-DTL- 38999 S III 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. MIL-DTL-5015 Features and Application Series III (Rear Release) Features and Application Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. 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. 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. MIL-DTL- 5015 S III 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. 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. 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. 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. 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. www.conesys.com - 46 - sales@aero-electric.com MIL-DTL-5015 Performance Specifications MS345*/AE55* Performance Specifications 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: Operating Temperature Range Classes KS and LS: -55C to +200C (-67F to +392F) Classes KT and W: -55C to +175C (-67F to +347F) Class L: -55C to +200C (-67F to +392F) Class A*: -55C to +200C (-67F to +392F) 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. 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. 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. 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 Maximum Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level 50,000 Ft 70,000 Ft. 110,000 Ft. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS Inst. 200 250 1000 400 260 200 A 500 700 2000 600 360 200 D 900 1250 2800 675 400 200 E 1250 1750 3500 750 440 200 B 1750 2450 4500 825 480 200 C 3000 4200 7000 975 560 200 * Not MS approved, available to Aero-Electric part number only. ** To be used by designer only as a guide. www.conesys.com - 47 - sales@aero-electric.com MIL-DTL- 5015 S III 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 MIL-DTL-5015 Series III Part Number Development Rear Release Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS34 AE5 50 50 L L 14S 14S - 5 5 P P X 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 fi f nish, ffirewall (n/a in MS3451, MS3452, MS3454) LS = Stainless steel shell, passivated MIL-DTL- 5015 S III 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 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. www.conesys.com 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. - 48 - sales@aero-electric.com MS3450 per AS34501 Wall Mount Receptacle AE550 Threaded Coupling, Crimp Removable, Rear Release L G MAX F D POLARIZING KEY B A MATING THREAD MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS 3 ACCESSORY TEETH J ACCESSORY THREAD 4x [ H HOLES Page 48 Page 56 Pages 63-68 Page 47 Pages 58-62 Page 58 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size 8S 10S 10SL 12 12S 14 14S 16 16S 18 20 22 24 28 32 36 40 Mating Thread Class 2A 1/2-28 UNEF 5/8-24 UNEF 5/8-24 UNEF 3/4-20 UNEF 3/4-20 UNEF 7/8-20 UNEF 7/8-20 UNEF 1-20 UNEF 1-20 UNEF 1 1/8-18 UNEF 1 1/4-18 UNEF 1 3/8-18 UNEF 1 1/2-18 UNEF 1 3/4-18 UNS 2-18 UNS 2 1/4-16 UN 2 1/2-16 UN www.conesys.com B .015 inch .083 .083 .083 .083 .083 .083 .083 .083 .083 .125 .125 .125 .125 .125 .125 .125 .125 D .38 mm 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 2.11 3.18 3.18 3.18 3.18 3.18 3.18 3.18 3.18 +.031 -.000 inch .562 .562 .562 .750 .562 .750 .562 .750 .562 .750 .750 .750 .812 .812 .875 .875 .875 Note 1: L MAX is same as L MAX for AE551 on next page. Note 2: Maximum grommet O.D. is same as [ E MAX for AE551 on next page. F +.79 -.00 mm 14.27 14.27 14.27 19.05 14.27 19.05 14.27 19.05 14.27 19.05 19.05 19.05 20.62 20.62 22.23 22.23 22.23 (TP) inch mm .594 15.09 .719 18.26 .719 18.26 .812 20.62 .812 20.62 .906 23.01 .906 23.01 .969 24.61 .969 24.61 1.062 26.97 1.156 29.36 1.250 31.75 1.375 34.93 1.562 39.67 1.750 44.45 1.938 49.23 2.188 55.58 - 49 - G .031 inch .875 1.000 1.000 1.094 1.094 1.188 1.188 1.281 1.281 1.375 1.500 1.625 1.750 2.000 2.250 2.500 2.750 J [H .79 mm 22.23 25.40 25.40 27.79 27.79 30.18 30.18 32.54 32.54 34.93 38.10 41.28 44.45 50.80 57.15 63.50 69.85 Classes L, LS, W +.010 +.25 -.005 -.13 inch mm .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .120 3.05 .147 3.73 .147 3.73 .173 4.39 .173 4.39 .173 4.39 Classes KS, KT +.010 +.25 -.005 -.13 inch mm .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .150 3.81 .177 4.50 .177 4.50 .177 4.50 .177 4.50 .177 4.50 .209 5.31 .209 5.31 .209 5.31 Accessory Thread Class 2A 1/2-20UNF 5/8-24UNEF 5/8-24UNEF 3/4-20UNEF 3/4-20UNEF 7/8-20UNEF 7/8-20UNEF 1-20UNEF 1-20UNEF 1-1/16-18UNEF 1-3/16-18UNEF 1-5/16-18UNEF 1-7/16-18UNEF 1-3/4-18UNS 2-18UNS 2-1/4-16UN 2-1/2-16UN sales@aero-electric.com MIL-DTL- 5015 S III BLUE COLOR BANDS MS3451 per AS34511 Cable Connecting Receptacle AE551 Threaded Coupling, Crimp Removable, Rear Release L MAX R ACROSS FLATS .083.015(2.11.38) FOR 8S-16S .125.015(3.18.38) FOR 18-40 M A POLARIZING KEY MATING THREAD MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 [E [S MAX GROMMET 3 ACCESSORY TEETH .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS MIL-DTL- 5015 S III BLUE COLOR BANDS Page 48 Page 56 Pages 63-68 Page 47 Pages 58-62 Page 58 V GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS ACCESSORY THREAD Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Mating Thread Class 2A [E L MAX Maximum inch mm 16 & 12 Contacts inch mm M 8, 4 & 0 Contacts inch mm R +.031 -.000 inch +.79 -.00 mm [S Accessory Thread Class 2A inch mm .031 inch 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 Shell Size www.conesys.com - 50 - .79 mm V sales@aero-electric.com MS3452 Box Mount Receptacle AE552 Threaded Coupling, Crimp Removable, Rear Release L S MAX R .083.015(2.11.38) FOR 8S-16S .125.015(3.18.38) FOR 18-40 M POLARIZING KEY A MATING THREAD [ GG BLUE COLOR BAND Page 48 Page 56 Pages 63-68 Page 47 Pages 58-62 Page 58 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size Mating Thread Class 2A [ GG 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 of catalog printing, MS3452 was not superseded by SAE document - AS34521. L MAX .016 inch .41 mm 16 & 12 Contacts inch mm M 8, 4 & 0 Contacts inch mm R +.031 -.000 inch +.79 -.00 mm S (TP) [T .031 inch .79 mm +.010 -.005 inch +.25 -.13 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 www.conesys.com - 51 - sales@aero-electric.com MIL-DTL- 5015 S III 4x [ T HOLES MS3454 per AS34541 Jam Nut Receptacle AE554 Threaded Coupling, Crimp Removable, Rear Release E B MAX .180(4.57) .165(4.19) D POLARIZING KEY SPRING PIN MS171430 MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS .196(4.98) .186(4.72) GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS 3 ACCESSORY TEETH A [ C H BLUE COLOR BAND ACCESSORY THREAD "O" RING BLUE COLOR BAND F MATING THREAD MIL-DTL- 5015 S III PANEL THICKNESS .128(3.25) MAX [ .032(.81) MAX SAFETY WIRE HOLE (3 EQALLY SPACED) Page 48 Page 56 Pages 63-68 Page 47 Pages 58-62 Page 58 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C Note: Maximum grommet O.D. is same as [ E MAX on next page. D E MAX Shell Size .005 inch .13 mm .010 inch .25 mm .005 inch .13 mm .005 inch .13 mm 16 & 12 Contacts inch mm 8, 4 & 0 Contacts inch mm F H Mating Thread Class 2A Accessory Thread Class 2A 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 www.conesys.com - 52 - sales@aero-electric.com MS3456 Straight Plug AE556 Threaded Coupling, Crimp Removable, Rear Release [ H MAX A MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 MAX POLARIZING KEYWAY .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS [ [ B E MAX GROMMET 3 TEETH EQUALLY SPACED C MATING THREAD F ACCESSORY THREAD BLUE COLOR BAND Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A Shell Size [B Maximum inch mm .005 inch Note: At time of catalog printing, MS3456 was not superseded by SAE document - AS34561. C .13 mm Mating Thread Class 2B MIL-DTL- 5015 S III Page 48 Page 56 Pages 63-68 Page 47 Pages 58-62 Page 58 3x [ .035(.89) SAFETY WIRE HOLES EQUALLY SPACED [E F Maximum inch mm Accessory Thread Class 2A H MAX 16 & 12 Contacts inch mm 8, 4 & 0 Contacts 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) www.conesys.com - 53 - sales@aero-electric.com MS3459 per AS34591 Self-Locking Plug AE559 Threaded Coupling, Crimp Removable, Rear Release [ C MAX L .340(8.64) .130(3.30) FOR 8,4, AND 0 CONTACTS MAX POLARIZING KEYWAY GROMMET EXTENSION .190(4.83) .130(3.30) FOR 16 AND 12 CONTACTS [ [ D E MAX GROMMET 3 ACCESSORY TEETH A MATING THREAD MIN FULL THREAD .290(7.37) FOR 8S-24 .467(11.86) FOR 28-40 BLUE COLOR BAND MIL-DTL- 5015 S III B ACCESSORY THREAD Page 48 Page 56 Pages 63-68 Page 47 Pages 58-62 Page 58 Shell Size Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Mating Thread Class 2B Accessory Thread Class 2A [C [D Maximum inch mm .005 inch [E L MAX .13 mm Maximum inch mm 16 & 12 Contacts inch mm 8, 4 & 0 Contacts 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) www.conesys.com - 54 - sales@aero-electric.com MIL-DTL-5015 Series III, Rear Release Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts .100(2.54) DIA. .095(2.41) [ C [ B E [ D MIL-DTL- 5015 S III MS3454 (AE554) CUTOUT A Flange and Jam Nut Mounting Dimensions A [B (TP) [C [D .25 Classes L, LS, W +.010 +.25 -.005 -.13 Classes KS, KT +.010 +.25 -.005 -.13 +.015 -.000 +.38 -.00 .005 inch mm inch mm .505 12.83 .323 8.20 3.81 .630 16.00 .385 9.78 3.81 .755 19.18 .448 11.38 3.81 .880 22.35 .510 12.95 3.81 1.005 25.53 .573 14.55 .177 4.50 1.130 28.70 .635 16.13 3.05 .177 4.50 1.255 31.88 .698 17.73 3.05 .177 4.50 1.380 35.05 .760 19.30 .147 3.73 .177 4.50 1.505 38.23 .823 20.90 .147 3.73 .177 4.50 1.755 44.58 .948 24.08 52.37 .173 4.39 .209 5.31 2.005 50.93 1.073 27.25 2.312 58.72 .173 4.39 .209 5.31 2.255 57.28 1.198 30.43 2.562 65.07 .173 4.39 .209 5.31 2.505 63.63 1.323 33.60 .010 Shell Size inch mm inch mm inch mm inch mm 8S .594 15.09 .562 14.27 .120 3.05 .150 3.81 10S, 10SL .719 18.26 .688 17.48 .120 3.05 .150 12, 12S .812 20.62 .812 20.62 .120 3.05 .150 14, 14S .906 23.01 .938 23.83 .120 3.05 .150 16, 16S .969 24.61 1.062 26.97 .120 3.05 .150 18 1.062 26.97 1.188 30.18 .120 3.05 20 1.156 29.36 1.312 33.32 .120 22 1.250 31.75 1.438 36.53 .120 24 1.375 34.93 1.562 39.67 28 1.562 39.67 1.812 46.02 32 1.750 44.45 2.062 36 1.938 49.23 40 2.188 55.58 www.conesys.com E - 55 - .13 sales@aero-electric.com MIL-DTL-5015 Contacts, Tools and Seal Plugs MS345*/AE55* Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Contact Size Type Military No. Military No. Military No. Military No. 16S Power/Signal N/A M39029/30-217 16 Power/Signal M39029/29-212 M39029/30-218 MS27488-16-1 M81969/14-03 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 0 Power M39029/29-216* M39029/30-222* MS27488-0-1** M81969/14-08 Locator Extraction Tool Plastic * No spare size 0, 4 and 8 contacts are provided in connector contact packages. ** Not supplied as part of connector contact packages. Crimping and Metal Insertion/Extraction Tools MIL-DTL- 5015 S III Crimp Tool Positioner Die Set Pin & Socket Contacts Pin & Socket Contacts Pin & Socket Contacts Metal Contact Size 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 and Wire Data Test Current Voltage DC Test Max. Drop Well Dia. Amps Millivolts inch inch mm AWG mm2 inch 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 8 46 26 .181 .002 .485 12.32 10-8 5.26-8.37 .132 3.35 .255 6.48 4 80 23 .281 .002 .485 12.32 6-4 13.30-21.15 .237 6.02 .370 9.40 0 150 21 .453 .002 .580 14.73 2-0 33.63-53.48 .360 9.14 .550 13.97 Contact Size Crimp Well Data Wire Range Minimum Well Dept Finished Wire [ Range Minimum Maximum 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 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. Note 2: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com - 56 - sales@aero-electric.com MIL-DTL-5015 Contact Installation Instructions MS345*/AE55* Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 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. 4.1 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. 4. Place the contact, mating end first, into the tool. 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. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 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. 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. 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. 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 0 M39029/29-216 M39029/30-222 M22520/23-01 -- M22520/23-05 M22520/23-13 M81969/14-08 I/R = Insertion/Removal * 16S socket contact is only used in shell sizes 8S, 10S, 10SL, 12S, 14S and 16S. www.conesys.com - 57 - sales@aero-electric.com MIL-DTL- 5015 S III 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. MIL-DTL-5015 Series III (Rear Release) Polarization, Insert Availability & Contact Information per MIL-STD-1651 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. L MASTER KEYWAY(KEY) OF A SHELL INSERT VERTICAL CENTERLINE Note: Be careful with alternate positions. See table below for position availability on layouts of interest. PIN INSERT MATING FACE (SOCKET INSERT IS OPPOSITE) MIL-DTL- 5015 S III Insert Availability, Contact Information and Clocking Positions Shell Size & Insert Arrangement Aero-Electric Status Contacts Total Insert Positions 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** A All 0 -- -- -- -- 10S-2 Yes Yes 1 1 16/16S** A All 0 -- -- -- -- 10SL-3*** Yes Yes 3 3 16/16S** A All 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** A All 0 70 145 215 290 12S-4 Yes Yes 1 1 16/16S** D All 0 -- -- -- -- 14-3 Yes Yes 1 1 8 A All 0 -- -- -- -- 14S-1* Yes Yes 3 3 16/16S** A All 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 0 90 180 270 -- 14S-9* Yes Yes 2 2 16/16S** A All 0 70 145 215 290 16-10 Yes Yes 3 3 12 A All 0 90 180 270 -- 16-11 Yes Yes 2 2 12 A All 0 35 110 250 325 16-12 Yes Yes 1 1 4 A All 0 -- -- -- -- 16S-1 Yes Yes 7 7 16/16S** A All 0 80 -- -- 280 16S-4 Yes Yes 2 2 16/16S** D All 0 35 110 250 325 16S-5* Yes Yes 3 3 16/16S** A All 0 70 145 215 290 16S-8 Yes Yes 5 5 16/16S** A All 0 -- 170 265 -- * Inactive for new design ** Pin contact is size 16, socket contact is size 16S *** Service Rating = Inst. for classes KS and KT only. www.conesys.com - 58 - sales@aero-electric.com MIL-DTL-5015 Series III (Rear Release) Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Contacts Aero-Electric Shell Size & Insert Arrangement Status QPL'd Total Tooled Number 18-1 Yes Yes 10 18-4 Yes Yes 4 18-5 Yes Yes 3 18-6 Yes Yes 1 Insert Positions Quantity by Size Service Contact Qty Size Rating Location 4 16 A B,C,F,G 6 16 Inst. All others 4 16 D 1 16 2 12 1 4 7 16 1 12 5 16 2 12 "L" Degrees W X Y Z 0 70 145 215 290 All 0 35 110 250 325 D All 0 80 110 250 280 D -- 0 -- -- -- -- A All 0 70 -- -- 290 Inst. All 0 80 110 250 280 -- 18-8 Yes Yes 8 18-9 Yes Yes 7 18-10* Yes Yes 4 4 12 A All 0 -- 120 240 18-11 Yes Yes 5 5 12 A All 0 -- 170 265 -- 18-12 Yes Yes 6 6 16 A All 0 80 -- -- 280 18-20* Yes Yes 5 5 16 A All 0 90 180 270 -- 20-2 Yes Yes 1 1 0 D --- 0 -- -- -- -- 20-3* Yes Yes 3 3 12 D All 0 70 145 215 290 20-4 Yes Yes 4 4 12 D All 0 45 110 250 -- 20-7 Yes Yes 8 4 16 D A,B,G,H 4 16 A All others 0 80 110 250 280 20-8 Yes Yes 6 4 16 2 8 Inst. All 0 80 110 250 280 20-11* Yes Yes 13 13 16 Inst. All 0 -- -- -- -- 3 12 2 8 A All 0 80 110 250 280 7 12 A All 0 80 -- -- 280 7 16 2 12 A All 0 80 110 250 280 1 16 5 12 A All 0 90 180 270 -- 6 16 3 12 A All 0 35 110 250 325 3 16 3 8 A All 0 80 110 250 280 2 16 2 8 A All 0 35 110 250 325 20-14 Yes No 5 20-15 Yes Yes 7 20-16 Yes Yes 9 20-17 Yes Yes 6 20-18 Yes Yes 9 20-22 Yes Yes 6 20-24* Yes Yes 4 20-27 Yes Yes 14 14 16 A All 0 35 110 250 325 20-29 Yes Yes 17 17 16 A All 0 80 -- -- 280 20-33 Yes Yes 11 11 16 A All 0 -- -- -- -- 22-1* Yes Yes 2 2 8 D All 0 35 110 250 325 * Inactive for new design www.conesys.com - 59 - sales@aero-electric.com MIL-DTL- 5015 S III N MIL-DTL-5015 Series III (Rear Release) Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Aero-Electric Shell Size & Insert Arrangement Status Contacts Total Insert Positions Quantity by Size Service Contact QPL'd Tooled Number Qty Size Rating Location N W X Y Z 22-2 Yes Yes 3 3 8 D All 0 70 145 215 290 22-9 Yes Yes 3 3 12 E All 0 70 145 215 290 3 16 2 8 D All 0 80 110 250 280 1 16 D E 4 12 A All others 0 35 110 250 325 19 16 A All 0 80 110 250 280 3 16 A C,D,E 5 16 D All others 0 80 110 250 280 22-12 Yes Yes 5 22-13* Yes Yes 5 22-14** Yes Yes 19 "L" Degrees MIL-DTL- 5015 S III 22-18 Yes Yes 8 22-19 Yes Yes 14 14 16 A All 0 80 110 250 280 22-20* Yes Yes 9 9 16 A All 0 35 110 250 325 22-22 Yes Yes 4 4 8 A All 0 -- 110 250 -- 1 12 D H 7 12 A All others 0 35 -- 250 -- 1 8 D J 8 16 A All others 0 80 -- 250 280 3 16 A E,F,G 4 16 D All others 0 80 110 250 280 7 12 D All 0 80 -- -- 280 3 16 1 0 D All 0 80 110 250 280 3 12 D A,G,H 5 12 A All others 0 80 110 250 280 14 16 2 12 A All 0 80 110 250 280 22-23 Yes Yes 8 22-27 Yes Yes 9 22-33* Yes Yes 7 24-2 Yes Yes 7 24-4 Yes Yes 4 24-6 Yes Yes 8 24-7 Yes Yes 16 24-9* Yes Yes 2 2 4 A All 0 35 110 250 325 24-10 Yes Yes 7 7 8 A All 0 80 -- -- 280 6 12 3 8 A All 0 35 110 250 325 3 12 2 4 A All 0 80 110 250 280 9 16 2 12 D All 0 80 110 250 280 9 16 1 8 D All 0 80 110 250 280 24-11 Yes Yes 9 24-12 Yes Yes 5 24-20 Yes Yes 11 24-21 Yes No 10 24-22 Yes Yes 4 4 8 D All 0 45 110 250 -- 24-27 Yes Yes 7 7 16 E All 0 80 -- -- 280 24-28 Yes Yes 24 24 16 Inst. All 0 80 110 250 280 * Inactive for new design ** Alternate positions X, Y are cancelled after June 26, 1968. www.conesys.com - 60 - sales@aero-electric.com 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 Status QPL'd 28-1 Yes Contacts Total Tooled Yes Number 9 28-2 Yes Yes 14 28-3 Yes Yes 3 28-5 Yes Yes Yes 5 12 Quantity by Size Service Contact Qty Size Rating Location 2 12 D A,E 4 12 A B,D,F,H 1 8 D J A G,C D 2 8 12 16 2 12 "L" Degrees N W X Y Z 0 80 110 250 280 All 0 35 110 250 325 E All 0 70 145 215 290 D All 0 35 110 250 325 0 80 110 250 280 3 8 2 16 1 12 2 4 2 12 E L,M 1 16 D B 9 16 A All others 6 16 6 12 D All 0 80 110 250 280 18 16 4 12 A All 0 80 110 250 280 28-9 Yes Yes 12 28-11 Yes Yes 22 28-12 Yes Yes 26 26 16 A All 0 90 180 270 -- 28-15 Yes Yes 35 35 16 A All 0 80 110 250 280 28-16* Yes Yes 20 20 16 A All 0 80 110 250 280 2 16 B H,M 2 16 D A,B 2 16 0 80 110 250 280 4 12 A All others 4 16 10 12 A All 0 80 110 250 280 37 16 A All 0 80 110 250 280 3 16 3 4 D All 0 70 145 215 290 1 12 2 12 0 80 110 250 280 2 0 4 16 2 12 2 4 1 0 28-19 Yes Yes 10 28-20 Yes Yes 14 28-21 Yes Yes 37 28-22 Yes Yes 6 32-1 Yes Yes 5 32-3 Yes Yes 9 32-5* Yes Yes 2 32-6 Yes Yes 23 2 0 16 16 2 12 3 8 2 4 E D A D,C B,E D All 0 80 110 250 280 D All 0 80 110 250 325 A All 0 80 110 250 280 * Inactive for new design www.conesys.com - 61 - sales@aero-electric.com MIL-DTL- 5015 S III 28-8 Yes Insert Positions MIL-DTL-5015 Series III (Rear Release) Insert Availability, Contact Information and Clocking per MIL-STD-1651 Insert Availability, Contact Information and Clocking Positions Aero-Electric Shell Size & Insert Arrangement 32-7 32-8* 32-10* Status QPL'd Yes Yes Yes Contacts Total Tooled Yes Yes Yes Number 35 30 7 MIL-DTL- 5015 S III 8 Insert Positions Quantity by Size Service Contact Qty Size Rating Location 4 16 Inst. A,B,h,j 24 16 7 12 A All others 24 16 6 12 A All 2 16 E A,F 1 16 B G 2 8 D B,E 2 4 A C,D 6 12 2 0 D "L" Degrees N W X Y Z 0 80 125 235 280 0 80 125 235 280 0 80 110 250 280 All 0 35 110 250 280 32-15 Yes Yes 32-17 Yes Yes 4 4 4 D All 0 45 110 250 --- 32-22** Yes Yes 54 54 16 A All 0 80 110 250 280 32-63 Yes Yes 5 5 4 D All 0 -- -- -- -- 32-73 Yes Yes 46 46 16 A All 0 36 -- -- -- 3 12 3 0 D All 0 70 145 215 290 4 0 A All 0 -- 120 240 -- 4 4 2 0 A All 0 35 110 250 325 40 16 7 12 A All 0 80 110 250 280 46 16 1 12 A All 0 80 110 250 280 14 16 14 12 2 8 A All 0 80 125 235 280 A All 0 80 125 235 280 A All 0 65 125 225 310 A All 0 72 144 216 288 36-3 Yes No 6 36-5 Yes Yes 4 36-6 Yes Yes 6 36-7 Yes Yes 47 36-8 Yes Yes 47 36-9 Yes Yes 31 36-10 Yes Yes 48 40-10 40-56 Yes Yes Yes Yes 29 85 1 4 48 16 16 16 9 8 4 4 85 16 * Inactive for new design ** Alternate positions U (100 degrees) and V (260 degrees) are also available per MIL-STD-1651. www.conesys.com - 62 - sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangements Views A C A C A B B A B B 8S-1 1- #16 10S-2 1- #16 10SL-3 3- #16 A D 12S-3 2- #16 14-3 1- #8 12S-4 1- #16 E A B C A C A B B A C D E B C B D 14S-5 5- #16 B B 14S-6 6- #16 14S-7 3- #16 16-10 3- #12 14S-9* 2- #16 16-11 2- #12 H E F A D G E B B I G A C F B B C C J D E 16-12 1- #4 16S-1 7- #16 B A C D A A 16S-4 2- # 16 16S-5* 3- #16 18-1 10- #16 16S-8 5- #16 G F A A D F A E C B 18-5 1- #16, 2- #12 18-6 1- #4 C D C B 18-8 7- #16, 1- #12 A 18-9 5- #16, 2- #12 18-10* 4- #12 F E A B B D 18-4 4- #16 D B G H C C E A B A E D A A E B C C B D B C D C 18-11 5- #12 18-12 6- #16 18-20* 5- # 16 20-2 1- #0 20-3* 3- #12 * Inactive for new design www.conesys.com - 63 - sales@aero-electric.com MIL-DTL- 5015 S III 14S-2 4- #16 14S-1* 3- #16 A F A C 12-5 1- #12 10SL-4 2- #16 MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangements Views A L C B D A G E C B E B A F E M F D H G F C C B A D E A D 20-4 4- #12 20-8 4- #16, 2- #8 B C J D 20-7 8- #16 K H N 20-11* 13- #16 20-14 3- #12, 2- #8 F E F A F G G E G E B D A MIL-DTL- 5015 S III E A D B A F F H I H I B D A C D C C B E D C B 20-15 7- #12 C 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 M A B K A J K I B H J B N L C C D K C H E D H E 20-27 14- #16 D F F G E 20-29 17- #16 20-33 11- #16 22-1* 2- #8 A A A B L R J M F 20-24* 2- #16, 2- #8 M P S G B C T D A N L L D A M A A U K E B J E C B B C 22-2 3- #8 22-9 3- #12 22-12 3- #16, 2- #8 B P R C D B C D V S H C N T G 22-13* 1- #16, 4- #12 F E 22-14 19- #16 * Inactive for new design www.conesys.com - 64 - sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangements Views G A G B K A G H A D A A L F C J F M P B H F H B J B N H D C E G E E C D E B C C F D 22-18 8- #16 D 22-19 14- #16 22-20* 9- #16 22-22 4- #8 22-23 8- #12 C A F D B H A G A D B A E C B H G G B C B E A D F F G E C D C E D 22-27 1- #8, 8- #16 L 22-33* 7- #16 A 24-4 3- #16, 1- #0 A A F B M K 24-2 7- #12 C A E C E J B 24-6 8- #12 N P B D B A D E F G B I E O D H F C D G G 24-7 14- #16, 2- #12 24-9* 2- #4 A 24-10 7- #8 24-11 6- #12, 3- #8 A J B A L E B F G K A G K J K F 24-20 9- #16, 2- #12 M H S N J U T Q P V D C E G F L R F D C C G D B A D C 24-12 3- #12, 2- #4 B H H C J H B E 24-21 9- #16, 1- #8 C E W X Y Z D 24-22 4- #8 24-27 7- #16 24-28 24- #16 * Inactive for new design www.conesys.com - 65 - sales@aero-electric.com MIL-DTL- 5015 S III F J MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangements Views K H A A J J G A A B L H C B P M C E G F E D N B C D D F 28-1 6- #12, 3- #8 28-2 12- #16, 2- #12 28-3 3- #8 J A G 28-5 2- #16, 1- #12, 2- #4 J A H R E N A U K MIL-DTL- 5015 S III P J G L C F E B E K L S X Y M U T a Z e d I D V A T L W S H U V R Q P C B N K P G D C L M G J h G F E D F H m E 28-15 35- #16 A E H E k l C B 28-19 6- #16, 4- #12 28-16* 20- #16 28-20 4- #16, 10- #12 A A F D G F A J K N G 28-12 26- #16 B L C M F H M c g f B N b j A E W J 28-11 18- #16, 4- #12 G F K R X K D 28-9 6- #16, 6- #12 J J H X M A D D Y L H T E 28-8 2- #12, 10- #16 C U V L S C C Z M W K P B d M D T b G R C a V B B B S N F K A P M F C E H L B B C J H E K L M N P A C R D E S U T a c b g V W e d j h k n p X f E D m 28-21 37- #16 D B 28-22 3- #16, 3- #4 C 32-1 3- #12, 2- #0 * Inactive for new design www.conesys.com J G s r F B Z - 66 - H 32-3 4- #16, 2- #12, 2- #4, 1- #0 sales@aero-electric.com MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangements Views B A C A G N J R d h R P S S Y e k V f G M a H J a W P X R b O G S 32-7 28- #16, 7- #12 32-8* 24- #16, 6- #12 D N S E B E D b F C D C P U T X e j h n t w z AA AC AE AF 32-17 4- #4 AG 32-22 54- #16 21 20 E A 1 22 36 18 3 23 35 44 17 37 34 33 31 30 32-63 5- #4 12 B 27 7 28 29 13 C 6 39 40 14 D 8 C 9 11 B D E 26 46 41 B 5 38 42 32 15 D F 4 24 25 45 43 16 A 2 19 A r v y AD 32-15 6- #12, 2- #0 k u x f q p s W a d G 32-10* 3- #16, 2- #8, 2- #4 R V Z Y c AB B J M O g m H E H L K C B G A D G B C F C 10 32-73 46- #16 36-3 3- #12, 3- #0 36-5 4- #0 * Inactive for new design www.conesys.com - 67 - sales@aero-electric.com MIL-DTL- 5015 S III A A A F C F L U 32-6 16- #16, 2- #12, 3- #8, 2- #4 B K D V 32-5* 2- #0 E V e I b X W A I O d C N T g U c Z B B U L D N F j Z T Y K A M L O X H T E H I K M J c F E P W D MIL-STD-1651 Insert Arrangements (Pin Front View) for MIL-DTL-5015 Connectors Insert Arrangements Views A A B M Z Y e n C M K H b Y v w x 36-6 4- #4, 2- #0 w MIL-DTL- 5015 S III O C U Z I 36-8 46- #16, 1- #12 B D y z A C A r t v 36-7 40- #16, 7- #12 M S j p x y z e h u s r D a d k n m V Z c g f p D B E G F E F H G D J H K L M N K J a d V E J P Y H O A W X L R Y g I c b j h m u t G q p n L M O N Q P k s r v w y T a Z f U T C F b c S R X e d K W Q P V B e f R U T s u L P X m g k t J O W c f j E S b a d h N X W F I T S V D G N R P U E J I L O B G H K B C E F F A D C R U S x T W V z X Y N b Z 36-9 14- #16, 14- #12, 2- #8, 1- #4 36-10 48- #16 A E N X h F P Y j i t AC AP k m v w AD AE AF AR AS AT BA BJ BL BS d y W q z AA AB AN AK AL AM AV AW AX BE BN BU s r AJ BD g f AU BM BT M V p x BC BB BK c n AH L U b u AZ K T a Z D J S R 40-10 16- #16, 9- #8, 4- #4 C B H a c BF BP AY BH BR BV 40-56 85- #16 www.conesys.com - 68 - sales@aero-electric.com MIL-DTL-26482 Features and Application Series 2 Features and Application 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. 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 intermountable and interchangeable with both solder and front-release crimp Series 1. They are also identical to the inactivated MIL-DTL- 83723 Series I connectors. 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. Series 2 connectors are widely used on commercial, military and aerospace systems requiring general-purpose, miniature cylindrical bayonet coupling connectors. 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. 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 incorporate "O" ring seals, designed for rear panel "D" hole mounting. MIL-DTL- 26482 S 2 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. www.conesys.com - 69 - sales@aero-electric.com MIL-DTL-26482 Performance Specifications Series 2 Performance Specifications Durability Mated connectors withstand a minimum of 250 mating cycles for RFI plug (MS3475) and 500 cycles for standard plug (MS3476). Operating Temperature Range Classes A, L and S*: -55C to +200C (-67F to +392F) Classes W and ZC*: -55C to +175C (-67F to +347F) 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: 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 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. Corrosion Resistance Classes A, S*, W and ZC* withstand 500-hour salt spray. Class L withstands 48-hour salt spray. Vibration Mated connectors withstand the following vibration levels: Random vibration per MIL-STD-202, method 214, test condition II, letter J. MIL-DTL- 26482 S 2 Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-26482 Series 2. 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. 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. 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. * Not on QPL, can be supplied to Aero-Electric P/N only. Voltage Rating 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. DC V RMS V RMS V RMS V RMS AC (RMS) I 600 850 1,500 500 375 200 II 1,000 1,275 2,300 750 500 200 ** To be used by designer only as a guide. www.conesys.com - 70 - sales@aero-electric.com MIL-DTL-26482 Part Number Development Series 2 Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix MS34 AE7 70 70 L L 12 12 - 10 10 P P W 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 MIL-DTL- 26482 S 2 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 * Not on QPL, can be supplied to Aero part number only. Consult factory for availability. 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 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. www.conesys.com 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. - 71 - sales@aero-electric.com MS3470 Narrow Flange Receptacle AE770 Bayonet Coupling, Crimp Removable, Rear Release D MAX A MAX PANEL THICKNESS .125(3.18) MAX B E F MASTER KEYWAY .290 (7.37) MIN FULL THREAD .190 (4.83) .130 (3.30) GROMMET EXTENSION 3 ACCESSORY TEETH [ 4x [ C H 3 BAYONET PINS MOUNTING HOLES G ACCESSORY THREAD 4 MINOR KEYWAYS BLUE COLOR BAND BLUE COLOR BAND MIL-DTL- 26482 S 2 MAX PANEL THICKNESS & SCREWHEAD .087(2.21) S.S. 8-18 .212(5.38) S.S. 20-24 Page 71 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C Note: Maximum grommet O.D. is same as [ C MAX on page 74. D E F G Shell Size .005 .13 .016 .41 +.016 -.015 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 10 .954 24.23 .719 18.26 .120 3.05 1.215 30.86 .062 1.57 .446 12 1.047 26.59 .812 20.62 .120 3.05 1.215 30.86 .062 1.57 14 1.141 28.98 .906 23.01 .120 3.05 1.215 30.86 .062 1.57 16 1.234 31.34 .969 24.61 .120 3.05 1.215 30.86 .062 18 1.328 33.73 1.062 26.97 .120 3.05 1.215 30.86 .062 20 1.453 36.91 1.156 29.36 .120 3.05 1.275 32.39 22 1.578 40.08 1.250 31.75 .120 3.05 1.275 24 1.703 43.26 1.375 34.93 .147 3.73 1.275 Maximum www.conesys.com (TP) Maximum +.41 -.38 [H Accessory Thread Class 2A .003 .08 inch mm 1/2-20UNF .471 11.96 11.33 5/8-24UNEF .588 14.94 .446 11.33 3/4-20UNEF .748 19.00 .446 11.33 7/8-20UNEF .873 22.17 1.57 .446 11.33 1-20UNEF .998 25.35 1.57 .446 11.33 1-1/16-18UNEF 1.123 28.52 .094 2.39 .571 14.50 1-3/16-18UNEF 1.248 31.70 32.39 .094 2.39 .571 14.50 1-5/16-18UNEF 1.373 34.87 32.39 .094 2.39 .604 15.34 1-7/16-18UNEF 1.498 38.05 - 72 - sales@aero-electric.com MS3471 Cable Connecting Receptacle AE771 Bayonet Coupling, Crimp Removable, Rear Release A C MAX MAX MASTER KEYWAY .290 (7.37) MIN FULL THREAD D E .190 (4.83) .130 (3.30) GROMMET EXTENSION 3 ACCESSORY TEETH [F [B 4 MINOR KEYWAYS 3 BAYONET PINS G ACCESSORY THREAD BLUE COLOR BANDS Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A [B Note: Maximum grommet O.D. is same as [ C MAX on page 74. C D E [F Shell Size .020 .51 .016 .41 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 Maximum www.conesys.com Maximum - 73 - +.41 -.38 .003 G +.016 -.015 .08 Accessory Thread Class 2A sales@aero-electric.com MIL-DTL- 26482 S 2 Page 71 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 MS3472 Wide Flange Receptacle AE772 Bayonet Coupling, Crimp Removable, Rear Release D A MAX MAX PANEL THICKNESS .125(3.18) MAX B F MASTER KEYWAY E .190 (4.83) .130 (3.30) GROMMET EXTENSION .290 (7.37) MIN FULL THREAD 3 ACCESSORY TEETH [C [H [ .150.005 ([ 3.81.13) MOUNTING HOLES MAX GROMMET 3 BAYONET PINS G ACCESSORY THREAD 4 MINOR KEYWAYS BLUE COLOR BAND BLUE COLOR BAND MIL-DTL- 26482 S 2 MAX PANEL THICKNESS & SCREWHEAD .118(3.00) S.S. 8-18 .212(5.38) S.S. 20-24 Page 71 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B D [C E F G [H Shell Size .016 .41 +.016 -.015 inch mm inch mm inch mm inch mm inch mm inch mm 8 1.065 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 Maximum www.conesys.com (TP) Maximum Maximum - 74 - +.41 -.38 Accessory Thread Class 2A .003 inch mm .08 sales@aero-electric.com MS3474 Jam Nut Receptacle AE774 Bayonet Coupling, Crimp Removable, Rear Release C MAX A E D MASTER KEYWAY .290(7.37) MIN FULL THREAD "O" RING .190 (4.83) .130 (3.30) GROMMET EXTENSION F 3X REAR ACCESSORY TEETH FLAT [B 3 BAYONET PINS G BLUE COLOR BAND ACCESSORY THREAD (SAME AS FOR MS3472 ON PREVIOUS PAGE) H THREAD HEX NUT PER MS3186 EXCEPT FOR THICKNESS BLUE COLOR BAND .125(3.18) .108(2.74) PANEL THICKNESS .250(6.35) S.S. 20-24 .062(1.57) Page 71 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A [B Note: Maximum grommet O.D. is same as [ E MAX on page 76. C D E F H Flat .005 .13 Jam Nut Thread mm inch mm UNEF-2A 17.96/16.71 .525 13.34 9/16-24 17.96/16.71 .650 16.51 11/16-24 .707/.658 17.96/16.71 .813 20.65 7/8-20 .707/.658 17.96/16.71 .937 23.80 1-20 2.87/2.18 .707/.658 17.96/16.71 1.061 26.95 1-1/8-18 2.87/2.18 .707/.658 17.96/16.71 1.186 30.12 1-1/4-18 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.311 33.30 1-3/8-18 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.436 36.47 1-1/2-18 32.39 .148/.096 3.76/2.44 .772/.721 19.61/18.31 1.561 39.65 1-5/8-18 +.000 -.031 +.00 -.79 +.000 -.031 +.00 -.79 inch mm inch mm inch mm inch mm inch 8 .954 24.23 1.078 27.38 1.215 30.86 .113/.086 2.87/2.18 .707/.658 10 1.078 27.38 1.203 30.56 1.215 30.86 .113/.086 2.87/2.18 .707/.658 12 1.266 32.16 1.391 35.33 1.215 30.86 .113/.086 2.87/2.18 14 1.391 35.33 1.516 38.51 1.215 30.86 .113/.086 2.87/2.18 16 1.516 38.51 1.641 41.68 1.215 30.86 .113/.086 18 1.641 41.68 1.766 44.86 1.215 30.86 .113/.086 20 1.828 46.43 1.954 49.63 1.275 32.39 22 1.954 49.63 2.078 52.78 1.275 24 2.078 52.78 2.203 55.96 1.275 Shell Size www.conesys.com Maximum - 75 - sales@aero-electric.com MIL-DTL- 26482 S 2 .187(4.75) S.S. 8-18 .062(1.57) MS3476 Straight Plug AE776 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX .320(8.13) MIN [C MAX COUPLING NUT .290 (7.37) MIN FULL THREAD BLUE COLOR BAND MASTER KEY 3 ACCESSORY TEETH EQUALLY SPACED [E [A [ B MAX MAX GROMMET INSERT .190 (4.83) .130 (3.30) GROMMET EXTENSION 4 MINOR KEYS MIL-DTL- 26482 S 2 Page 71 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 D ACCESSORY THREAD Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A [B Maximum [C D Maximum Accessory Thread Class 2A Shell Size .003 .08 inch mm inch mm inch mm 8 .285 7.24 .355 9.02 .782 19.86 10 .402 10.21 .483 12.27 .926 12 .516 13.11 .595 15.11 14 .641 16.28 .720 18.29 16 .766 19.46 .845 18 .855 21.72 .945 20 .980 24.89 22 1.105 24 1.229 www.conesys.com [E Maximum inch mm 1/2-20UNF .305 7.75 23.52 5/8-24UNEF .405 10.29 1.043 26.49 3/4-20UNEF .531 13.49 1.183 30.05 7/8-20UNEF .665 16.89 21.46 1.305 33.15 1-20UNEF .790 20.07 24.00 1.391 35.33 1-1/16-18UNEF .869 22.07 1.070 27.18 1.531 38.89 1-3/16-18UNEF .994 25.25 28.07 1.195 30.35 1.656 42.06 1-5/16-18UNEF 1.119 28.42 31.22 1.320 33.53 1.777 45.14 1-7/16-18UNEF 1.244 31.60 - 76 - sales@aero-electric.com MS3475 RFI Grounding Plug AE775 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX .320(8.13) MIN [C MAX COUPLING NUT .290 (7.37) MIN FULL THREAD BLUE COLOR BAND MASTER KEY RFI STRIP 3 ACCESSORY TEETH EQUALLY SPACED [B [A [E MAX INSERT MAX GROMMET .190 (4.83) .130 (3.30) GROMMET EXTENSION 4 MINOR KEYS MIL-DTL- 26482 S 2 Page 71 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 D ACCESSORY THREAD Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A [B Maximum [C D Maximum Accessory Thread Class 2A Shell Size .003 .08 inch mm inch mm inch mm 8 .285 7.24 .355 9.02 .782 19.86 10 .402 10.21 .483 12.27 .926 12 .516 13.11 .595 15.11 14 .641 16.28 .720 18.29 16 .766 19.46 .845 18 .855 21.72 .945 20 .980 24.89 22 1.105 24 1.229 www.conesys.com [E Maximum inch mm 1/2-20UNF .305 7.75 23.52 5/8-24UNEF .405 10.29 1.043 26.49 3/4-20UNEF .531 13.49 1.183 30.05 7/8-20UNEF .665 16.89 21.46 1.305 33.15 1-20UNEF .790 20.07 24.00 1.391 35.33 1-1/16-18UNEF .869 22.07 1.070 27.18 1.531 38.89 1-3/16-18UNEF .994 25.25 28.07 1.195 30.35 1.656 42.06 1-5/16-18UNEF 1.119 28.42 31.22 1.320 33.53 1.777 45.14 1-7/16-18UNEF 1.244 31.60 - 77 - sales@aero-electric.com AC3475 Arctic Coupling Nut, RFI Plug Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX [C MAX COUPLING NUT MASTER KEY .290 (7.37) MIN FULL THREAD RFI STRIP 3 ACCESSORY TEETH EQUALLY SPACED [B [E [A MAX GROMMET MAX INSERT .190 (4.83) .130 (3.30) GROMMET EXTENSION 4 MINOR KEYS D ACCESSORY THREAD AC3475 - 10- 7 P N Aero Prefix Polarization N = Normal (N included in part number marking) A, B, C, D, E or F (Alternate key positions) and W, X, Y or Z (Alternate insert clocking positions) Class (Material and Finish) - = Aluminum shell, cadmium olive drab over nickel ZC = Aluminum shell, zinc cobalt finish MIL-DTL- 26482 S 2 Contact Style Shell Size P = Pin S = Socket 8, 10, 12, 14, 16, 18, 20, 22 or 24 Layout See pages 82 thru 85 Page 80 Pages 84, 85 Page 70 Pages 82, 83 Page 82 Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A Shell Size 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). [B Maximum inch mm .003 inch [C .08 mm D Maximum inch mm Accessory Thread Class 2A [E Maximum 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 www.conesys.com - 78 - sales@aero-electric.com MIL-DTL-26482 Series 2 Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts [C [A [A F [E B [G D MS3470(AE770) MS3474(AE774) MS3472(AE772) MIL-DTL- 26482 S 2 Flange and Jam Nut Mounting Dimensions [A B [C (TP) D [E (TP) F [G Shell Size .005 .13 .010 .25 .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 Note: For [ C and [ E, MS3470 and MS3472 call out for tolerance of .010 (.25), however we recommend .005 (.13). www.conesys.com - 79 - sales@aero-electric.com MIL-DTL-26482 Contacts, Tools and Seal Plugs Series 2 Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Contact Size 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 Plastic * 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. Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size MIL-DTL- 26482 S 2 Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. M81969/8-205 M81969/8-206 Military No. Military No. Military No. M22520/1-01 M22520/1-02 M22520/1-02 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 M22520/1-01 M22520/1-02 M22520/1-02 M22520/2-01 M22520/2-02 M22520/2-02 M81969/8-205 M81969/8-206 20 20* Contact and Wire Data Test Current Voltage DC Test Max. Drop Well Dia. Amps Millivolts inch inch mm AWG 20 7.5 55 .049 .001 .155 3.94 16 13.0 49 .067 .001 .250 6.35 12 23.0 42 .100 .002 .250 6.35 Contact Size Crimp Well Data Wire Range Minimum Well Dept Finished Wire [ Range Minimum Maximum mm2 inch mm inch mm 24-20 .20-.52 .040 1.02 .083 2.11 20-16 .52-1.31 .053 1.35 .103 2.62 14-12 2.08-3.31 .097 2.46 .158 4.01 Note: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com - 80 - sales@aero-electric.com MIL-DTL-26482 Contact Installation Instructions Series 2 Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 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. 4.1 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. 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. 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. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. 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. 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. 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. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner M22520/1-01 M22520/1-02 Red M22520/1-02 Red M22520/2-01 M22520/2-02 M22520/2-02 Insertion/Removal Tool 20 M39029/4-110 M39029/5-115 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 M22520/2-01 M22520/2-02 M22520/2-02 M81969/14-11 M81969/39-01 * Aero-Electric proprietary size 20 contacts used in 8-2, 8-3 and 8-4 layouts only. www.conesys.com - 81 - sales@aero-electric.com MIL-DTL- 26482 S 2 Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. MIL-DTL-26482 Series 2 Polarization, Insert Availability & Contact Information per MIL-STD-1669 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. L MASTER KEYWAY (KEY) OF A SHELL INSERT VERTICAL CENTERLINE Note: Be careful with alternate positions. See table below for position availability on layouts of interest. PIN INSERT MATING FACE (SOCKET INSERT IS OPPOSITE) Insert Availability, Contact Information and Clocking Positions MIL-DTL- 26482 S 2 Insert Arrangement Aero-Electric Total Contact Quantity Status No. of By Size QPL'd Tooled Contacts 20 8-2* No Yes 2 8-3* No Yes 3 8-4* No Yes 8-33 Yes 8-98 Yes 10-6 16 Service Insert Positions In Degrees 12 Rating N W X Y Z 2 I 0 58 122 -- -- 3 I 0 60 210 -- -- 4 4 I 0 45 -- -- -- Yes 3 3 I 0 90 -- -- -- Yes 3 3 I 0 -- -- -- -- Yes Yes 6 6 I 0 90 -- -- -- 10-7** N/A Yes 7 7 -- 12-3 Yes Yes 3 12-8 Yes Yes 8 8 12-10 Yes Yes 10 10 14-2** N/A Yes 2 2 14-4 Yes Yes 4 4 14 -5 Yes Yes 5 14-9 Yes Yes 9 5 14-12 Yes Yes 12 8 14-15 Yes Yes 15 14 14-18 Yes Yes 18 14-19 Yes Yes 19 I 0 90 -- -- II 0 -- -- 180 -- I 0 90 112 203 292 I 0 60 155 270 295 I 0 -- -- -- -- I 0 45 -- -- -- II 0 40 92 184 273 I 0 15 90 180 240 4 I 0 43 90 -- -- 1 I 0 17 110 155 234 18 I 0 15 90 180 270 19 I 0 30 165 315 -- 3 5 4 ** 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. * 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". www.conesys.com - 82 - sales@aero-electric.com MIL-DTL-26482 Series 2 Polarization, Insert Availability & Contact Information per MIL-STD-1669 Insert Availability, Contact Information and Clocking Positions Aero-Electric Total Contact Quantity Status No. of By Size Insert Arrangement QPL'd Tooled Contacts 16-8 Yes Yes 8 16-14 Yes Yes 14 8 16-23 Yes Yes 23 22 16-26 Yes Yes 26 26 20 12 Yes Yes 8 Yes Yes 11 18-30 Yes Yes 30 29 18-32 Yes Yes 32 32 20-16 Yes Yes 16 20-24 Yes Yes 24 24 20-39 Yes Yes 39 37 20-41 Yes Yes 41 41 22-12 Yes Yes 12 22-21 Yes Yes 21 22-41 Yes Yes 41 27 22-55 Yes Yes 55 55 22-95 Yes Yes 32 26 24-19 Yes No 19 24-31 Yes Yes 31 24-61 Yes Yes 61 6 1 8 Rating N W X Y Z II 0 54 152 180 331 I 0 25 78 180 240 I 0 158 270 -- -- I 0 60 -- 275 338 I 0 180 -- -- -- 11 II 0 62 119 241 340 1 I 0 180 193 285 350 I 0 85 138 222 265 II 0 238 318 333 347 I 0 70 145 215 290 I 0 63 144 252 333 I 0 45 126 225 -- I 0 -- -- -- -- 21 II 0 16 135 175 349 14 I 0 39 135 264 -- I 0 30 142 226 314 6 I 0 26 180 266 -- 19 II 0 30 165 315 -- I 0 90 225 255 -- I 0 90 180 270 324 16 2 12 31 61 - 83 - sales@aero-electric.com MIL-DTL- 26482 S 2 18-8 Insert Positions In Degrees 8 18-11 www.conesys.com 16 Service MIL-STD-1669 Insert Arrangements (Pin Front View) for MIL-DTL-26482 Series 2 Connectors Insert Arrangements Views B A C A B A D B C C A C B A F B E A B C D 8-2* 2 # 20, I 8-3* 3 # 20, I G B A A F G D G B H E C E 10-6 6 # 20, I A H C 8-98 3 # 20, I A A F 8-33 3 # 20, I 8-4* 4 # 20, I K J B C E F C B A D B D D B C 10-7** 7 # 20, I 12-3 3 # 16, II 12-8 8 # 20, I A H H A E B J K C F C MIL-DTL- 26482 S 2 P L L A S A d T B c M C L Z K G g L K E f Z J D D P E N M F X Y E D 18-8 8 # 12, I L A K C f W B M D S J N g C E c h X F b K H C F B d L G W G V J W H H U e V a B F E A S R F D U 16-26 26 # 20, I U e G V X D E 14-19 19 # 20, I C c Y S G H E R V T J C P U D B b L C b F M F B N G a T R K V N 16-23 1 # 16, 22 # 20, I P F T S J 16-14 8 # 20, 6 # 12, I J H U H F 16-8 8 # 16, II R N K D E J E D C T W G E Z C P B A L A A R S X M C S M B 14-18 18 # 20, I P K D H F Y C P U G B R M N H H A N B B G N T 14-15 1 # 16, 14 # 20, I A J J A M D 14-12 4 # 16, 8 # 20, I K A C L E F E K D G L D 14-9 5 # 20, 4 # 12, I N P C E 14-5 5 # 16, II R H M F B M J 14-4 4 # 12, I 14-2** 2 # 12, I A K J G G D L A B B 12-10 10 # 20, I Y a Z J H H R G D P G E F 18-11 11 # 16, II 18-30 1 # 16, 29 # 20, I 18-32 32 # 20, I * Not on QPL, available to Aero-Electric part number only. www.conesys.com 20-16 16 # 16, II ** Non MIL-STD-1669 layout, available in AC3470 through AC3475 shell styles only. - 84 - sales@aero-electric.com MIL-STD-1669 Insert Arrangements (Pin Front View) for MIL-DTL-26482 Series 2 Connectors Insert Arrangements Views L K A M W N X H h Z U D R m r S q f P n P F r g G c e N N a V C X D n K T D H T G H e g P F f N M L h G H d q R E e N P C N Z U R V a Y D X S E J W G F J N Q W s V T T E CC p S U x F y AA z BB 24-19 19 # 12, II www.conesys.com 24-31 31 # 16, I - 85 - h i m k H J j K P F G g G n R E f KK LL DD D e JJ PP MM C d w NN EE q B c HH r c A b v GG FF U H Z a u t D L 22-95 6 # 12, 26 # 20, I Y S K M R d V H d P P g e T J G H X C G c H J B b f K K e R A M L L b f F 22-55 55 # 20, I B F N L M 24-61 61 # 20, I sales@aero-electric.com MIL-DTL- 26482 S 2 A M b c d f 22-41 14 # 16, 27 # 20, I 22-21 21 # 16, II S u K a j a v L D E g T E t w M J Z EE x C Z U D DD B Y h Y s FF A V X CC g K C r HH y P N F P r S U J q GG i S V X W B W BB l E c t i AA z R 22-12 12 # 12, I V p m k b s U S C m j E A U n T B Z k W R W L A Y X B P D F 20-41 41 # 20, I 20-39 2 # 16, 37 # 20, I A M L G J K L 20-24 24 # 20, I H d M K L p f P C K b q G H M H F n R c d E a t J M m s B D Z h F N E k i J Y j S b e T G T E a g R V D Z C X U Y k i C P C A B V B X J T S Y a J B A W A W V U MIL-DTL-83723 Series III Features and Application Bayonet and Threaded Coupling Features and Application Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having same insert arrangement. 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. 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. 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. 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. 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. MIL-DTL- 83723 S III 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. www.conesys.com - 86 - sales@aero-electric.com MIL-DTL-83723 Series III Performance Specifications Bayonet and Threaded Coupling Performance Specifications 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). Operating Temperature Range Classes A and R: -65C to +200C (-85F to +392F) Class W: -65C to +175C (-85F to +347F) Classes G and K: -65C to +200C (-85F to +392F) Classes N and S: -65C to +200C (-85F to +392F) 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: 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 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. 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. 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 leakage 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. Voltage 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. DC V RMS V RMS V RMS V RMS Service Rating AC (RMS) I 600 850 1500 500 375 200 II 900 1250 2300 750 500 200 * To be used by designer only as a guide. www.conesys.com - 87 - sales@aero-electric.com MIL-DTL- 83723 S 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. MIL-DTL-83723 Series III Part Number Development Bayonet Coupling Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix M83723/ AE833 71 71 R R 12 12 12 12 N 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) MIL-DTL- 83723 S III 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 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. www.conesys.com 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. - 88 - sales@aero-electric.com M83723/71, 72 Wall Mounting Receptacle AE83371, 72 Bayonet Coupling, Crimp Removable, Rear Release 1.300(33.02) MAX A .728(18.49) .708(17.98) B .072(1.83) .052(1.32) .290(7.37) MIN FULL THREAD 3x BAYONET PINS EQUALLY SPACED MASTER KEYWAY .190(4.83) GROMMET .130(3.30) EXTENSION 3 ACCESSORY TEETH EQUALLY SPACED [D [F MAX GROMMET E 4x MINOR KEYS 4x [ C ACCESSORY THREAD BLUE COLOR BANDS MOUNTING HOLES Page 88 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization B [C [D E Shell Size .005 .13 .005 .13 +.000 -.005 inch mm inch mm inch mm inch mm 8 .812 20.62 .594 15.09 .120 3.05 .536 13.61 10 .937 23.80 .719 18.26 .120 3.05 .659 12 1.031 26.19 .812 20.62 .120 3.05 14 1.125 28.58 .906 23.01 .120 3.05 16 1.250 31.75 .969 24.61 .120 18 1.343 34.11 1.062 26.97 .120 20 1.437 36.50 1.156 29.36 22 1.562 39.67 1.250 24 1.703 43.26 1.375 www.conesys.com (TP) +.00 -.13 Accessory Thread Class 2A [F Maximum inch mm 1/2-20UNF .305 7.75 16.74 5/8-24UNEF .405 10.29 .829 21.06 3/4-20UNEF .531 13.49 .898 22.81 7/8-20UNEF .665 16.89 3.05 1.025 26.04 1-20UNEF .790 20.07 3.05 1.131 28.73 1-1/16-18UNEF .869 22.07 .120 3.05 1.256 31.90 1-3/16-18UNEF .994 25.25 31.75 .120 3.05 1.381 35.08 1-5/16-18UNEF 1.119 28.42 34.93 .149 3.78 1.506 38.25 1-7/16-18UNEF 1.244 31.60 - 89 - sales@aero-electric.com MIL-DTL- 83723 S III A M83723/73, 74 Jam Nut Receptacle AE83373, 74 Bayonet Coupling, Crimp Removable, Rear Release A MAX 1.300(33.02) MAX .190(4.83) GROMMET .130(3.30) EXTENSION E MOUNTING FLAT .781(19.84) .761(19.33) MASTER KEYWAY "O" RING 3 ACCESSORY TEETH EQUALLY SPACED [C [D MAX GROMMET F JAM NUT G ACCESSORY THREAD [B THREAD MAX 4x MINOR KEYWAYS HEX NUT PER MS3186 BLUE COLOR BAND BLUE COLOR BAND PANEL THICKNESS: .125(3.18) .062(1.58) Page 88 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization MIL-DTL- 83723 S III A [B Maximum [C Maximum [D Maximum E +.000 -.005 +.00 -.13 .003 .08 F G Jam Nut Thread Class 2A Accessory Thread Class 2A Shell Size 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 www.conesys.com - 90 - sales@aero-electric.com M83723/75, 76 Straight Plug AE83375, 76 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX [F 3x BAYONET HOLES EQUALLY SPACED MAX COUPLING NUT .290(7.37) MIN FULL THREAD .190(4.83) GROMMET .130(3.30) EXTENSION MASTER KEY 3 ACCESSORY TEETH EQUALLY SPACED [E [G MAX GROMMET 4 MINOR KEYS H ACCESSORY THREAD BLUE COLOR BAND Page 88 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [F Maximum [G +.005 -.004 Maximum H +.13 -.10 Accessory Thread Class 2A Shell Size 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 www.conesys.com - 91 - sales@aero-electric.com MIL-DTL- 83723 S III [E M83723/77, 78 RFI Grounding Plug AE83377, 78 Bayonet Coupling, Crimp Removable, Rear Release 1.230(31.24) MAX [F 3x BAYONET HOLES EQUALLY SPACED MAX COUPLING NUT MASTER KEY .290(7.37) MIN FULL THREAD .190(4.83) GROMMET .130(3.30) EXTENSION R.F.I SPRING 3 ACCESSORY TEETH EQUALLY SPACED [E [G MAX GROMMET 4 MINOR KEYS H ACCESSORY THREAD BLUE COLOR BAND Page 88 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization MIL-DTL- 83723 S III [E [F Maximum Maximum H [G +.005 -.004 +.13 -.10 Accessory Thread Class 2A Shell Size 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 www.conesys.com - 92 - sales@aero-electric.com MIL-DTL-83723 Series III Part Number Development Threaded Coupling Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix M83723/ AE833 95 95 R R 12 12 12 12 N 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 MIL-DTL- 83723 S III 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 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. www.conesys.com 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. - 93 - sales@aero-electric.com M83723/82, 83 Wall Mounting Receptacle AE83382, 83 Threaded Coupling, Crimp Removable, Rear Release 1.340(34.04) MAX CLASSES: "N" & "S" ONLY 1.248(31.70) MAX .072(1.83) .728(18.49) .052(1.32) .708(17.98) A B .290(7.37) MIN FULL THREAD MASTER KEYWAY .190(4.83) GROMMET .130(3.30) EXTENSION .290(7.37) MIN FULL THREAD .160(4.06) GROMMET .010(0.25) EXTENSION 3 ACCESORY TEETH EQUALLY SPACED [F [F MAX GROMMET H No. OF TEETH CLASSES: "N" & "S" ONLY E ACCESSORY THREAD D MATING THREAD 4 MINOR KEYWAYS MAX GROMMET E ACCESSORY THREAD BLUE COLOR BANDS 4x [ C MOUNTING HOLES FULL MATE INDICATOR COLOR: RED PANEL THICKNESS: .125(3.18) MAX Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization MIL-DTL- 83723 S III A B Shell Size .005 .13 inch mm inch [C +.005 -.004 +.13 -.10 mm inch mm (TP) D E [F H Mating Thread Class 2A Accessory Thread Class 2A Maximum No. of Teeth 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 www.conesys.com - 94 - sales@aero-electric.com M83723/84, 85 Jam Nut Receptacle AE83384, 85 Threaded Coupling, Crimp Removable, Rear Release 1.340(34.04) MAX CLASSES: "N" & "S" ONLY A 1.240(31.50) MAX G HEX NUT PER MS3186 MOUNTING FLAT MASTER KEYWAY "O" RING .290(7.37) MIN FULL THREAD FULL MATE INDICATOR COLOR: RED .290(7.37) MIN FULL THREAD .190(4.83) .130(3.30) GROMMET EXTENSION .160(4.06) GROMMET .010(0.25) EXTENSION CLASSES: "N" & "S" [C MAX GROMMET [C MAX GROMMET 3 ACCESSORY TEETH 120 APART F No. OF TEETH H ACCESSORY THREAD [B CLASSES: "N" & "S" ONLY H ACCESSORY THREAD E JAM NUT BLUE COLOR BAND THREAD D 4 MINOR KEYWAYS MATING THREAD BLUE COLOR BAND .781(19.84) .761(19.33) PANEL THICKNESS: .125(3.18) .062(1.57) Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization Shell Size [C D E F Maximum Mating Thread Class 2A Jam Nut Thread Class 2A No. of Teeth [B +.016 -.015 +.41 -.38 +.016 -.015 +.41 -.38 inch mm inch mm inch mm G H .003 .08 Accessory Thread 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 www.conesys.com - 95 - sales@aero-electric.com MIL-DTL- 83723 S III A M83723/86, 87 Straight Plug AE83386, 87 Threaded Coupling, Crimp Removable, Rear Release 1.180(29.97) MAX 3x [ .035(.89) SAFETY WIRE HOLES [ B MAX COUPLING NUT MASTER KEY .290(7.37) MIN FULL THREAD .190(4.83) .130(3.30) GROMMET EXTENSION [A [C MAX GROMMET 3 ACCESSORY TEETH EQUALLY SPACED D MATING THREAD 4 MINOR KEYS BLUE COLOR BAND Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization MIL-DTL- 83723 S III [A Shell Size E ACCESSORY THREAD [ B [ +.005 -.004 +.13 -.10 inch mm inch mm inch Maximum C Maximum D E Mating Thread Class 2B Accessory Thread Class 2A 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 www.conesys.com - 96 - sales@aero-electric.com M83723/91, 92 RFI Grounding Plug AE83391, 92 Threaded Coupling, Crimp Removable, Rear Release 1.180(29.97) MAX 3X [ .035(.89) SAFETY WIRE HOLES [ B MAX COUPLING NUT MASTER KEY .290(7.37) MIN FULL THREAD .190(4.83) .130(3.30) GROMMET EXTENSION RFI STRIP [C [A MAX GROMMET 3 ACCESSORY TEETH EQUALLY SPACED D MATING THREAD 4 MINOR KEYS Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 BLUE COLOR BAND ACCESSORY THREAD Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [B [C D E Maximum Maximum Mating Thread Class 2B Accessory Thread Class 2A +.005 -.004 +.13 -.10 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 www.conesys.com - 97 - sales@aero-electric.com MIL-DTL- 83723 S III [A Shell Size E M83723/95, 96 Self-Locking Plug AE83395, 96 Threaded Coupling, Crimp Removable, Rear Release 1.180(29.97) MAX [ C MAX .290(7.37) MIN FULL THREAD COUPLING NUT MASTER KEY .190(4.83) .130(3.30) GROMMET EXTENSION [B [A MAX GROMMET 3 ACCESSORY TEETH EQUALLY SPACED D MATING THREAD 4 MINOR KEYS E ACCESSORY THREAD BLUE COLOR BAND Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization MIL-DTL- 83723 S III [A Shell Size [B +.005 -.004 +.13 -.10 inch mm inch Maximum [C D E Maximum Mating Thread Class 2B Accessory Thread Class 2A 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 www.conesys.com - 98 - sales@aero-electric.com M83723/97, 98 Self-Locking, RFI Grounding Plug AE83397, 98 Threaded Coupling, Crimp Removable, Rear Release 1.280(32.51) MAX [ D MAX .290(7.37) MIN FULL THREAD COUPLING NUT MASTER KEY .160(4.06) .010(0.25) GROMMET EXTENSION [C [A MAX GROMMET RFI STRIP B NUMBER OF TEETH E MATING THREAD 4 MINOR KEYS F ACCESSORY THREAD BLUE COLOR BAND Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization Shell Size +.005 -.004 +.13 -.10 inch mm B [C [D E F No. of Teeth Maximum Maximum Mating Thread Class 2B Accessory Thread Class 2A 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 www.conesys.com - 99 - sales@aero-electric.com MIL-DTL- 83723 S III [A M83723/68, 69 Lanyard Release, Quick-Disconnect Plug AE83368, 69 Quick-Disconnect, Threaded Coupling, Crimp Removable, Rear Release [A 7.500(190.50) MAX MAX C ACCESSORY THREAD BLUE COLOR BAND MASTER KEY [B [D MAX GROMMET 4 MINOR KEYS LENGTH TO BE MEASURED WITH A [ .750(19.05).060(1.52) BAR TO PULL LANYARD TAUT 3 ACCESSORY TEETH EQUALLY SPACED 1.180(29.97) MAX .190(4.83) .130(3.30) GROMMET EXTENSION Page 93 Page 104 Pages 107, 108 Page 87 Page 106 Page 102 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization Note 2: Not available in shell size 8. MIL-DTL- 83723 S III [A [B C Maximum Maximum Accessory Thread Class 2A Shell Size inch mm inch mm 10 1.240 31.50 .405 10.29 12 1.432 36.37 .531 14 1.490 37.85 .665 16 1.711 43.46 .790 18 1.815 46.10 .869 20 1.962 49.83 22 2.070 24 2.195 www.conesys.com Note 1: M83723/70 receptacle adapter (page 101) is required to mate the Quick-Disconnect Plug with a receptacle. [D inch mm 5/8-24UNEF .526/.517 13.36/13.13 13.49 3/4-20UNEF .696/.687 17.68/17.45 16.89 7/8-20UNEF .765/.756 19.43/19.20 20.07 1-20UNEF .892/.883 22.66/22.43 22.07 1-1/16-18UNEF .998/.989 25.35/25.12 .994 25.25 1-3/16-18UNEF 1.123/1.114 28.52/28.30 52.58 1.119 28.42 1-5/16-18UNEF 1.248/1.239 31.70/31.47 55.75 1.244 31.60 1-7/16-18UNEF 1.373/1.364 34.87/34.65 - 100 - sales@aero-electric.com M83723/70 Receptacle Adapter, Quick-Disconnect AE83370 Quick-Disconnect (Push-Pull) Receptacle Adapter .442(11.23) .005(.13) [ C D THREAD [ A [ B [ E COLOR BAND Mil Prefix Aero Prefix M83723/ AE833 70 70 W W 10 10 Specification Sheet (Shell type) 70 = Receptacle adapter, quick-disconnect Class (Material and Finish) A = Aluminum shell, black anodized finsih 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. G = Stainless steel shell, passivated R = Aluminum shell, elctroless nickel finish W = Aluminum shell, cadmium olive drab over nickel base D Shell Size Coupling Thread Class 2B [A [B [C [E .002 .05 .002 .05 .002 .05 .005 inch mm inch mm inch mm inch .13 mm 8 9/16-24UNEF .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 www.conesys.com - 101 - sales@aero-electric.com MIL-DTL- 83723 S III Shell Size 8, 10, 12, 14, 16, 18, 20, 22 or 24 MIL-DTL-83723 Series III Polarization (Shell Keying, Insert Clocking) Bayonet and Threaded Shell Keying D B Insert Clocking E MASTER KEYWAY(KEY) OF SHELL MASTER KEYWAY A ENGAGING FACE VIEW FOR RECEPTACLE SHELL KEYWAYS (PLUG SHELL KEYS, OPPOSITE) C INSERT VERTICAL CENTERLINE PIN INSERT MATING FACE (SOCKET INSERT IS OPPOSITE) 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 keyway (key) as indicated in the keying position table below. Polarizing Shell Size 8*, 10 MIL-DTL- 83723 S III 10 only 12 thru 24, 28** 10 thru 24 Position N 6 7 8 9 Y N 6 7 8 9 Y 1 2 3 4 5 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. Key/Keyway Positions A 105 102 80 35 64 25 105 18 92 84 24 98 105 105 105 105 105 B 140 132 118 140 155 115 140 149 152 152 135 152 140 140 140 140 140 C 215 248 230 205 234 220 215 192 222 204 189 268 215 215 215 215 215 Insert Position D 265 320 312 275 304 270 265 259 342 334 240 338 265 265 265 265 265 E 0 0 0 0 0 0 0 0 0 0 0 0 10 20 30 40 50 * Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5 are not available in shell size 8. Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Shell size 28 is not from military standard. It is only availabe in threaded family to Aero-Electric part number. Note: Alternate positions "Z" and "10" are cancelled and superseded by Position "Y". www.conesys.com - 102 - sales@aero-electric.com MIL-DTL-83723 Series III, Bayonet and Threaded Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts S [ LL [J [Z L Panel Thickness Receptacle Type Rear Mounting Wall Mount Receptacle, Bayonet Front Mounting inch mm inch mm .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 -- -- * Includes screw-head L [J [J (TP) For Back Mounting Minimum For Front Mounting Minimum [ LL S +.000 -.009 +.00 -.23 [Z Shell Size .005 .13 .005 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 www.conesys.com - 103 - .13 sales@aero-electric.com MIL-DTL- 83723 S III Flange and Jam Nut Mounting Dimensions MIL-DTL-83723 Contacts, Tools and Seal Plugs Series III Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Plastic Contact Size 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 Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. Military No. Military No. Military No. M22520/1-01 M22520/1-02 M22520/1-02 M22520/2-01 M22520/2-02 M22520/2-02 M81969/8-205 M81969/8-206 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 Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size 20 MIL-DTL- 83723 S III Contact and Wire Data Test Current Voltage DC Test Max. Drop Well Dia. Amps Millivolts inch inch mm AWG 20 7.5 55 .049 .001 .155 3.94 16 13.0 49 .067 .001 .250 6.35 12 23.0 42 .100 .002 .250 6.35 Contact Size Crimp Well Data Wire Range Minimum Well Dept Finished Wire [ Range Minimum Maximum mm2 inch mm inch mm 24-20 .20-.52 .040 1.02 .083 2.11 20-16 .52-1.31 .053 1.35 .103 2.62 14-12 2.08-3.31 .097 2.46 .158 4.01 Note: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com - 104 - sales@aero-electric.com MIL-DTL-83723 Series III Contact Installation Instructions Bayonet and Threaded Coupling Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 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. 4.1 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. 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. 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. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. 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. 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. Size 20 Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner M22520/1-01 M22520/1-02 Red M22520/1-02 Red M22520/2-01 M22520/2-02 M22520/2-02 M22520/1-02 Blue M22520/1-02 Blue M39029/4-110 M39029/5-115 16 M39029/4-111 M39029/5-116 M22520/1-01 12 M39029/4-113 M39029/5-118 M22520/1-01 www.conesys.com M22520/1-02 Yellow M22520/1-02 Yellow - 105 - Insertion/Removal Tool M81969/14-11 M81969/14-03 M81969/14-04 sales@aero-electric.com MIL-DTL- 83723 S III 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. MIL-DTL-83723 Series III Insert Availability and Contact Information per MIL-STD-1554 Insert Availability and Contact Information Aero-Electric Status Total Quantity of Contacts No. of Service Alternate Positions** (by Size) Insert Arrangement QPL'd Tooled Contacts 20 8-2D Yes Yes 2 8-3 Yes Yes 8-98 Yes Yes 10-2 Yes 10-5 Yes 10-6 16 (Insert Rotation in Degrees) 12 MIL-DTL- 83723 S III Rating 1 2 3 4 5 2 I N/A N/A N/A N/A N/A 3 3 I N/A N/A N/A N/A N/A 3 3 I N/A N/A N/A N/A N/A Yes 2 2 I 10 20 30 40 50 Yes 5 5 I 10 20 30 40 50 Yes Yes 6 6 I 10 20 30 40 50 10-20 Yes Yes 2 2 I 10 20 30 40 50 12-3 Yes Yes 3 3 I 10 20 30 40 50 12-12 Yes Yes 12 I 10 20 30 40 50 14-4 Yes Yes 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 I 10 20 30 40 50 16-10 Yes Yes 10 I 10 20 30 40 50 16-24 Yes Yes 24 I 10 20 30 40 50 18-8 Yes Yes 8 I 10 20 30 40 50 18 -14 Yes Yes 14 I 10 20 30 40 50 18 -31 Yes Yes 31 I 10 20 30 40 50 20-16 Yes Yes 16 I 10 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 I 10 20 30 40 50 20-41 Yes Yes 41 41 I 10 20 30 40 50 22-12 Yes Yes 12 I 10 20 30 40 50 22-19 Yes Yes 19 I 10 20 30 40 50 22-32 Yes Yes 32 26 I 10 20 30 40 50 22-55 Yes Yes 55 55 I 10 20 30 40 50 24-19 Yes Yes 19 I 10 20 30 40 50 24-29* N/A Yes 29 29 I 10 20 30 40 50 24-30* N/A Yes 30 30 I 10 20 30 40 50 24-43 Yes Yes 43 23 20 I 10 20 30 40 50 24-57 Yes Yes 57 55 I 10 20 30 40 50 24-61 Yes Yes 61 61 I 10 20 30 40 50 28-42* N/A Yes 42 I 10 20 30 40 50 12 4 10 24 8 14 31 16 2 12 19 6 19 2 42 * Non MIL-STD-1554 layout, available to Aero-Electric part number only. D Consult factory for pin insert availablility. www.conesys.com # 8coax ** Alternate clocking positions (1, 2, 3, 4, and 5) are for interchangeability use only. Inactive for new design per MIL-STD-1554. - 106 - sales@aero-electric.com MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-83723 Series III Connectors Insert Arrangements Views 1 6 5 1 3 1 1 5 2 1 1 2 3 2 803 3 # 20 I 802* 2 # 20 I 2 898 3 # 20 I 1002 2 # 20 I 1005 5 # 20 I 4 1 4 3 1006 6 # 20 I 7 1 2 1 1 1 1 12 12 2 1020 2 # 16 I 3 1203 3 # 16 I 1212 12 # 20 I 1404 4 # 12 I 1407 7 # 16 I 1412 9 # 20, 3 # 16 I 8 10 15 1 1 1 1 24 1415 15 # 20 I 1610 10 # 16 I 1624 24 # 20 I 1808 8 # 12 I 16 14 31 25 1 1 1 1831 31 # 20 I 2016 16 # 16 I 2025 19 # 20, 6 # 12 I 41 12 28 39 1 1 2028 24 # 20, 4 # 12 I 1 1 2041 41 # 20 I 2039 37 # 20, 2 # 16 I 2212 12 # 12 I * Consult factory for pin insert availability. www.conesys.com - 107 - sales@aero-electric.com MIL-DTL- 83723 S III 1814 14 # 16 I 1 MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-83723 Series III Connectors Insert Arrangements Views 19 32 55 1 1 1 2219 19 # 16 I 2255 55 # 20 I 2232 26 # 20, 6 # 12 I 19 1 1 1 30 29 2419 19 # 12 I 2430D 30 # 16 I 2429D 29 # 16 I 43 61 42 57 MIL-DTL- 83723 S III 1 2443 23 # 20, 20 # 16 I 1 1 2461 61 # 20 I 2457 55 # 20, 2 # 12 I 1 2842D 42 # 16 I D Non MIL-STD-1554 layout, available to Aero-Electric part number only. www.conesys.com - 108 - sales@aero-electric.com MIL-DTL-26500 Features and Application MS2426*/AE66* Features and Application AE66 connectors are widely used on commercial, military and aerospace systems requiring general-purpose, miniature cylindrical bayonet or threaded coupling connectors. 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. 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. 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. 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. Closed Entry Socket Contacts Closed-entry socket contacts facilitate positive mating. 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). 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. www.conesys.com MIL-DTL- 26500 Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having same insert arrangement. - 109 - sales@aero-electric.com MIL-DTL-26500 Performance Specifications MS2426*/AE66* Performance Specifications 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: Operating Temperature Range Class R: -55C to +200C (-67F to +392F) Class E*: -55C to +200C (-67F to +392F) 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. 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. Vibration Mated connectors withstand the following vibration levels: Vibration per EIA-364, test procedure 28 conducted at a low temperature ambient of -55C (-67F) and high ambient of +200C (392F). Environmental Seal Wired, mated connectors shall meet the altitude-immersion test specified by MIL-DTL-26500. Shell-to-Shell Conductivity Class R is non-conductive. Maximum potential drop shall not exceed 200 millivolts for class E*. 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 MIL-DTL- 26500 Voltage 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. Service Rating AC (RMS) DC V RMS V RMS V RMS V RMS I 600 850 1500 450 275 200 * 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. www.conesys.com - 110 - sales@aero-electric.com MIL-DTL-26500 Part Number Development Bayonet & Threaded Coupling Part Number Development Mil. Prefix Aero Prefix MS AE 24266 666 R R 12 12 T T 12 12 P P N 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. www.conesys.com 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. - 111 - sales@aero-electric.com MIL-DTL- 26500 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. MS24264R**B Wall Mounting Receptacle AE664R**B Bayonet Coupling, Crimp Removable, Front Release A 1.421(36.09) MAX B .728(18.49) .708(17.98) MASTER KEYWAY 4x [ C MOUNTING HOLES .072(1.83) .052(1.32) [F [D MAX GROMMET E ACCESSORY THREAD 3 ORANGE COLOR STRIPES EQUALLY SPACED 4 MINOR KEYWAYS Page 111 Page 120 Page 123 Page 110 Page 122 Page 118 .306(7.77) MIN FULL THREAD PANEL THICKNESS: .125(3.18)MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C E +.00 -.23 +.000 -.005 +.00 -.13 MIL-DTL- 26500 Shell Size .005 .13 inch mm inch mm inch mm inch mm 8 .812 20.62 .594 15.09 .125 3.18 .536 13.61 10 .937 23.80 .719 18.26 .125 3.18 .659 16.74 12 1.031 26.19 .812 20.62 .125 3.18 .829 14 1.125 28.58 .906 23.01 .125 3.18 .898 16 1.250 31.75 .969 24.61 .125 3.18 1.025 18 1.343 34.11 1.062 26.97 .125 3.18 1.131 20 1.437 36.50 1.156 29.36 .125 3.18 22 1.562 39.67 1.250 31.75 .125 24 1.703 43.26 1.375 34.93 .154 www.conesys.com (TP) [D +.000 -.009 Accessory Thread Class 2A [F Maximum inch mm 7/16-28UNEF .328 8.33 9/16-24UNEF .420 10.67 21.06 3/4-20UNEF .580 14.73 22.81 13/16-20UNEF .664 16.87 26.04 15/16-20UNEF .769 19.53 28.73 1-1/16-18UNEF .902 22.91 1.256 31.90 1-3/16-18UNEF 1.033 26.24 3.18 1.381 35.08 1-5/16-18UNEF 1.152 29.26 3.91 1.506 38.25 1-7/16-18UNEF 1.282 32.56 - 112 - sales@aero-electric.com MS24265R**B Jam Nut Receptacle AE665R**B Bayonet Coupling, Crimp Removable, Front Release 1.421(36.09) MAX B .781(19.84) .761(19.33) C MASTER KEYWAY MOUNTING FLAT .306(7.77) MIN FULL THREAD [ [ [ D F MAX GROMMET A MAX 3 ORANGE COLOR STRIPES EQUALLY SPACED E ACCESSORY THREAD G JAM-NUT THREAD "O" RING HEX NUT WITH 3 TEFLON PLUGS EQUALLY SPACED Page 111 Page 120 Page 123 Page 110 Page 122 Page 118 PANEL THICKNESS: .125(3.18) MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A B Maximum Shell Size inch mm C [D .005 .13 .003 .08 +.000 -.005 +.00 -.13 inch mm inch mm inch mm E [F G Accessory Thread Class 2A Maximum Jam Nut Thread Class 2A inch mm 1.068 27.13 .979 24.87 .593 15.06 .536 13.61 7/16-28UNEF .328 8.33 5/8-20UN 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 www.conesys.com - 113 - sales@aero-electric.com MIL-DTL- 26500 8 10 MS24266R**B Straight Plug AE666R**B Bayonet Coupling, Crimp Removable, Front Release [ A MAX COUPLING NUT 1.375(34.93) MAX MASTER KEY .306(7.77) MIN FULL THREAD [ [ B C MAX GROMMET 3 ORANGE STRIPES EQUALLY SPACED D ACCESSORY THREAD 4 MINOR KEYS Page 111 Page 120 Page 123 Page 110 Page 122 Page 118 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A [B Maximum +.000 -.005 +.00 -.13 [C D Maximum Accessory Thread Class 2A MIL-DTL- 26500 Shell Size 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 www.conesys.com - 114 - sales@aero-electric.com MS24264R**T Wall Mounting Receptacle AE664R**T Threaded Coupling, Crimp Removable, Front Release A 1.421(36.09) MAX B 4x [ C .728(18.49) .708(17.98) MASTER KEYWAY MOUNTING HOLES .072(1.83) .052(1.32) [F MAX GROMMET D MATING THREAD 4 MINOR KEYWAYS E ACCESSORY THREAD FULL MATE INDICATOR COLOR: ORANGE .306(7.77) MIN FULL THREAD PANEL THICKNESS: .125(3.18) MAX Page 111 Page 120 Page 123 Page 110 Page 122 Page 118 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B [C +.00 -.23 D E Mating Thread Class 2A Accessory Thread Class 2A .005 .13 inch mm inch mm inch mm 8 .812 20.62 .594 15.09 .125 3.18 9/16-24UNEF 10 .937 23.80 .719 18.26 .125 3.18 11/16-24UNEF 12 1.031 26.19 .812 20.62 .125 3.18 14 1.125 28.58 .906 23.01 .125 3.18 16 1.250 31.75 .969 24.61 .125 3.18 18 1.343 34.11 1.062 26.97 .125 3.18 20 1.437 36.50 1.156 29.36 .125 22 1.562 39.67 1.250 31.75 24 1.703 43.26 1.375 34.93 [F Maximum inch mm 7/16-28UNEF .328 8.33 9/16-24UNEF .420 10.67 7/8-20UNEF 3/4-20UNEF .580 14.73 15/16-20UNEF 13/16-20UNEF .664 16.87 1-1/16-18UNEF 15/16-20UNEF .769 19.53 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91 3.18 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24 .125 3.18 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26 .154 3.91 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56 - 115 - sales@aero-electric.com MIL-DTL- 26500 Shell Size www.conesys.com (TP) +.000 -.009 MS24265R**T Jam Nut Receptacle AE665R**T Threaded Coupling, Crimp Removable, Front Release 1.421(36.09) MAX B .781(19.84) .761(19.33) C MOUNTING FLAT MASTER KEYWAY .306(7.77) MIN FULL THREAD [ F MAX GROMMET [ A D MATING THREAD MAX FULL MATE INDICATOR COLOR: ORANGE E ACCESSORY THREAD G JAM-NUT THREAD "O" RING HEX NUT WITH 3 TEFLON PLUGS EQUALLY SPACED Page 111 Page 120 Page 123 Page 110 Page 122 Page 118 PANEL THICKNESS: .125(3.18) MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization B [A Maximum E [F G Mating Thread Class 2A Accessory Thread Class 2A Maximum Jam Nut Thread Class 2A MIL-DTL- 26500 .003 inch mm inch mm inch mm .979 24.87 .593 15.06 9/16-24UNEF 7/16-28UNEF .328 8.33 5/8-20UN 30.28 1.104 28.04 .718 18.24 11/16-24UNEF 9/16-24UNEF .420 10.67 3/4-20UNEF 1.380 35.05 1.291 32.79 .905 22.99 7/8-20UNEF 3/4-20UNEF .580 14.73 15/16-20UNEF 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 inch mm 8 1.068 27.13 10 1.192 12 14 www.conesys.com .08 D .13 Shell Size .005 C - 116 - sales@aero-electric.com MS24266R**T Straight Plug AE666R**T Threaded Coupling, Crimp Removable, Front Release [ A MAX COUPLING NUT 1.375(34.93) MAX MASTER KEY .306(7.77) MIN FULL THREAD [ [ B C MAX GROMMET E MATING THREAD D ACCESSORY THREAD 4 MINOR KEYS Page 111 Page 120 Page 123 Page 110 Page 122 Page 118 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization [A [B Maximum +.000 -.005 +.00 -.13 [C D E Maximum Accessory Thread Class 2A Mating Thread 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 www.conesys.com - 117 - sales@aero-electric.com MIL-DTL- 26500 Shell Size MIL-DTL-26500 Polarization (Shell Keying, Insert Clocking) Bayonet and Threaded Shell Keying D B Insert Clocking E MASTER KEYWAY(KEY) OF SHELL MASTER KEYWAY A C ENGAGING FACE VIEW FOR RECEPTACLE SHELL KEYWAYS (PLUG SHELL KEYS, OPPOSITE) INSERT VERTICAL CENTERLINE PIN INSERT MATING FACE (SOCKET INSERT IS OPPOSITE) 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. Polarizing Shell Size 8*, 10 10 only 12 thru 24 MIL-DTL- 26500 10 thru 24 Key/Keyway Positions Insert Position Position A B C D E N 6 7 8 9 Y** N 6 7 8 9 Y** 1 2 3 4 5 105 102 80 35 64 25 105 18 92 84 24 98 105 105 105 105 105 140 132 118 140 155 115 140 149 152 152 135 152 140 140 140 140 140 215 248 230 205 234 220 215 192 222 204 189 268 215 215 215 215 215 265 320 312 275 304 270 265 259 342 334 240 338 265 265 265 265 265 0 0 0 0 0 0 0 0 0 0 0 0 10 20 30 40 50 * Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5 are not available in shell size 8. Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Alterate positions "Z" and "10" are cancelled and superseded by Position "Y". www.conesys.com - 118 - sales@aero-electric.com MIL-DTL-26500 Bayonet and Threaded Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts S [ LL [J [Z L Note: Maximum panel thickness of .125 inch (3.18 mm). Flange and Jam Nut Mounting Dimensions L [J [J (TP) For Back Mounting Minimum For Front Mounting Minimum [ LL S +.000 -.009 +.00 -.23 [Z .005 .13 .005 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 www.conesys.com - 119 - .13 sales@aero-electric.com MIL-DTL- 26500 Shell Size MIL-DTL-26500 Contacts, Tools and Seal Plugs MS2426*/AE66* Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Plastic Contact Size 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 Coax M39029/54-343 M39029/55-345 MS27488-8-1 N/A 8 Coax Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size/Type Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. M81969/17-03 M81969/19-07 Military No. Military No. Military No. M22520/1-01 M22520/1-02 M22520/1-02 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 8 Coax Outer M22520/5-01 M22520/5-10 M22520/5-10 M81969/17-06 M81969/19-03 20 Contact and Wire Data Contact Size Test Current Potential DC Test Drop Crimp Well Data Well Dia. Wire Range Minimum Well Dept Finished Wire [ Range Minimum Maximum MIL-DTL- 26500 Amps Millivolts inch inch mm AWG mm2 inch 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 Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com 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. - 120 - sales@aero-electric.com MIL-DTL-26500 Contact Installation Instructions MS2426*/AE66* Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 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. 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. 4. Place the contact, mating end first, into the tool. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 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. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. 2. Select the appropriate tool. Place tool over the contact on mating side and insert into the cavity. 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. 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. 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. 5. Grasp contact or wire and pull the wired contact out of the rear of the insulator. 6. Remove extraction tool axially. Size Pin Contact Socket Contact 20 M39029/31-241 M39029/32-260 16 12 M39029/31-229 M39029/31-235 M39029/32-248 M39029/32-254 www.conesys.com 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. Basic Crimp Tool M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 - 121 - Positioner M22520/1-02 Red M22520/2-02 M22520/1-02 Blue M22520/1-02 Yellow Insertion Tool Removal Tool M81969/17-03 M81969/19-07 M81969/17-04 M81969/17-05 M81969/19-08 M81969/19-09 sales@aero-electric.com MIL-DTL- 26500 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. MIL-DTL-26500 Bayonet and Threaded Insert Availability and Contact Information per MIL-STD-1554 Insert Availability and Contact Information Aero-Electric Status Total Quantity of Contacts No. of Service Alternate Positions (by Size) Insert Arrangement QPL'd Tooled Contacts 20 8-3 Yes Yes 3 3 10-5 Yes Yes 5 5 12-3 Yes Yes 3 12-12 Yes Yes 12 14-7 Yes Yes 7 14-12 Yes Yes 12 9 14-15 Yes Yes 15 15 16-10 Yes Yes 10 16-24 Yes Yes 24 18-8 Yes Yes 8 18-11 Yes Yes 11 18-14 Yes Yes 14 18-31 Yes Yes 31 20-16 Yes Yes 16 20-25 Yes Yes 25 19 20-39 Yes Yes 39 37 20 -41 Yes Yes 41 41 22-19 Yes Yes 19 22-55 Yes Yes 55 24-30** N/A Yes 30 24-43 Yes Yes 43 23 24-57 Yes Yes 57 55 16 (Insert Rotation in Degrees) 12 # 8 Coax 3 12 Rating 1* 2* 3* 4* 5* I N/A N/A N/A N/A N/A I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 7 I 10 20 30 40 50 3 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 10 24 8 10 1 14 31 16 6 2 19 55 I 10 20 30 40 50 30 I 10 20 30 40 50 20 I 10 20 30 40 50 I 10 20 30 40 50 2 * 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. MIL-DTL- 26500 www.conesys.com - 122 - sales@aero-electric.com MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-26500 Connectors Insert Arrangements Views 7 1 5 1 1 1 1 12 3 2 8-3 3 # 20 I 10-5 5 # 20 I 3 12-3 3 # 16 I 12-12 12 # 20 I 14-7 7 # 16 I 8 10 15 1 1 1 1 12 1 24 14-12 9 # 20, 3 # 16 I 14-15 15 # 20 I 16-10 10 # 16 I 16-24 24 # 20 I 16 14 11 18-8 8 # 12 I 31 25 1 1 1 1 18-14 14 # 16 I 18-11 10 # 16, 1 # 8 Coax. I 1 18-31 31 # 20 I 20-16 16 # 16 I 41 20-25 19 # 20, 6 # 12 I 19 55 39 1 1 20-39 37 # 20, 2 # 16 I 1 20-41 41 # 20 I 1 22-19 19 # 16 I 22-55 55 # 20 I 43 MIL-DTL- 26500 57 1 30 1 24-30D 30 # 16 I 24-43 23 # 20, 20 # 16 I 1 24-57 55 # 20, 2 # 12 I D Non MIL-STD-1554 layout, available to Aero-Electric part number only. www.conesys.com - 123 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Military Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero (MIL-DTL-) Document MS Number Aero D38999/20 D38999/21 D38999/22 D38999/23 D38999/24 D38999/25 D38999/26 D38999/27 D38999/28 D38999/29 D38999/30 D38999/31 D38999/32 D38999/33 M38999/1 M38999/2 M38999/3 M38999/4 M38999/5 M38999/6 M38999/7 M38999/8 M38999/9 M38999/10 M83723/1 M83723/2 M83723/3 M83723/4 M83723/5 M83723/6 M83723/7 M83723/8 M83723/9 M83723/10 M83723/11 M83723/12 M83723/13 M83723/14 M83723/15A M83723/15N M83723/15S M83723/16A M83723/16M M83723/16S Yes No No No Yes No Yes No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No P&S C, P, X -- C, P, X P&S C, P, X P&S C, P, X -- P S P -- -- -- -- -- -- -- -- -- -- -- -- S P S P S P S P P P P P S P -- -- -- -- -- -- 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III, IV 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series III 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I, II 38999 Series I 38999 Series II 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I, III 83723 Series I, III 83723 Series I, III 83723 Series I 83723 Series I 83723 Series I Active Active Active Active Active Active Active Active Active Active Active Active Active Active Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Active Active Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Active Active Active -- -- -- -- -- -- -- -- -- -- -- -- -- -- M85049/27 M85049/62 M85049/33-2 M85049/30 M85049/17 M85049/29 M85049/36 M85049/37 -- -- MS3470 MS3470 MS3472 MS3472 MS3474 MS3474 MS3471 MS3471 MS3440 MS3442 MS3443 MS3449 MS3476 MS3476 M85049/51 M85049/31 M85049/52 -- M85049/60-2 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- No No No No No No No No -- -- Yes Yes Yes Yes Yes Yes Yes Yes No No No No Yes Yes No No No -- No -- Wall Mount Receptacle Box Mount Receptacle, Hermetic Dummy Receptacle Jam Nut Receptacle, Hermetic Jam Nut Receptacle Solder Mount Receptacle, Hermetic RFI Grounding Plug Weld Mount Receptacle, Hermetic Hex Mounting Nut (Jam Nut) Lanyard Release Plug, Pin Contact Lanyard Release Plug, Socket Contact Lanyard Release Plug, SS 25, Pin Metal Protective Cover, Plug Metal Protective Cover, Receptacle Grommet Nut (E-Nut) Boot Adapter EMI/RFI Crimp Ring Adapter Individual Shield Termination Backshell Straight Backshell, EMI, Environmental Straight Backshell, Non Environmental Straight Backshell, EMI/RFI 90 Split Backshell, EMI/RFI Dummy Receptacle Dummy Receptacle Narrow Flange Mount Receptacle Narrow Flange Mount Receptacle Wide Flange Mount Receptacle Wide Flange Mount Receptacle Jam Nut Receptacle Jam Nut Receptacle Cable Connecting Receptacle Cable Connecting Receptacle Narrow Flange Mt. Recept., Hermetic Wide Flange Mt. Recept., Hermetic Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Straight Plug Straight Plug 90 Strain Relief Grommet Nut (E-Nut) Straight Strain Relief 90 Heat Shrink Boot Boot Adapter Straight Heat Shrink Boot * 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 intermountable; some differences in accessory threads and contact release may exist. www.conesys.com Superseding Available 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. - 124 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Part from Shell Type Style Cable Connecting Receptacle Cable Connecting Receptacle Wall Mount Receptacle Wall Mount Receptacle Box Mount Receptacle Box Mount Receptacle Straight Plug Straight Plug Wall Mount Receptacle, Hermetic Solder Mount Receptacle, Hermetic 90 Heat Shrink Boot Boot Adapter Straight Heat Shrink Boot Seal Plugs Pin Contacts (0 thru 16) Socket Contacts (0 thru 16) Insertion/Extraction Tools (20, 16, 12) Insertion/Extraction Tools (0, 4, 8) Pin Contacts (20, 16, 12) Socket Contacts (20, 16, 12) 90 Backshell with Cable Clamp Grommet Nut (E-Nut) Straight Backshell with Cable Clamp Pre-wired Plug for 8-2, 8-3, 8-4 Layouts only Pre-wired Plug for 8-2, 8-3, 8-4 Layouts only Pre-wired Narrow Flange Receptacle for 8-2, 8-3, 8-4 Layouts only Pre-wired Narrow Flange Receptacle for 8-2, 8-3, 8-4 Layouts Pre-wired Wide Flange Receptacle for 8-2, 8-3, 8-4 Layouts Pre-wired Wide Flange Receptacle for 8-2, 8-3, 8-4 Layouts RFI Grounding Plug RFI Grounding Plug Metal Protective Cover, Receptacle Dummy Receptacle Metal Protective Cover, Plug Shield Termination l, RFI Grounding Pre-wired RFI Plug for 8-2, 8-3, 8-4 Layouts only Pre-wired RFI Plug for 8-2, 8-3, 8-4 Layouts only Number Aero M83723/17 M83723/18 M83723/19 M83723/20 M83723/21 M83723/22 M83723/23 M83723/24 M83723/25 M83723/26 M83723/27A M83723/27M M83723/27S M83723/28 M83723/29 M83723/30 M83723/31 M83723/32 M83723/33 M83723/34 M83723/35A M83723/35N M83723/35S M83723/36 M83723/37 No No No No No No No No No No No No No No No No No No No No No No No No Yes M83723/38 No M83723/39 No M83723/40 No M83723/41 No M83723/42 M83723/43 M83723/44 M83723/45 M83723/46 M83723/47 M83723/48 M83723/49 No No No No No No No No * 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 intermountable; some differences in accessory threads and contact release may exist. www.conesys.com Military Status* Superseding Available Specification & Series (MIL-DTL-) of Equivalent** from Document MS Number Aero S P S P S P S P P P -- -- -- -- P S -- -- P S -- -- -- P S 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series I, III 83723 Series II 83723 Series II 83723 Series I, III 83723 Series II 83723 Series I, III 83723 Series I, III 83723 Series II 83723 Series II 83723 Series II 83723 Series I 83723 Series I Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Inactive, Use Canceled, Superseded by Canceled, Superseded by Inactive Inactive Inactive Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Inactive Inactive Inactive Canceled Inactive MS3451 MS3451 MS3450 MS3450 MS3452 MS3452 MS3456 MS3456 MS3142 MS3143 -- -- -- MS27488 M39029/29 M39029/30 M81969/14 M81969/14 M39029/4 M39029/5 -- -- -- -- -- Yes Yes Yes Yes Yes Yes Yes Yes No No -- -- -- Yes Yes Yes Yes Yes Yes Yes -- -- -- -- -- P 83723 Series I Canceled -- -- S 83723 Series I Canceled -- -- P 83723 Series I Canceled -- -- S 83723 Series I Canceled -- -- P S -- -- -- -- P S 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I 83723 Series I Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Superseded by Canceled, Canceled Canceled MS3475 MS3475 MS3181 MS3115 MS3180 M85049/26 -- -- Yes Yes No No No No -- -- 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. - 125 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Military Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero Document MS Number Aero M83723/50A M83723/50B M83723/50R M83723/51A M83723/51B M83723/51R M83723/52 M83723/53 M83723/59 M83723/60 M83723/61 M83723/65 M83723/66 M83723/67 M83723/68 M83723/69 M83723/70 M83723/71 M83723/72 M83723/73 M83723/74 M83723/75 M83723/76 M83723/77 M83723/78 M83723/79 M83723/80 M83723/81 M83723/82 M83723/83 M83723/84 M83723/85 M83723/86 M83723/87 M83723/88 M83723/89 M83723/90 M83723/91 M83723/92 M83723/93 M83723/94 M83723/95 M83723/96 No No No No No No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No Yes Yes Yes Yes Yes Yes No No No Yes Yes No No Yes Yes 90 Cable Tie Strain Relief 45 Cable Tie Strain Relief Straight Cable Tie Strain Relief Environmental 90 Backshell Environmental 45 Backshell Environmental Straight Backshell Self Locking Plug, Firewall Self Locking Plug, Firewall Metal Protective Cover, Plug Metal Protective Cover, Receptacle Dummy Receptacle Jam Nut Receptacle, Hermetic Quick-Disconnect Plug, Less Lanyard Quick-Disconnect Plug, Less Lanyard Quick-Disconnect Plug, With Lanyard Quick-Disconnect Plug, With Lanyard Recept. Adapter for Quick-Dis. Plugs Wall Mount Receptacle Wall Mount Receptacle Jam Nut Receptacle Jam Nut Receptacle Straight Plug Straight Plug RFI Grounding Plug RFI Grounding Plug Wall Mount Receptacle, Hermetic Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Wall Mount Receptacle Wall Mount Receptacle Jam Nut Receptacle Jam Nut Receptacle Straight Plug Straight Plug Wall Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Solder Mount Receptacle, Hermetic RFI Grounding Plug RFI Grounding Plug Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Self Locking Plug Self Locking Plug -- -- -- -- -- -- P S -- -- -- P P S P S -- S P S P S P S P P P P S P S P S P P P P S P P P S P Inactive Inactive Inactive Canceled Canceled Canceled Canceled, Superseded by Canceled, Superseded by Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active -- -- -- -- -- -- MS3459 MS3459 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Yes Yes -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- (MIL-DTL-) 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 Series II 83723 SIII, Bay & Thr 83723 SIII, Bay & Thr 83723 SIII, Bay & Thr 83723 Series III, Bay 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Thr 83723 Series III, Bay 83723 Series III, Bay 83723 Series III, Thr 83723 Series III, Thr Superseding Available * 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 intermountable; some differences in accessory threads and contact release may exist. Note 1: M83723/59, 60, 61 metal plug and receptacle covers and dummy receptacle can be used on MIL-DTL-26500 connectors. 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. www.conesys.com - 126 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability 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 M83723/98 MS24264 "B" MS24264 "T" MS24265 "B" MS24265 "T" MS24266 "B" MS24266 "T" MS25042 MS25043 MS25183 MS27034 MS27291 MS27466 MS27467 MS27468 MS27469 MS27470 MS27471 MS27472 MS27473 MS27474 MS27475 MS27476 MS27477 MS27478 MS27479 MS27480 MS27481 MS27482 MS27483 MS27484 MS27485 MS27486 MS27487 MS27488 MS27489 MS27496 MS27497 MS27498 MS27499 MS27500 MS27501 Yes Yes Yes Yes Yes Yes Yes Yes No No No No No Yes Yes Yes No No No Yes Yes Yes No No No No No No No No No Yes No No No Yes No Yes Yes No Yes Yes No RFI Grounding, Self Locking Plug RFI Grounding, Self Locking Plug Wall Mount Receptacle Wall Mount Receptacle Jam Nut Mount Receptacle Jam Nut Mount Receptacle Straight Plug Straight Plug Metal Protective Cover, Plug Metal Protective Cover, Receptacle Straight Plug, Potting Seal, Solder Solder Mount Receptacle, Hermetic Straight Clamp Front Wall Mount Receptacle RFI Grounding Plug Jam Nut Receptacle Wall Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Solder Mount Receptacle, Hermetic Front Wall Mount Receptacle Straight Plug Jam Nut Receptacle Wall Mount Receptacle, Hermetic Box Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Solder Mount Receptacle, Hermetic Wall Mount Receptacle Straight Plug Jam Nut Receptacle Wall Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic RFI Grounding Plug Potting Boot Ring Potting Boot Straight and 90 Adapter Seal Plug (22, 20, 16, 12, 8, 4, 0) Adapter Reducer Front Box Mount Receptacle Rear Wall Mount Receptacle RFI Plug with 90 Clamp Front Box Mount Receptacle Straight Plug with 90 Strain Relief Metal Protective Cover, Plug S P P&S P&S P&S P&S P&S P&S -- -- P&S C, E -- P&S P&S P&S C, P, X C, P, X C, P, X P&S P&S P&S C, P, X C, P, X C, P, X C, P, X P&S P&S P&S P P P&S -- -- -- -- -- P&S P&S P&S P&S P&S -- 83723 Series III, Thr 83723 Series III, Thr 26500 Bayonet 26500 Threaded 26500 Bayonet 26500 Threaded 26500 Bayonet 26500 Threaded 5015 Series I, II, III 5015 Series I, II, III 5015 Series I (Solder) 26500 Bay & Thr 26500 Bay & Thr 38999 Series I 38999 Series I 38999 Series I 38999 Series I 38999 Series I 38999 Series I 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series I, II 38999 Series I, II All 38999 Series I, II 38999 Series I 38999 Series II 38999 Series I 38999 Series II 38999 Series II 38999 Series I Active Active Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Can Use Active Active Inactive, Can Use Inactive, Use Inactive Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Canceled, Superseded by Canceled, Superseded by Active Canceled, Superseded by Canceled, Superseded by Active Active Active Active Active Canceled, Superseded by Active Active Active -- -- M83723/72,71 M83723/83,82 M83723/74,73 M83723/85,84 M83723/76,75 M83723/87,86 -- -- MS3456 M83723/93,90 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- MS27475 MS27477 -- M85049/58 M85049/75 -- -- -- -- -- MS27467 -- -- -- -- -- Yes Yes Yes Yes Yes Yes -- -- Yes No -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- No No -- No No -- -- -- -- -- Yes -- -- -- * 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 intermountable; some differences in accessory threads and contact release may exist. Note 1: MS24264 "T", MS24265 "T" and MS24266 "T" equivalents (M83723/82 thru 87) listed above do not apply for shell size 8. 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. www.conesys.com - 127 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Mil Connector Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero Document MS Number Aero MS27502 MS27504 MS27505 MS27506 MS27507 MS27508 MS27510 MS27511 MS27512 MS27513 MS27515 MS27534 MS27535 MS27536 MS27558 MS27559 MS27613 MS27614 MS27615 MS27652 MS27653 MS27654 MS27656 MS27657 MS27661 MS27662 MS27663-1 MS27663-2 MS27664 MS27667 MS27668 MS27669 MS27670 MS3100 MS3101 MS3102 MS3103 MS3105 MS3106 MS3107 MS3108 MS3110 No No Yes No No Yes No No No Yes No No No No No No No No No No No No Yes No No No No No No No No No No No No No No No No No No No Metal Protective Cover, Receptacle Box Mount Receptacle Rear Box Mount Receptacle Straight Strain Relief 90 Strain Relief Rear Box Mount Receptacle Metal Protective Cover, Plug Metal Protective Cover, Receptacle Hex Mounting Nut (Jam Nut) Front Box Mt. Receptacle, Long Grommet Rear Wall Mount Receptacle Insertion/Removal Tools Size 8 Coax Contact, Socket Size 8 Coax Contact, Pin 90 Cable Support, Closed 90 Cable Clamp Wall Mount Receptacle, Firewall Jam Nut Receptacle, Firewall Ratchet Lock & Standard Plug, Firewall Wall Mount Receptacle Straight Plug Rear Wall Mount Receptacle Rear Wall Mount Receptacle Short Cable Support for Classes E, K Lanyard Release Plug Thru-Bulkhead Mounting Receptacle Straight Non-Metallic Strain Relief 90 Non-Metallic Strain Relief Rear Wall Mount Receptacle Thru-Bulkhead Mounting Receptacle Straight Cable Tie Strain Relief 45 Cable Tie Strain Relief 90 Cable Tie Strain Relief Wall Mount Receptacle Cable Connecting Receptacle Box Mount Recptacle Flange Mount Receptacle, Potting Seal Dummy Receptacle Straight Plug Quick Disconnect Plug 90 Plug Wall Mount Receptacle -- P&S P&S -- -- P&S -- -- -- P&S P&S -- S P -- -- P&S P&S P&S P&S P&S P&S P&S -- P&S C -- -- P&S C -- -- -- P&S P&S P&S P&S -- P&S P&S P&S P&S 38999 Series I 38999 Series II 38999 Series I 38999 Series I, II 38999 Series I, II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series II 38999 Series I 38999 Series I, II 38999 Series I 38999 Series I 26500 Bay & Thr 26500 Bay & Thr 26500 Bay & Thr 26500 Bay & Thr 26500 Bay & Thr 38999 Series I 38999 Series I 38999 Series I 38999 Series I 26500 Bay & Thr 38999 Series I 38999 Series I 38999 Series I, II 38999 Series I, II 38999 Series II 38999 Series II 38999 Series I, II 38999 Series I, II 38999 Series I, II 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 5015 Series I (Solder) 26482 Series 1 Solder (MIL-DTL-) * 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 intermountable; some differences in accessory threads and contact release may exist. D "Bayonet Coupling" equivalents do not exist. www.conesys.com Superseding Available Active -- Active -- Active -- Canceled, Superseded by M85049/49 Canceled, Superseded by M85049/47 Active -- Active -- Active -- Inactive, Use MS3186 Active -- Inactive, Use MS27656 Inactive, Use M81969/14 Inactive, Use M39029/59 Inactive, Use M39029/60 Inactive -- Inactive -- Inactive, Use M83723/83, 82 Inactive, Use M83723/85, 84 Inactive, Use M83723/96, 95 Inactive, Use MS27466 Inactive, Use MS27467 Inactive, Use MS27656 Active -- Inactive -- Active -- Active -- Canceled, Superseded by M85049/45 Canceled, Superseded by M85049/46 Canceled, Use MS27497 Canceled -- Canceled, Superseded by M85049/56 Canceled, Superseded by M85049/57 Canceled, Superseded by M85049/63 Inactive MS3450 Inactive MS3451 Inactive MS3452 Inactive -- Inactive -- Inactive MS3456 Inactive -- Inactive MS3456 & B/S Inactive, Can Use MS3470 -- -- -- No No -- -- -- No -- Yes Yes Yes Yes -- -- Yes Yes Yes Yes Yes Yes -- -- -- -- No No Yes -- No No No Yes Yes Yes -- -- Yes -- Yes Yes 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. - 128 - sales@aero-electric.com Part Number Cross Reference Part Number Cross Reference, Status and Availability Military Available Description Contact Mil Connector Status* Part from Shell Type Style Specification & Series of Equivalent** from Number Aero Document MS Number Aero MS3111 MS3112 MS3113 MS3114 MS3115 MS3116 MS3119 MS3120 MS3121 MS3122 MS3124 MS3126 MS3127 MS3128 MS3180 MS3181 MS3400 MS3401 MS3402 MS3404 MS3406 MS3408 MS3409 MS3412 MS3436 MS3440 MS3442 MS3443 MS3449 MS3450 MS3451 MS3452 MS3454 MS3456 MS3459 MS3470 MS3471 MS3472 MS3473 MS3474 MS3475 MS3476 MS3477 MS3479 MS3507 No No No No No No No No No No No No No No No No No No No No No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes No No No Cable Connecting Receptacle Box Mount Receptacle Solder Mount Receptacle Jam Nut Receptacle Dummy Receptacle Straight Plug Thru-Bulkhead Mounting Receptacle Wall Mount Receptacle Cable Connecting Receptacle Box Mount Receptacle Jam Nut Receptacle Straight Plug Box Mount Receptacle Wall Mount Receptacle Metal Protective Cover, Plug Metal Protective Cover, Recepacle Wall Mount Receptacle Cable Connecting Receptacle Box Mount Receptacle Jam Nut Receptacle Straight Plug 90 Plug 45 Plug Wall Mount Receptacle RFI Plug, Utility (20-4 layout only) Narrow Flange Mt. Receptacle, Hermetic Wide Flange Mt. Receptacle, Hermetic Solder Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Wall Mount Receptacle Cable Connecting Receptacle Box Mount Receptacle Jam Nut Receptacle Straight Plug Self locking Plug Wall Mount Receptacle Cable Connecting Receptacle Wide Flange Mount Receptacle Solder Mount Receptacle, Hermetic Jam Nut Receptacle RFI Grounding Plug Straight Plug Box Mount Receptacle, Hermetic Jam Nut Receptacle, Hermetic Quick Disconnect Plug (20-4 layout only) P&S P&S P P&S -- P&S S to P P&S P&S P&S P&S P&S P&S P&S -- -- P&S P&S P&S P&S P&S P&S P&S P&S P&S P P P P P&S P&S P&S P&S P&S P&S P&S P&S P&S P P&S P&S P&S P P P 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1, 2 26482 Series 1 Solder 26482 Series 1 Solder 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1 Crimp 26482 Series 1, 2 26482 Series 1, 2 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 SII (Front Rel) 5015 Series I (Solder) 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 5015 SIII (Rear Rel) 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 26482 Series 2 5015 Series I (Solder) MS3471 MS3470 MS3443 MS3474 -- MS3476 -- MS3470 MS3471 MS3470 MS3474 MS3476 MS3470 MS3470 -- -- MS3450 MS3451 MS3452 MS3454 MS3456 MS456 & B/S MS456 & B/S MS3450 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Yes Yes -- Yes -- Yes -- Yes Yes Yes Yes Yes Yes Yes -- -- Yes Yes Yes Yes Yes Yes Yes Yes -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- (MIL-DTL-) * 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 intermountable; some differences in accessory threads and contact release may exist. www.conesys.com Inactive, Can Use Inactive, Can Use Inactive, Use Inactive, Use Inactive Inactive, Can Use Inactive Inactive, Can Use Inactive, Can Use Inactive, Can Use Inactive, Inactive, Use Inactive, Can Use Inactive, Can Use Inactive Inactive Active Active Active Active Active Active Active Active Inactive Inactive Inactive Inactive Inactive Active Active Active Active Active Active Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Active Superseding Available 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. - 129 - sales@aero-electric.com Glossary of Terms 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 dislodged from its normal position within the insert of the connector. contact size A 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. 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 receptacle 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 corresponding 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 environmentally 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 www.conesys.com D depth of crimp The distance the crimp die indenter penetrates into the wire barrel. - 130 - sales@aero-electric.com Glossary of Terms 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." 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. 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. 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. 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. 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. 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. I insert The insulating core of the connector designed to position, 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 www.conesys.com 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 - 131 - sales@aero-electric.com Glossary of Terms 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 especially 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 contact A contact whose engaging end is designed to accept the entry of a pin contact. solder contact A pin or socket contact that accepts a conductor (wire) which is soldered onto the "solder cup," not crimped into the wire barrel. splice Wire 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. 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. 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. 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 looswww.conesys.com - 132 - sales@aero-electric.com