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Connectors, Contacts & Tooling

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The document describes various types of crimping tools that should conform to military specifications for crimping electrical connector contacts. It also details procedures for installing wires into multiple termination connectors and describes safety precautions for using hot air guns on fueled aircraft.

The document describes crimping tools that conform to MIL-DTL-22520 specification including the M22520/1-01, M22520/2-01, M22520/4-01, and M22520/7-01 tools.

The document lists the steps for installing wires into multiple termination connectors (MTCs) which include inserting the wafer removal tool, clamping the wafer holding fixture, installing the connector solder sleeve terminator, stripping the wire, heating the solder joint with a hot air gun, and inspecting the connection.

AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Removable Solder Type Shielded Contacts

26. Damaged removable solder-type shielded


contacts should be replaced with equivalent crimp type
shielded contacts. Procedures for installing shielded
contacts are packaged with the contacts.

CRIMP CONTACTS

27. Removable crimp-type contacts conforming to


specification MIL-C-39029 are used with the connector
types indicated in paragraph 5. The method of crimping
wires to these contacts is essentially the same
throughout the entire group of connectors. Standard
crimping tools conforming to MIL-DTL-22520 are used
to crimp the contacts. Contacts manufactured after April
1978 will be identified with BIN (basic identification on
number) code colour bands (see Figure 10–15). Each
digit of the BIN code will be designated on the contact
by a colour band in accordance with the following:
Figure 10–13 Insulation Sleeve or Heat
Shrinkable Tubing Bottomed Against Insert 0 – Black 5 – Green
1 – Brown 6 – Blue
Preshaping Wires 2 – Red 7 – Violet
3 – Orange 8 – Grey
25. Preshape large diameter wires (No. 14 and 4 – Yellow 9 – White
larger) before soldering to contacts. This will avoid
strain on soldered connection when cable clamp is 28. See Table 10–5 for contact to BIN code cross
installed. See Figure 10–14. reference.

PRESHAPING IS A NECESSITY FOR


CONNECTORS USING RESILIENT INSERTS.
SIDE STRAIN ON THE CONTACTS WILL
CAUSE CONTACT SPLAYING AND
PREVENT PROPER MATING OF PIN AND
SOCKET CONTACTS.

Figure 10–15 Contact Marking

HAND CRIMPING TOOLS FOR CONNECTOR


CONTACTS

29. Crimping tools used for crimping removable


contacts to wire conductors for use in electrical
connectors, terminal junction systems, and other
electrical or electronic components, should conform to
MIL-DTL-22520 and one of its associated specification
sheets. These tools are capable of crimping a range of
contact wire barrel sizes 12 to 28, to a range of wire
sizes 12 to 32. All MIL-DTL-22520 hand operated tools
are cycle controlled by means of a ratchet mechanism
Figure 10–14 Preshaping and Tying Wires that will not release until the crimping cycle has been
completed. A brief description of each of these tools
follows:

10
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

head combination is used to crimp outer pin and socket


coaxial contacts to the shielded cables specified for
them. The tool, which is not operator adjustable, creates
a circular crimp around the contact. For specific tool
application, see MIL-DTL-22520/4.
DO NOT DISASSEMBLE ANY CRIMPING
TOOLS. DO NOT TIGHTEN OR LOOSEN MIL-DTL-22520/7 Crimping Tool
NUTS OR OTHERWISE ATTEMPT TO
ADJUST. REQUIRED ADJUSTMENTS 33. The basic crimping tool, M22520/7-01,
SHOULD BE MADE ONLY BY THE accommodates contacts with wire barrel sizes 16
MANUFACTURER, OR BY A CALIBRATION through 22, and has a provision for selecting the proper
LABORATORY. depth of crimp depending on the contact/wire
combination being used. It is similar to the M22520/2-
MIL-DTL-22520/1 Crimping Tool 01 in that it is smaller than the M22520/1-01 and is
therefore easier to handle. It is also similar in
30. The basic crimping tool, M22520/l-0l, appearance and has the same method of operation.
accommodates contacts with wire barrel sizes 12
through 20 and has a provision for selecting the proper TOOL INSPECTION GAUGING
depth of crimp depending on the contact/wire
combination being used. The contact is crimped by the 34. All crimping tools can be checked for proper
creation of four sets of double impressions caused by calibration of the crimping jaws (indenters) by means of
the closure of the four indenters. Appropriate turret or GO/NO GO inspection gages. If the GO gauge does not
positioner heads are installed depending on the pass through the indenter tips and/or the NO GO gauge
application. passes through the tips, do not use the tool but return it
for repair. The tools should be checked before each
MIL-DTL-22520/2 Crimping Tool series of crimping operations.

31. The basic crimping tool, M22520/2-01,


accommodates contacts with wire barrel sizes 20
through 28, and has a provision for selecting the proper
depth of crimp depending on the contact/wire
combination being used. The contact is crimped by the
creation of four sets of double impressions caused by
the closure of the four indenters. Appropriate DO NOT CRIMP DOWN ON THE GAUGE
positioners are installed depending on the application. PINS AS THIS WILL PREVENT THE TOOL
FROM FULL CYCLING TO THE RATCHET
MIL-DTL-22520/4 Crimping Tool RELEASE POSITION.

32. The basic tool, MS22520/4-01, is used only


with the M22520/4-02 single positioner head. This tool

11
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing

Bin Code Current Superseded Pin or


Part Number Part Number Socket
100 M39029/1-100 M39029/1-16-22 P
101 M39029/1-101 M39029/1-16-20 P
102 M39029/1-102 M39029/1-14-16 P
103 M39029/1-103 M39029/1-12-12 P
104 M39029/2-104 M39029/2-22-22 P
105 M39029/2-105 M39029/2-20-20 P
106 M39029/2-106 M39029/2-16-16 P
107 M39029/3-107 M39029/3-22-22 S
108 M39029/3-108 M39029/3-20-20 S
109 M39029/3-109 M39029/3-16-16 S
110 M39029/4-110 M39029/4-20-20 P
M83723-33B20 P
111 M39029/4-111 M39029/4-16-16 P
M83723-33B16 P
112 M39029/4-112 M39029/4-16-20 P
113 M39029/4-113 M39029/4-12-12 P
M83723-33B12 P
114 M39029/4-114 M39029/4-12-16 P
115 M39029/5-115 M39029/5-20-20 S
M83723-34B20 S
116 M39029/5-116 M39029/5-16-16 S
M83723-34B16 S
117 M39029/5-117 M39029/5-16-20 S
118 M39029/5-118 M39029/5-12-12 S
M83723-34B12 S
119 M39029/5-119 M39029/5-12-16 S
120 M39029/6-120 M39029/6-01 P
121 M39029/6-121 M39029/6-02 P
122 M39029/6-122 M39029/6-03 P
123 M39029/6-123 M39029/6-04 P
124 M39029/6-124 M39029/6-05 P
125 M39029/6-125 M39029/6-06 P
126 M39029/7-126 M39029/7-001 P
127 M39029/7-127 M39029/7-002 P
128 M39029/7-128 M39029/7-003 P
129 M39029/8-129 M39029/8-001 S
130 M39029/8-130 M39029/8-002 S
131 M39029/8-131 M39029/8-003 S
132 M39029/9-132 M39029/9-20-20-C1 P
133 M39029/9-133 M39029/9-20-20-C2 P
134 M39029/9-134 M39029/9-20-20-C3 P
135 M39029/9-135 M39029/9-20-20-C4 P
136 M39029/9-136 M39029/9-20-20-C5 P
138 M39029/10-138 M39029/10-20-20-C1 S
139 M39029/10-139 M39029/10-20-20-C2 S
140 M39029/10-140 M39029/10-20-20-C3 S

12
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
141 M39029/10-141 M39029/10-20-20-C4 S
142 M39029/10-142 M39029/10-20-20-C5 S
144 M39029/11-144 M39029/11-22-22 P
145 M39029/11-145 M39029/11-20-20 P
146 M39029/11-146 M39029/11-16-16 P
147 M39029/11-147 M39029/11-12-12 P
148 M39029/12-148 M39029/12-22-22 S
149 M39029/12-149 M39029/12-20-20 S
150 M39029/12-150 M39029/12-16-16 S
151 M39029/12-151 M39029/12-12-12 S
152 M39029/13-152 M39029/13-01 S
153 M39029/13-153 M39029/13-02 S
154 M39029/13-154 M39029/13-03 S
155 M39029/13-155 M39029/13-04 S
156 M39029/13-156 M39029/13-05 S
157 M39029/13-157 M39029/13-06 S
158 M39029/14-158 M39029/14-01 S
159 M39029/14-159 M39029/14-02 S
160 M39029/14-160 M39029/14-03 S
161 M39029/14-161 M39029/14-04 S
162 M39029/14-162 M39029/14-05 S
163 M39029/14-163 M39029/14-06 S
166 M39029/16-166 M39029/16-23-28 S
167 M39029/16-167 M39029/16-23-22 S
168 M39029/16-168 M39029/16-20-20 S
169 M39029/16-169 M39029/16-16-16 S
170 M39029/16-170 M39029/16-12-12 S
171 M39029/17-171 M39029/17-23-28 S
172 M39029/17-172 M39029/17-23-22 S
173 M39029/17-173 M39029/17-20-20 S
174 M39029/17-174 M39029/17-16-16 S
175 M39029/17-175 M39029/17-12-12 S
176 M39029/18-176 M39029/18-23-28 P
177 M39029/18-177 M39029/18-23-22 P
178 M39029/18-178 M39029/18-20-20 P
179 M39029/18-179 M39029/18-16-16 P
180 M39029/18-180 M39029/18-12-12 P
181 M39029/19-181 M39029/19-01 P
182 M39029/19-182 M39029/19-02 P
183 M39029/19-183 M39029/19-03 P
184 M39029/20-184 M39029/20-01 P
185 M39029/20-185 M39029/20-02 P
186 M39029/20-186 M39029/20-03 P
187 M39029/21-187 M39029/21-01 S
188 M39029/21-188 M39029/21-02 S

13
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
189 M39029/21-189 M39029/21-03 S
190 M39029/22-190 M39029/22-22-28 S
M39029/15-22-28 S
191 M39029/22-191 M39029/22-22-22 S
M39029/15-22-22 S
192 M39029/22-192 M39029/22-20-20 S
193 M39029/22-193 M39029/22-16-16 S
194 M39029/23-194 M39029/23-01 P
195 M39029/23-195 M39029/23-02 P
196 M39029/23-196 M39029/23-02 P
197 M39029/23-197 M39029/23-04 P
198 M39029/23-198 M39029/23-05 P
199 M39029/24-199 M39029/24-01 S
200 M39029/24-200 M39029/24-02 S
201 M39029/24-201 M39029/24-03 S
202 M39029/24-202 M39029/24-04 S
203 M39029/24-203 M39029/24-05 S
204 M39029/25-204 M39029/25-01 P
205 M39029/25-205 M39029/25-02 P
206 M39029/25-206 M39029/25-03 P
207 M39029/26-207 M39029/26-01 S
208 M39029/26-208 M39029/26-02 S
209 M39029/26-209 M39029/26-03 S
210 M39029/27-210 M39029/27-12A S
211 M39029/28-211 M39029/28-12A P
212 M39029/29-212 M39029/29-16-16 P
M83723-29T16 P
M53162-16-16 P
213 M39029/29-213 M39029/29-12-12 P
M83723-29T12 P
M53162-12-12 P
214 M39029/29-214 M39029/29-8-8 P
M83723-29T8 P
M53162-8-8 P
215 M39029/29-215 M39029/29-4-4 P
M83723-29T4 P
M53162-4-4 P
216 M39029/29-216 M39029/29-0-0 P
M83723-29T0 P
M53162-0-0 P
217 M39029/30-217 M39029/30-16S-16 S
M83723-30T16 S
M53163-16S-16 S
218 M39029/30-218 M39029/30-16-16 S
M83723-30T16 S
M53163-16-16 S

14
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
219 M39029/30-219 M39029/30-12-12 S
M83723-30T12 S
M53163-12-12 S
220 M39029/30-220 M39029/30-8-8 S
M83723-30T8 S
M53163-8-8 S
221 M39029/30-221 M39029/30-4-4 S
M83723-30T4 S
M53163-4-4 S
222 M39029/30-222 M39029/30-0-0 S
M83723-30T0 S
M53163-0-0 S
223 M39029/31-223 MS3192-20-20A P
224 M39029/31-224 MS3192-20-20C4 P
225 M39029/31-225 MS3192-20-20C1 P
226 M39029/31-226 MS3192-20-20C2 P
227 M39029/31-227 MS3192-20-20C3 P
228 M39029/31-228 MS3192-16-16A P
229 M39029/31-229 MS24254-16P P
230 M39029/31-230 MS3192-16-16C4 P
231 M39029/31-231 MS3192-16-16C1 P
232 M39029/31-232 MS3192-16-16C2 P
233 M39029/31-233 MS3192-16-16C3 P
234 M39029/31-234 MS3192-12-12A P
235 M39029/31-235 MS24254-12P P
236 M39029/31-236 MS3192-12-12C4 P
237 M39029/31-237 MS3192-12-12C1 P
238 M39029/31-238 MS3192-12-12C2 P
239 M39029/31-239 MS3192-12-12C3 P
240 M39029/31-240 MS3192-A20-20A P
241 M39029/31-241 MS24254-20P P
242 M39029/32-242 MS3193-20-20A S
243 M39029/32-243 MS3193-20-20C4 S
244 M39029/32-244 MS3193-20-20C1 S
245 M39029/32-245 MS3193-20-20C2 S
246 M39029/32-246 MS3193-20-20C3 S
247 M39029/32-247 MS3193-16-16A S
248 M39029/32-248 MS24255-16S S
249 M39029/32-249 MS3193-16-16C4 S
250 M39029/32-250 MS3193-16-16C1 S
251 M39029/32-251 MS3193-16-16C2 S
252 M39029/32-252 MS3193-16-16C3 S
253 M39029/32-253 MS3193-12-12A S
254 M39029/32-254 MS24255-12S S
255 M39029/32-255 MS3193-12-12C4 S
256 M39029/32-256 MS3193-12-12C1 S

15
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
257 M39029/32-257 MS3193-12-12C2 S
258 M39029/32-258 MS3193-12-12C3 S
259 M39029/32-259 MS3193-A20-20A S
260 M39029/32-260 MS24255-20S S
261 M39029/33-261 MS3343A23-28 S
262 M39029/33-262 MS3343B23-28 S
263 M39029/33-263 MS3343A23-22 S
264 M39029/33-264 MS3343B23-22 S
265 M39029/33-265 MS3343A20-20 S
266 M39029/33-266 MS3343B20-20 S
267 M39029/33-267 MS3343A16-16 S
268 M39029/33-268 MS3343B16-16 S
269 M39029/33-269 MS3343A12-12 S
270 M39029/33-270 MS3343B12-12 S
271 M39029/34-271 MS17803-20-20 P
272 M39029/34-272 MS17803-16-20 P
273 M39029/34-273 MS17803-16-16 P
274 M39029/35-274 MS17804-20-20 S
275 M39029/35-275 MS17804-16-20 S
276 M39029/35-276 MS17804-16-16 S
277 MS39029/36-277 MS17807-16-20 P
278 MS39029/36-278 MS17807-16-16 P
279 MS39029/36-279 MS17808-16-20 S
280 MS39029/37-280 MS17808-16-16 S
287 MS39029/44-287 MS90453-16-22 P
288 MS39029/44-288 MS90453-16-16 P
289 MS39029/44-289 MS90453-12-16 P
290 MS39029/44-290 MS90453-12-12 P
291 MS39029/44-291 MS90453-8-8 P
292 MS39029/44-292 MS90453-4-4 P
293 MS39029/44-293 MS90453-0-0 P
294 MS39029/45-294 MS90454-16-22 S
295 MS39029/45-295 MS90454-16-16 S
296 MS39029/45-296 MS90454-12-16 S
297 MS39029/45-297 MS90454-12-12 S
298 MS39029/45-298 MS90454-8-8 S
299 MS39029/45-299 MS90454-4-4 S
300 MS39029/45-300 MS90454-0-0 S
301 M39029/46-301 MS90460A23-28 S
302 M39029/46-302 MS90460B23-28 S
303 M39029/46-303 MS90460A23-22 S
304 M39029/46-304 MS90460B23-22 S
305 M39029/46-305 MS90460A20-20 S
306 M39029/46-306 MS90460B20-20 S
307 M39029/46-307 MS90460A16-16 S
308 M39029/46-308 MS90460B16-16 S
309 M39029/46-309 MS90460A12-12 S

16
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
310 M39029/46-310 MS90460B12-12 S
311 M39029/47-311 MS90461-A23-28 P
312 M39029/47-312 MS90461-B23-28 P
313 M39029/47-313 MS90461-A23-22 P
314 M39029/47-314 MS90461-B23-22 P
315 M39029/47-315 MS90461-A20-20 P
316 M39029/47-316 MS90461-B20-20 P
317 M39029/48-317 MS90559-11 P
318 M39029/48-318 MS90559-12 P
319 M39029/48-319 MS90559-14 P
320 M39029/48-320 MS90559-8 P
321 M39029/48-321 MS90559-9 P
322 M39029/48-322 MS90559-13 P
323 M39029/48-323 MS90559-5 P
324 M39029/48-324 MS90559-6 P
325 M39029/48-325 MS90559-3 P
326 M39029/48-326 MS90559-4 P
327 M39029/48-327 MS90559-1 P
328 M39029/48-328 MS90559-2 P
329 M39029/49-329 MS90560-7 S
330 M39029/49-330 MS90560-8 S
331 M39029/49-331 MS90560-5 S
332 M39029/49-332 MS90560-9 S
333 M39029/49-333 MS90560-3 S
334 M39029/49-334 MS90560-2 S
335 M39029/49-335 MS90560-1 S
336 M39029/47-336 MS90461-A16-16 P
337 M39029/47-337 MS90461-B16-16 P
338 M39029/47-338 MS90461-A12-12 P
339 M39029/47-339 MS90461-B12-12 P
340 M39029/50-340 N83733/13-12 P
341 M39029/51-341 N83733/14-12 S
342 M39029/54-342 MS27184-22P P
343 M39029/54-343 MS27184-20P P
344 M39029/55-344 MS27185-22S S
345 M39029/55-345 MS27185-20S S
348 M39029/56-348 MS27490-22D S
349 M39029/56-349 MS27490-22M S
350 M39029/56-350 MS27490-22 S
351 M39029/56-351 MS27490-20 S
352 M39029/56-352 MS27490-16 S
353 M39029/56-353 MS27490-12 S
354 M39029/57-354 MS27491-22D S
355 M39029/57-355 MS27491-22M S
356 M39029/57-356 MS27491-22 S
357 M39029/57-357 MS27491-20 S
358 M39029/57-358 MS27491-16 S

17
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
359 M39029/57-359 MS27491-12 S
360 M39029/58-360 MS27493-22D P
361 M39029/58-361 MS27493-22M S
362 M39029/58-362 MS27493-22 S
363 M39029/58-363 MS27493-20 S
364 M39029/58-364 MS27493-16 P
365 M39029/58-365 MS27493-12 P
366 M39029/59-366 MS27535 P
367 M39029/60-367 MS27536 P
368 M39029/63-368 MS24308/10-1 P
369 M39029/64-369 MS24308/11-1 P
384 M39029/69-384 M39029/69-1 P
385 M39029/69-385 M39029/69-2 P
386 M39029/69-386 M39029/69-3 P
387 M39029/70-387 M39029/70-1 P
388 M39029/70-388 M39029/70-2 P
389 M39029/70-389 M39029/70-3 P
390 M39029/71-390 M39029/71-1 P
391 M39029/71-391 M39029/71-2 P
392 M39029/71-392 M39029/71-3 P
393 M39029/72-393 M39029/72-1 S
394 M39029/72-394 M39029/72-2 S
395 M39029/72-395 M39029/72-3 S
396 M39029/73-396 M39029/73-12A S
397 M39029/73-397 M39029/73-12B S
398 M39029/73-398 M39029/73-12C S
399 M39029/74-399 M39029/74-12A P
400 M39029/74-400 M39029/74-12B P
401 M39029/74-401 M39029/74-12C P
402 M39029/27-402 M39029/27-12B S
403 M39029/27-403 M39029/27-12C S
404 M39029/27-404 M39029/27-12D S
405 M39029/27-405 M39029/27-12E S
406 M39029/27-406 M39029/27-12F S
407 M39029/27-407 M39029/27-12G S
408 M39029/27-408 M39029/27-12H S
409 M39029/28-409 M39029/28-12B P
410 M39029/28-410 M39029/28-12C P
411 M39029/28-411 M39029/28-12D P
412 M39029/28-412 M39029/28-12E P
413 M39029/28-413 M39029/28-12F P
414 M39029/28-414 M39029/28-12G P
415 M39029/28-415 M39029/28-12H P
416 M39029/75-416 M39029/75-12A S
417 M39029/75-417 M39029/75-12B S
418 M39029/75-418 M39029/75-12C S
419 M39029/75-419 M39029/75-12D S

18
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
420 M39029/75-420 M39029/75-12E S
421 M39029/75-421 M39029/75-12F S
422 M39029/75-422 M39029/75-12G S
423 M39029/75-423 M39029/75-12H S
424 M39029/76-424 M39029/76-16A P
425 M39029/76-425 M39029/76-16B P
426 M39029/76-426 M39029/76-16C P
427 M39029/76-427 M39029/76-16D P
428 M39029/77-428 M39029/77-16A S
429 M39029/77-429 M39029/77-16B S
430 M39029/77-430 M39029/77-16C S
431 M39029/77-431 M39029/77-16D S
432 M39029/78-432 M39029/78-16A S
433 M39029/78-433 M39029/78-16B S
434 M39029/78-434 M39029/78-16C S
435 M39029/78-435 M39029/78-16D S
436 M39029/79-436 M39029/79-16A P
437 M39029/79-437 M39029/79-16B P
438 M39029/80-438 M39029/80-16A S
439 M39029/80-439 M39029/80-16B S
440 M39029/34-440 M39029/34-22-22 P
441 M39029/35-441 M39029/35-22-22 S
448 M39029/31-448 M39029/31-20-20 P
449 M39029/32-449 M39029/32-20-20 S
450 M39029/83-450 M39029/83-20-22 P
451 M39029/83-451 M39029/83-20-28 P
452 M39029/84-452 M39029/84-20-22 S
453 M39029/84-453 M39029/84-20-28 S
454 M39029/85-454 M39029/85-16-16-C1 P
455 M39029/85-455 M39029/85-16-16-C2 P
456 M39029/85-456 M39029/85-16-16-C3 P
457 M39029/85-457 M39029/85-16-16-C4 P
458 M39029/85-458 M39029/85-12-12-C1 P
459 M39029/85-459 M39029/85-12-12-C2 P
460 M39029/85-460 M39029/85-12-12-C3 P
461 M39029/85-461 M39029/85-12-12-C4 P
462 M39029/86-462 M39029/86-16-16-C1 S
463 M39029/86-463 M39029/86-16-16-C2 S
464 M39029/86-464 M39029/86-16-16-C3 S
465 M39029/86-465 M39029/86-16-16-C4 S
466 M39029/86-466 M39029/86-12-12-C1 S
467 M39029/86-467 M39029/86-12-12-C2 S
468 M39029/86-468 M39029/86-12-12-C3 S
469 M39029/86-469 M39029/86-12-12-C4 S
470 M39029/87-470 M39029/87-22-22-C1 P
471 M39029/87-471 M39029/87-22-22-C2 P
472 M39029/87-472 M39029/87-22-22-C3 P

19
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–5 Electrical Contact BIN Code Listing (Continued)

Bin Code Current Superseded Pin or


Part Number Part Number Socket
473 M39029/87-473 M39029/87-22-22-C4 P
474 M39029/87-474 M39029/87-20-20-C1 P
475 M39029/87-475 M39029/87-20-20-C2 P
476 M39029/87-476 M39029/87-20-20-C3 P
477 M39029/87-477 M39029/87-20-20-C4 P
478 M39029/87-478 M39029/87-16-16-C1 P
479 M39029/87-479 M39029/87-16-16-C2 P
480 M39029/87-480 M39029/87-16-16-C3 P
481 M39029/87-481 M39029/87-16-16-C4 P
482 M39029/88-482 M39029/88-22-22-C1 S
483 M39029/88-483 M39029/88-22-22-C2 S
484 M39029/88-484 M39029/88-22-22-C3 S
485 M39029/88-485 M39029/88-22-22-C4 S
486 M39029/88-486 M39029/88-20-20-C1 S
487 M39029/88-487 M39029/88-20-20-C2 S
488 M39029/88-488 M39029/88-20-20-C3 S
489 M39029/88-489 M39029/88-20-20-C4 S
490 M39029/88-490 M39029/88-16-16-C1 S
491 M39029/88-491 M39029/88-16-16-C2 S
492 M39029/88-492 M39029/88-16-16-C3 S
493 M39029/88-493 M39029/88-16-16-C4 S
494 M39029/89-494 M39029/89-22-22-C1 S
495 M39029/89-495 M39029/89-22-22-C2 S
496 M39029/89-496 M39029/89-22-22-C3 S
497 M39029/89-497 M39029/89-22-22-C4 S
498 M39029/89-498 M39029/89-20-20-C1 S
499 M39029/89-499 M39029/89-20-20-C2 S
500 M39029/89-500 M39029/89-20-20-C3 S
501 M39029/89-501 M39029/89-20-20-C4 S
502 M39029/89-502 M39029/89-16-16-C1 S
503 M39029/89-503 M39029/89-16-16-C2 S
504 M39029/89-504 M39029/89-16-16-C3 S
505 M39029/89-505 M39029/89-16-16-C4 S
506 M39029/89-506 ------ S
507 M39029/89-507 M39029//-20-22D S
508 M39029/83-508 ------ P
509 M39029/84-509 ------ S
528 M39029/58-528 ------ P
529 M39029/90-529 ------ S

20
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–6 Specification Replacements

MIL-DTL-83723, Series I are replaced by MIL-C-26482 as shown below


MIL-DTL-83723 Specification Sheet Superseded By
1 and 2 MS3470
3 and 4 MS3472
5 and 6 MS3474
7 and 8 MS3471
9 and 10 MS3440
11 and 12 MS3443
13 and 14 MS3476
33 MIL-C-39029/4
34 MIL-C-39029/4
36, 37, 38, 39, 40 and 41 No superseding document
42 and 43 MS3475
44 MS3181
45 MS3115
46 MS3180
48 and 49 No superseding document
MIL-DTL-83723, Series II are replaced by MIL-DTL-5015 as shown below
MIL-DTL-83723 Specification Sheet Superseded By
17 and 18 MS3451
19 and 20 MS3450
21 and 22 MS3452
23 and 24 MS3456
25 MS3141
26 MS3143
27 MS3109 or MS3117 and MS3158 or MS3416
29 MIL-C-29029/29
30 MIL-C-29029/30
35 No superseding document
50 No superseding document
52 and 53 MS3459

Inspection of M22520/1-01, M22520/2-01, M22520/4- b. Set the selector at the proper selector
01, M22520/7-01 Basic Tools number as specified in Table 10–7.

35. Inspection gauging is preformed on the basic c. Close the handles completely and hold.
tool only. However, the tools may be gauged with a
positioning device installed as long as it does not d. The GO gauge (green end) should pass
interfere with the gauging operation. If the presence of freely through the indenter tips.
the positioning device makes gauging difficult, remove
it before inspecting. The inspection procedure is as e. The NO GO gauge (red end) should not
follows: enter through the indenter tips.

a. Select the proper inspection gauge to be


used from Table 10–7.

21
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–7 Crimping Tool Inspection Gauges and Selector Settings

Crimping Tool Part Number Inspection Gauge Part Number Selector Setting
M22520/1-01 M22520/3-1 4
M22520/2-01 M22520/3-1 8
M22520/4-01 M22520/3-2 Not applicable
M22520/7-01 M22520/3-3 8

TYPES OF CONTACT POSITIONING DEVICES M22520/4-01 Basic Tool

36. All crimping tools have positioning devices 39. This is a single purpose tool that only uses the
available that are used for locating contacts in the M22520/4-02 single positioner head that is not operator
proper relation to the tool indenters. The following is a adjustable (see paragraph 32).
brief description of the types of positioners used for the
various types of tools: CRIMPING PROCEDURES

M22520/1-01 Basic Tools M22520/1-01 Crimping Tools with Turret Heads and
Single Position Heads
37. These tools use turret heads, single positioner
heads and universal heads. 40. The procedure for crimping contacts to wire
conductors is as follows:
a. Turret Heads. These heads have a turret
that has three separate positioners that a. Select the proper positioning head to be
are colour coded and marked with the used for the contacts being crimped.
applicable contact size accommodated
by each individual positioner within the b. If the head to be used is a turret head,
head. The colour and contact size first depress the turret trigger to release
correspond to the information on the foil the turret portion to the indexing or
label (data plate) attached to the side of extended position as shown in Figure
the head. The proper positioner is 10–16.
selected for the contact type and size to
be crimped by referring to the data plate. c. Place the head over the retaining ring on
the back of too1 (selector side) and seat
b. Single Position Heads. These heads against the tool body; secure the 3.5mm
have only one positioner and are not socket head screws with Allen wrench
adjustable. They also have data plates (see Figure 10–16). If the positioning
which provide crimping information. head is the single positioner type, omit
steps d. and e.
c. Universal Heads. These heads are used
for locating contacts which are not d. If the positioning head is the turret type,
military standard or for which no it has three separate positioners that are
positioning heads are available. They are colour coded and marked with the
adjusted for each application while applicable contact size accommodated
attached to the tool as described in by each individual positioner. The
paragraph 41, but have no data plate colour code and contact size correspond
with crimping information. to the information contained on the data
plate. Refer to the data plate to select the
M22520/2-01and M22520/7-01 Basic Tools proper positioner to be used for the
contact being crimped.
38. These tools use locating devices known as
positioners. They are individual locators with a data e. Rotate the turret until the correct
plate attached to the top that specifies the contact part positioner is lined up with the index
numbers(s) accommodated, and correlates the wire mark on the turret head and push the
sizes. turret in until it snaps into the locked
position (see Figure 10–16).

22
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–16 Typical M22520 Positioner and Turret Head

Figure 10–17 M22520 Crimping Tools

f. Refer again to the data plate for the g. Determine the proper length of
correct selector setting for the wire size insulation to be removed. Wire must be
being used. With the handles fully open, visible in inspection hole, insulation
remove spring clip lock wire from must be between 0.4mm and 0.8mm
selector knob, lift and rotate the selector from end of contact. Strip the insulation
knob (or slide the thumb button) to the from the conductor by using any of the
correct setting and release (see Figure methods described in Section 2, Chapter
10–17) and reinstall spring clip lock 3.
wire.

23
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

NOTE M22520/1-01 Crimping Tools with Universal Heads

When crimping contacts with an insulation 41. The universal head may be used when a turret
support cup, make sure the insulation extends or single position head is not available. The procedure is
into it (0.4 to 0.8 mm from bottom of cup). (The as follows:
contact shown in Figure 10–18 has this feature.)
a. Rotate the lock nut counterclockwise to
h. Insert the stripped wire into the wire the released position and turn adjustment
barrel of the contact until the end of the nut counter-clockwise until head can be
wire can be seen through the inspection seated on tool.
hole. Insert the wire and contact through
the indenters on the front side of tool b. Place the head over the retaining ring on
(opposite from selector side) until it the back of the tool (selector side) and
bottoms and fully seats in the positioner. seat against the tool body; secure the
3.5mm socket head screws with an Allen
i. Hold the wire and contact in place and wrench. With the tool handles fully
squeeze the tool handles until they fully open, remove spring clip lock wire from
bottom and the ratchet releases, allowing selector knob, raise and rotate the
the handles to automatically return the selector knob (or slide the thumb button)
open position. until the arrow is in line with the wire
size being crimped, release selector knob
j. Remove the crimped contact and and reinstall spring clip lock wire.
inspect, making sure the wire strands are
visible through the inspection hole in the
contact wire barrel (see Figure 10–18).

THE WIRE SIZES ARE FOR REFERENCE


ONLY. THEY ARE BASED ON THE USE OF
MIL-W-22759 SILVER PLATED WIRE
CRIMPED IN MS3190 WIRE BARRELS.
SETTINGS MUST BE ESTABLISHED WHEN
USING OTHER CONTACT/WIRE
COMBINATIONS.

c. Turn adjustment screw on head


clockwise until it stops. With the tool
opening facing up, insert contact through
indenter opening into positioner until it
bottoms. Begin turning adjustment
screw out until indenters are cantered
between inspection hole and end of wire
barrel. If contact has insulation support
cup, centre the indenters between
inspection hole and bottom of cup.

d. Without turning the adjustment screw,


tighten lock nut against head.

e. Strip wire as specified in paragraph 40.

f. Insert wire and contact, crimp and


inspect as specified in paragraph 40.

M22520/2-01 and M22520/7-01 Crimping Tools with


Positioners
Figure 10–18 Assembling Wires To Crimp Type
Contacts 42. The procedure for the crimping contacts with
these tools is as follows:

24
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

a. Select the proper positioner to be used Table 10–8 Contacts and Their Wire Size
for the contact being crimped. Range

b. Insert the positioner into the retaining Contact Wire Size


ring on the back of the tool (selector Size Range
side). The positioner is spring-loaded
and must be pushed in and then rotated 20 24-20
90° clock-wise until it locks into 16 22-16
position. Insert the spring clip lock wire 12 14-12
(if present) through the retaining ring. 8 10-8
4 6-4
c. Refer to the data plate for the correct
0 2-0
selector setting for the wire size being
used. With the handles fully open,
remove spring clip lock wire from
Assembling Wired Contacts into Front Release
selector knob, lift and rotate the selector
Connector
knob to the correct setting and release
and reinstall spring clip lock wire.
45. Insert the crimped contact into the connector as
follows:
d. Strip wire as described in paragraph 40.
a. Slide rear accessories back onto wire
e. Insert wire and contact, crimp and
bundle.
inspect as specified in paragraph 40.
NOTE
CRIMPING TOOL KITS
Before attempting any insertion of contacts into
43. There are several crimping tool kits available
MIL-C-81511 series 1 or 2 connectors,
for maintenance use.
determine that the rear nut assembly is in the
unlocked position. A coloured stripe will appear
INSTALLING AND REMOVING CRIMP TYPE when the rear nut assembly is rotated
CONTACTS counterclockwise. At this point, the connector is
in position for both insertion and removal of
Insertion Tools for Front Release Crimp Type contacts.
Contacts
b. Select the correct insertion tool. Insert
44. Type tools for inserting contacts into front the crimped end of the contact into the
release connector inserts are shown in Figure 10–19. hollow end of the insertion tool, and lay
There is a separate tool for each contact size. Contact along handle (see Figure 10–20).
sizes are listed in Table 10–8. An indicating band on the
working end of the tool determines the correct depth of c. Guide the contact into the correctly
tool insertion. Use these tools to insert contacts in front numbered grommet hole in the rear face
release connectors with removable contacts.
of the insert and feed the contact
carefully into the hole.

d. Push the tool straight in at right angles to


the grommet surface, until the contact is
fully seated.

DO NOT USE TOOLS THAT HAVE BURRS e. Withdraw the tool, keeping it
OR SHARP EDGES. BURRS OR SHARP perpendicular to the grommet face.
EDGES CAN CUT THROUGH GROMMET
WIRE SEALING WEBS AND DESTROY THE f. Gently pull on wire to make sure contact
ENVIRONMENTAL SEALING is held in place.
CAPABILITIES OF A CONNECTOR.
g. Fill all unused holes with unwired
contacts and sealing plugs of appropriate
size.

25
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

NOTE Extraction Tools for Front Release Crimp Type


Contacts
After all contacts and sealing plugs have been
inserted into MIL-C-81511 series 1 and 2 47. Typical tools for extracting contacts from front-
connectors, tighten the rear nut by turning release connector inserts are shown in Figure 10–19.
clockwise until the locking nut is tight. The sizes for each contact are listed in Table 10–8. This
tool has a hollow cylindrical probe which fits snugly
over the pin or socket end of the contact and releases the
insert retention clip when pushed over the contact. Two
indicating bands determine correct depth; the band
nearest the working end of the tool is for pin contacts,
the other for socket contacts. The extraction tool has a
DO NOT ATTEMPT TO RESEAT A thrust assist collar (or slide) which is pushed forward to
CONTACT ONCE THE INSERTION TOOL eject the contact from the insert retention clip by means
HAS BEEN REMOVED. REMOVE CONTACT of an internal plunger. Use these tools to remove
AND START AGAIN WITH CONTACT contacts from front release connectors with removable
BARREL PROPERLY LOCATED IN TOOL. contacts.
FAILURE TO FOLLOW THIS PRECAUTION
WILL CAUSE INSERTION TOOL TO SHEAR Removing Contacts from Front Release Connectors
BARREL WHILE INSIDE GROMMET.
SHARP EDGE OF SHEARED MATERIAL 48. Remove contacts from the connector as
WILL CUT THROUGH GROMMET WEB follows:
AND CAUSE SHORT CIRCUIT.
NOTE
Alternative Front Release Contact Assembly
Procedure This procedure does not apply to rear release
connectors.
46. If desired, the following procedure may be used
to insert wired contacts into the connector: a. Select the correct extraction tool for the
contact to be removed.
a. Push the wired contact carefully into the
correct grommet hole. Do not push all b. Slide rear accessories back on the wire
the way in. bundle.
b. Slide the insertion tool over the contact NOTE
barrel. (See Figure 10–20).
On MIL-C-81511 series 1 and 2 connectors,
c. Complete the procedure by following loosen the rear nut assembly by turning it
steps d, e, f and g of paragraph 45. counterclockwise when viewed from the wire
Observe caution and note in paragraph end. Approximately 1.5mm of axial movement
45. unlocks the contacts. The coloured stripe will
fully appear. The connector is now in position
for removal of contacts.

26
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–19 Insertion and Extraction Tools for Front Release Crimp Type Contacts

27
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–20 Assembling Wired Contacts Into Connector

28
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–21 Removing Crimp Type Contacts From Front Release Connectors

c. Series 1 and 2 (gauge release) contacts


are removed from the front of the
connector as follows:

29
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

(1) The pin contact removal tool has


a hole to accept the pin contact.
The socket removal tool has a pin
tip to insert in the socket.
ENSURE THE EXTRACTION TOOL IS
(2) Grasp the tool by the handle. ALWAYS EXACTLY ALIGNED WITH THE
Locate the contact to be removed CONTACT TO AVOID DAMAGE TO THE
by numbers on the insert face. CONTACT OR INSERT.
(See Figure 10–21)
Insertion and Extraction Tools for Rear-Release
(3) Mate the tool with the contact Crimp Type Contacts
and, holding the tool at right
angles with the insert face, push 49. There is a separate tool for each contact size,
axially against the tip of the The tools may be plastic or metal, single or double
contact until the contact appears ended tools (see Figure 10–22) or metal tweezer type
at the grommet (rear) end of the tools (see Figure 10–23). See Figure 10–23 and Figure
connector. The removal tools are 10–24 for contact installation instructions. See Figure
designed to bottom against the 10–25 and Figure 10–26 for contact removal
insert face when the contact is instructions.
completely released and pushed
out. NOTE

(4) The wire and contact can now be Connector rear accessory (cable clamp, etc) must
removed from the connector. be removed prior to installation or removal of
contacts.
d. Working from the front or mating end of
the connector, slip the hollow end of the NOTE
extraction tool over the contact, with the
tool parallel to the contact, and squarely Insertion/extraction tools are colour coded
perpendicular to the insert face. (See according to contact size; the insertion tool being
Figure 10–21) coloured and the extraction tool white. For
unwired contacts, an additional tool may have to
NOTE be used in conjunction with the extraction tool to
push the unwired contact from the front after the
Some extraction tools have a spacer sleeve with locking tines have been released by the
positions for either pin or socket contacts. Set to extraction tool in the rear.
correct position before installing tool on contact.
Refer to Figure 10–19.

e. Push the tool toward the rear of the


connector with a firm steady push until
the tool comes to a positive stop and
bottoms in the insert hole. A slight
rotation of the tool may aid the tool
insertion.

f. Push the thrust assist collar or slide


forward as far as it will go.

g. Withdraw the tool from the contact,


Figure 10–22 Insertion and Extraction Tool For
keeping the tool perpendicular to the
Rear Release Crimp Contacts
insert face.

h. Remove the contact from the back of the


connector.

30
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–23 Tweezer Type Installing Tools

Figure 10–24 Single or Double Ended Contact Installing Tools

31
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–25 Single or Double Ended Contact Removal Tools

Figure 10–26 Tweezer Type Removal Tools

32
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

SHIELD CONNECTIONS (1) For potted connector, pigtail


should start 1 inch (25mm) from
Connecting Single Shielded Wire to Connector end of wire.

50. Terminate shielded wire as described in Section (2) For other connectors, pigtail
2, Chapter 3. For connection to non-environmental should start far enough back to
resistant connectors, shield must end inside back shell remain outside cable clamp.
as shown in Figure 10–27. For connection to
environmental resistant connectors with rear wire seal b. Solder or crimp each wire to its contact.
or potted connectors, shield must end outside seal.
Splice pigtail to short length of wire that is then c. Crimp pigtails together into one end of
terminated inside connector to a contact in the regular permanent splice (see Figure 10–28).
manner, as shown in Figure 10–28.
d. Crimp single wire, doubled if necessary;
NOTE into other end of permanent splice (see
Figure 10–29).
Connector accessories (backshells) should not be
used to terminate ground wires or shields unless e. Slide sleeve over splice and tie or heat
they were specifically designed for that purpose. shrink as appropriate.

NOTE f. Solder or crimp single wire to proper


contact in connector as shown in Figure
Shield connections currently installed under 10–28.
cable clamp screws should not be disturbed
unless maintenance is being performed on the g. Complete connector assembly in normal
connector, and then shield connections must be manner.
installed in accordance with current
requirements.

Figure 10–27 Terminating Shielded Wire at MS


Connector

Multiple Shield Connections

51. Potted connectors that contain shielded wires Figure 10–28 Terminating Shielded Wires at
and all other connectors that have many shields should Potted Connector
terminate shields outside the connector. The procedure
is as follows:

a. Form pigtail from shield outside


connector area (see Figure 10–28).

33
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

ground shields on certain solder type MIL-DTL-5015


connectors.

a. Remove washers from the connector


cable clamp and slide clamp back on
wire bundle.

b. Install the AN3111 bonding ring on the


wire bundle between the connector back
shell and the cable clamp, with the
bonding ring lug toward the solder
contacts.

c. Make a hole in one shield and expand it


to hold up to three other shields as
shown in Figure 10–31. Tighten the
expanded shield around the others and
seat solder together. Repeat as necessary
for number of shields to be grounded.
Figure 10–29 Terminating Two Wires at One d. Pull one of the shields through to form a
Contact on Non-environmental Resistant jumper. Install a length of insulating
Connector sleeving over the jumper shield.
Multiple Connections e. Clamp the ears of the bonding ring lug
around the jumper(s) and solder. Pull the
insulating sleeve over the soldered
connection.

DO NOT CONNECT TWO WIRES TO ONE


CONTACT IN ENVIRONMENTAL TYPE
CONNECTORS; THIS WILL CAUSE LOSS
OF ENVIRONMENTAL SEALING.

52. Connect two wires to one contact by using one


of the following methods:

a. If both wires can be fitted into contact


solder cup, proceed as with single wire.
Slide insulating sleeve over both wires
together and insert them into solder cup.
Make sure all strands are inside cup
before soldering. When solder has
cooled, push insulating sleeve down
until it butts against insert. (See Figure
10–29).

b. If both wires cannot fit into solder cup,


use permanent splice to join both wires
to a third wire that can fit into solder cup
or crimp barrel. See Section 2, Chapter 6
for splicing procedure and Figure 10–30
and Figure 10–32 for illustration of this
Figure 10–30 Reducing Wire Size at Connector
connection.
Using Permanent Environmental Splice
Grounding Shields with Bonding Ring

53. When specified on the applicable engineering


drawing, an AN3111 bonding ring may be used to

34
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–31 Installing AN3111 Bonding Ring

diameter contact is sometimes required. A safe method


of making the reduction is as follows:

a. Select a permanent splice or sealed


splice that will accommodate the larger
wire. Crimp this splice to the stripped
wire as described in Section 2, Chapter
6.

b. Select a 15cm length of wire that will fit


the wire barrel of the contact. Strip one
end sufficiently long to be able to double
the stripped portion back on itself as
shown in Figure 10–30.

Assembly and Disassembly Instructions for


Connectors and Wire Terminations not Covered by
Military Specifications or Standards
Figure 10–32 Terminating Two Wires to One
Contact Using Permanent Environmental Splice 55. Assembly instructions and tool calibration
procedures recommended by the connector and/or tool
manufacturer(s) should be followed in assembling
Reducing Wire Size at MS Connector electrical connectors and wire terminations not covered
by military specifications or standards.

CONTINUITY TEST

56. Test all wires and wire groups as fabricated,


REDUCTION OF WIRE SIZE NEEDS with terminations attached, for short circuits as well as
APPROVAL BY AN ENGINEERING DESIGN for continuity between the termination points specified
APPROVAL. CURRENT CARRYING on the applicable schematic. Continuity test on
CAPACITY OF SMALLER WIRE AND unshielded wires and wires less than 15 meters can be
CONTACT MUST NOT BE EXCEEDED. accomplished by using a light or buzzer connected to a
nine volt battery.
54. Reduction of wire size to enable a larger
diameter wire to be soldered or crimped to a smaller

35
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–9 Test Leads

Item Name Part No


Test Leads (Black) Model B-36-0
DO NOT USE LEAD PENCILS TO COUNT Test Leads (Red) Model B-36-2
PINS IN CONNECTORS. POINTS CAN
BREAK OFF AND LODGE IN THE 22 Gauge Sockets (Black) 4690-0
CONNECTOR, LEADING TO ARCING,
SHORTING, AND SYSTEM MALFUNCTION. 22 Gauge Sockets (Red) 4690-2
DO NOT USE OVERSIZE PRODS IN 22 Gauge Pins (Black) 4691-0
CONNECTOR SOCKETS DURING TESTING;
THIS MAY RESULT IN SPLAYED OR 22 Gauge Pins (Red) 4691-2
DAMAGED SOCKETS. DO NOT PUNCTURE
20 Gauge Sockets (Black) 3560-0
WIRE INSULATION WITH A PROBE, OR
ATTACH CLAMPS TO WIRE INSULATION 20 Gauge Sockets (Red) 3560-2
WHILE CONTINUITY TESTING OR
TROUBLE SHOOTING. 20 Gauge Pins (Black) 3561-0

20 Gauge Pins (Red) 3561-2


57. Use the ohmmeter section of an approved
multimeter to determine circuit continuity. Continuity 18 Gauge Sockets (Black) 3562-0
for short runs, where conductor resistance is not a
factor, is defined as “zero” resistance. The procedure for 18 Gauge Sockets (Red) 3562-2
determining continuity, using a multimeter is as follows: 18 Gauge Pins (Black) 3563-0

a. Set the function control to OHMS, and 18 Gauge Pins (Red) 3563-2
the range control to Rx1. Zero the
16 Gauge Sockets (Black) 3564-0
instrument as directed in the operating
manual for the instrument used. 16 Gauge Sockets (Red) 3564-2

b. Attach the test leads to the terminations 16 Gauge Pins (Black) 3565-0
of the wire run.
16 Gauge Pins (Red) 3565-2

c. Note reading on the ohms scale. A


reading of 0.25 ohms, +0.25 ohms, is
considered verification of circuit PROTECTION OF ELECTRICAL CONNECTORS
continuity.
59. Protect all unmated connector plugs and/or
NOTE receptacles with protective covers. (See Figure 10–33)
Standard protective covers for connectors are listed in
The test lead extremities contacting the the applicable connector specification. Protective covers
terminations under test must provide adequate are available with or without an attaching chain. Plastic
constant contact, and must not damage the dust caps to fit MS plugs and receptacles are also
termination. available. Electrostatic free dust caps for electrical
connectors are listed in Table 10–10.
TEST LEADS

58. For ground points and terminal lugs, use test


leads with alligator clips. For connector pins and
sockets, use a special lead ending in a sleeve-insulated
pin or socket of the same size as that being tested. ENSURE BOTH THE PLUG AND
RECEPTACLE ARE COVERED WHILE NOT
IN USE. FOREIGN OBJECTS CAN PRESENT
A HAZARD THAT MAY DAMAGE
EQUIPMENT AND HARM PERSONNEL.

36
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

PROTECT ESD SUSCEPTIBLE ITEMS.


FAILURE ADEQUATLEY PROTECT ESD
COULD CAUSE DAMAGE TO EQUIPMENT.

60. All unmated connector plugs and/or receptacles


should be protected. All loose wires/cables should be
secured as detailed in Section 2, Chapter 4.

61. Unmated connectors can be wrapped with MIL-


I-46852, silicone rubber tapes. Both materials can be
secured with waxed or nylon cord. These are alternative
methods used to protect unmated connectors exposed to
contaminants during repairs or storage when standard
protective covers and plastic caps are not available.
Silicone rubber tapes should not be used where they will
be exposed to fluids, such as jet fuels, hydraulic fluids,
engine oils, silicone damping fluid (DC-200), etc. These
fluids may cause silicone tapes to swell and/or lose Figure 10–33 Typical Protective Connector
adhesive properties. Caps

Table 10–10 Electrostatic Free Dust Caps

Dust Cap Internal Diameter Part Number Nomenclature


(mm r 0.25)
15.5 MS90376-10RF
16.3 MS90376-12YF
18.3 MS90376-12RF
19.9 MS90376-14YF
21.6 MS90376-14RF
22.7 MS90376-16YF
24.7 MS90376-16RF
26.1 MS90376-18YF
27.8 MS90376-18RF
29.2 MS90376-20YF Cap Protective Antistatic
31.3 MS90376-20RF
32.3 MS90376-22YF
34.0 MS90376-22RF
35.3 MS90376-24YF
37.2 MS90376-24RF
41.9 MS90376-28YF
43.6 MS90376-28RF
48.0 MS90376-32YF
49.9 MS90376-32RF

37
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

c. Insulate the ends of all spare wires. (See


Figure 10–34). The preferred method of
insulating a spare wire is to crimp it into
an MS25274 wire end cap (Table 10–11)
DO NOT USE PRESSURE SENSITIVE TAPE with tool as detailed in Section 2,
ON CONNECTORS AS THE RESIDUE LEFT Chapter 6. The procedure for crimping
AFTER THE TAPE IS REMOVED WILL wire end caps with standard tool is as
CAUSE CONTAMINANTS TO STICK TO follows:
THE CONNECTORS.
(1) Select an end cap of the correct
POTTING CONNECTORS size for the wire to be insulated

62. These connectors are used only where potting is (2) Make sure the locator is properly
required. They are similar to other standard types, positioned behind the lower nest.
except that they have a shorter body shell and include a Position the wire end cap in the
potting mould. Potting connectors are supplied with a correct die nest with the closed
plastic potting mould. Installation is as follows: end of the cap resting against the
locator.
a. Slide the plastic mould over the wire
bundle. (3) Insert the stripped wire so that the
end of the stripped wire is seated
against the closed end of the cap,
and the insulation is against the
metal sleeve of the cap.
POLYTETRAFLUOROETHYLENE (TFE)
AND FLUORINATED POLYETHYLENE (4) Close tool handles until ratchet
PROPYLENE (FEP) INSULATED WIRES releases and the tool opens.
REQUIRE SPECIAL PREPARATION PRIOR Remove the crimped assembly.
TO POTTING (SEE SECTION 2, CHAPTER
11).

b. Identify and install wires into contacts.


SKIN, EYE, AND RESPIRATORY
NOTE PROTECTION IS REQUIRED. DO NOT
BREATHE FUMES, MAINTAIN GOOD
Spare wires should be installed in all unused VENTILATION.
contacts. Use the largest gauge wire suitable for
each contact. Spare wires should be d. Clean the complete connector assembly
approximately 23cm long. (See Figure 10–34.) by scraping off rosin and then brush
vigorously with suitable cleaning
solvent, such as Isopropyl Alcohol.

e. Rinse area to be potted with suitable


cleaning solvent, such as Isopropyl
Alcohol.

NOTE

Complete potting within two hours after


cleaning.

f. Slide plastic mould into position on rear


Figure 10–34 Spare Wires for Potting of connector.
Connector

38
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

j. Apply a light film of lubricating oil to all


exterior metal surfaces after potting
compound is completely cured.

THE ACCELERATOR CONTAINS TOXIC


COMPOUNDS. USE IN A WELL
VENTILATED AREA. AVOID EYE AND
SKIN CONTACT. USE PERSONAL
PROTECTIVE EQUIPMENT, RUBBER OR
POLYETHYLENE GLOVES AND
APPROVED EYE PROTECTION. CLEAN
HANDS THOROUGHLY AFTER USE.

MATE CONNECTORS BEFORE POTTING


EITHER PART TO AVOID SPLAYING
CONTACTS DURING THE POTTING
OPERATIONS.

g. Apply potting compound prepared in


accordance with directions in Section 2,
Chapter 11. Fill back of connectors by
inserting nozzle down between wires
until it almost touches back of insert (see
Figure 10–35). Fill slowly while moving
nozzle back from insert and ensure no
air bubbles are trapped. Fill to top of
mould. Tamp down the compound, if
necessary, with a wooden or metal 3mm
dowel. Tap connector assembly on a
resilient surface or vibrate mechanically
to help flow the compound into all
spaces and to release trapped air.

h. Immediately after filling each connector,


tie the wires together loosely about
15cm away from the connector. Ensure Figure 10–35 Filling and Curing Potting
that wires are centrally located in the Connector
connector so that each wire is
completely surrounded by potting
compound. Suspend the assembly so that
the potting material remains level, as
shown in Figure 10–35, and allow to air
cure for at least 1.5 hours at 24qC
without any movement. Make sure that
the tie is applied after potting.

i. Carefully place assembly, still


suspended, into drying oven for 3 to 4
hours at 38qC or air cure at 24°C for 24
hours.

NOTE
Figure 10–36 Installation of O-Ring on AN Type
Potted Connector Plug
Full cure with maximum electrical characteristics
is not achieved until 24 hours after potting. Do
not perform any electrical insulation resistance
tests until this period has passed.

39
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–11 Wire End Caps

Wire Wire Strip Cap Cap Part Crimp Tool Positioner


Gauge Length (mm) Colour Number
26-24 7.6 Yellow MS25274-1 M22520/5-01 M22520/5-100
M22520/10-01 M22520/10-101
22-18 7.6 Red MS25274-2 M22520/5-01 M22520/5-100
M22520/10-01 M22520/10-101
16-14 7.6 Blue MS25274-3 M22520/5-01 M22520/5-100
M22520/10-01 M22520/10-101
12-10 8.9 Yellow MS25274-4 M22520/5-01 M22520/5-100
M22520/10-01 M22520/10-101

Table 10–12 O-Ring Sizes For AN Type Connectors

Plug Size O-Ring O-Ring MS29513


Size ID (mm) Dash
(mm) Nos.
8S 1.8 7.9 -10
10 & 10S 1.8 9.2 -12
12 & 12S 1.8 12.4 -14
14 & 14S 1.8 12.4 -14
16 & 16S 1.8 15.6 -16
18 1.8 18.8 -18
20 1.8 21.9 -20
22 1.8 25.1 -22
24 1.8 28.3 -24
28 1.8 34.6 -28
32 1.8 34.6 -28
36 2.6 44.1 -132
40 2.6 50.5 -136
44 2.6 56.8 -140
48 2.6 63.2 -144

CONNECTOR ACCESSORIES b. Slide bushing (if needed) on wire bundle


before wires are connected.
63. Circular electrical connectors should be
provided with accessories. Connector accessories for all NOTE
new design and retrofit wiring systems should be in
accordance with SAE AS50881 and this publication. A wrap of teflon, silicone rubber or glass fibre
tape can be used instead of a bushing. Only
Installation of Cable Clamp teflon tapes, silicone rubber tapes and glass fibre
tapes should be used to build-up under saddle
64. The cable clamp, is installed as follows (see clamps. MIL-I-23594 teflon, tape, teflon tape
Figure 10–38, Figure 10–39 and Figure 10–40): part number P440-4IN, A-A-59163, Type 1,
silicone rubber tapes and MIL-I-19166 glass
a. Slide cable clamp without saddles on fibre tapes work satisfactorily as build-up tapes
wire bundle before wires are connected. under saddle clamps. Silicone rubber tapes
should not be used where they will be exposed to
fluids, such as jet fuels, hydraulic fluids, engine
oils, silicone damping fluid (DC-200), etc. These
fluids may cause silicone rubber tapes to swell

40
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

and/or lose adhesive properties. Neoprene rubber Installation of MS3057 Series Connector Cable
tapes and vinyl tapes should be not be used for Clamps
build-up under the saddle clamp because of their
shrinkage and out-gassing properties. If tape 65. There are three types of MS3057 connector
wrap is used, secure with nylon braid behind cable clamps. (See Figure 10–38 and Table 10-14).
saddle. A bushing or tape build-up is required
where the wire bundle diameter is too small to be a. MS3057 has a single saddle held by two
effectively gripped by the saddle bar. screws. It contains a metal or plastic
washer and a flat rubber bushing. For
c. Assemble wires to connector. shipping, to prevent loss of the metal or
plastic washer, it is placed inside the
d. Install bushing into cable clamp and clamp and held in place by the rubber
attach clamp to connector. Padded jaw bushing. Before use, reverse the position
connector pliers may be used to tighten to that shown in Figure 10–38 so that the
or loosen a cable clamp or other metal or plastic washer will contact the
backshell accessory if necessary. back shell of the connector.

b. MS3057A has two saddles separated by


a centreing bar. This cable clamp is
supplied with MS3420 bushing to
protect the wire bundle under the clamp.
CARE SHOULD BE TAKEN NOT TO BEND Add extra bushings if necessary.
THE COUPLING RING OR BACKSHELL
WHEN A STRAP WRENCH OR PADDED c. MS3057B has a gland and tapered
JAW PLIERS ARE USED. sleeve. The gland is squeezed around the
wire bundle when the cable clamp is
e. Attach saddle bars with supplied screws screwed to the connector back shell.
and lockwashers.
d. Before installing MS3057 cable clamps
onto connectors, screw the mating part
onto the connector with the coupling
nut. This will help to prevent contacts
ENSURE BUSHINGS ARE NOT PINCHED splaying when the cable clamp is
BETWEEN SADDLES AND CENTRE BAR. tightened.
ENSURE THAT THERE IS NO FLEXING OF
THE CABLE WITHIN THE TIGHTENED Installation of MS3057 Cable Clamp
SADDLE BARS. FLEXING WILL CAUSE
DAMAGE TO THE CONNECTOR WIRING. 66. The MS3057 cable clamp is installed as follows
CABLE ASSEMBLIES WITH CONNECTOR (see Figure 10–39):
CLAMPS SHOULD NOT BE DISTURBED
REGARDLESS OF BACKSHELL SCREW a. Slide the MS3420A telescoping
POSITIONS UNLESS AUTHORISED REPAIR bushings on the wire bundle if the
WORK IS WARRANTED. bundle diameter is too small to be
effectively gripped by the saddle.
NOTE
b. Slide the MS3057 cable clamp without
Ensure that the saddle clamp screw heads are saddle on the wire bundle followed by
placed so that pushing on screw heads will the rubber bushing and the metal or
tighten cable clamp to backshell. (Some saddle plastic washer.
bars have both screw heads on same side).
c. Assemble wires to the connector and
f. Attach saddles with both screws and tighten the backshell.
lockwashers and tighten until cable is
secured within the saddle clamp. There d. Push the MS3057 cable clamp toward
should be no flexing of the cable within the backshell and hand tighten. Use a
the saddle clamp. Use extra bushings in strap wrench to tighten fully.
original assembly if saddle is not tight.
e. Push the MS3420A bushings, if
required, into the cable clamp until it is
past the saddle.

41
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

f. Attach saddle with both screws and d. Push MS3057A cable clamp together
tighten until 1.6mm space is left with inserted MS3420 bushing toward
between the saddle and the body as back shell and hand tighten. Use plug
shown in Figure 10–39. MS3420A pliers or a strap wrench to tighten fully.
bushing, if used, should bulge slightly
when the saddle is tight. e. Attach both saddles with supplied
screws and lockwashers.
NOTE
NOTE
Ensure that the saddle clamp screw heads are
placed so that pushing on the screw heads will Ensure that the saddle clamp screw heads are
tighten the cable clamp to backshell. (Some placed so that pushing on screw heads will
saddle bars have both screw heads on same side). tighten cable clamp to backshell. (Some saddle
bars have both screw heads on same side).

ENSURE BUSHINGS ARE NOT PINCHED


BETWEEN SADDLES AND CENTRE BAR. ENSURE BUSHINGS ARE NOT PINCHED
ENSURE THAT THERE IS NO FLEXING OF BETWEEN SADDLES AND CENTRE BAR.
THE CABLE WITHIN THE TIGHTENED ENSURE THAT THERE IS NO FLEXING OF
SADDLE BARS. FLEXING WILL CAUSE THE CABLE WITHIN THE TIGHTENED
DAMAGE TO THE CONNECTOR WIRING. SADDLE BARS, FLEXING WILL CAUSE
DAMAGE TO THE CONNECTOR WIRING.
Installation of MS3057A Cable Clamp
f. Tighten saddles until firm against cable,
67. The MS3057A cable clamp is installed as making sure that the cable is not pinched
follows (see Figure 10–40): within the clamping assembly. If saddles
do not prevent cable from flexing inside
a. Slide MS3057A cable clamp, without the connector, use extra MS 3420
saddles, on to the wire bundle before telescoping bushings in the connector
wires are connected. assembly. See Table 10–13 for
telescoping bushing dimensions. The
b. Slide MS3420 telescoping bushing on saddle clamps may be tight against the
wire bundle before wires are connected. centreing bar as long as the cable is not
pinched within the assembly.
c. Assemble wires to connector and tighten
back shell.

42
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–37 Cable Clamps

Figure 10–38 MS3057 Connector Cable Clamp Types – Exploded View

43
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–39 Installation of MS3057 Cable Clamp

Table 10–13 Telescoping Bushings

Bushing
Connector Bushing Inside Diameter Outside Diameter Length
Size Part No. (mm) (mm) (mm)
8S, 10S MS3420-3A 3.3 5.3 73.0
10SL, 12S, 12 MS3420-4A 5.6 7.7 69.8
14, 14S MS3420-6A 7.9 10.8 66.7
16, 16S MS3420-8A 11.0 14.0 63.5
18 MS3420-10A 14.2 15.6 60.3
20, 22 MS3420-12A 15.9 18.8 57.1
24, 28 MS3420-16A 19.0 23.5 53.9
32 MS3420-20A 23.8 31.5 50.8
36 MS3420-24A 31.7 34.7 47.6
40 MS3420-28A 34.9 41.0 44.5
44 MS3420-32A 41.2 47.3 41.3
48 MS3420-40A 47.6 60.0 38.1

44
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–14 Selecting MS3057 Cable Clamp

Cable Clamp MS Connector


Shell Size
MS3057-3 8S, 10S
MS3057-4 10SL, 12S, 12
MS3057-6 14, 14S
MS3057-8 16, 16S
MS3057-10 18
MS3057-12 20, 22
MS3057-16 24, 28
Figure 10–40 Installation of MS3057A Cable MS3057-20 32
Clamp MS3057-24 36
MS3057-28 40
MS3057-32 44
MS3057-40 48
MS connector shell sizes are the same for type
MS3057 A or B cable clamps

Figure 10–41 Installation of MS3057B Cable Clamp

Installation of MS3057B Cable Clamp a. Slide MS3420A telescoping bushings, if


required, on wire bundle before wires
68. The MS3057B cable clamp is installed as are connected. See Table 10–13 for
follows (see Figure 10–41): telescoping dimensions.

45
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

b. Slide MS3057B cable clamp assembly Installation of MS3152 and MS3154 Cable Clamp
on wire bundle before wires are
connected. 69. The MS3152 and MS3154 cable clamps are
installed as follows (see Figure 10–37):

a. Slide cable clamp on wire bundle before


wires are connected.
PROPER LUBRICATION OF GLAND AND b. Assemble wires to connector and tighten
TAPERED SLEEVE IS IMPORTANT FOR back shell.
THIS ASSEMBLY. IN HANDLING PARTS,
KEEP THEM CLEAN AND FREE OF DIRT. c. Wrap cable using teflon, silicone rubber,
WASH AWAY DIRT WITH CLEAN or glass fibre tape at the point where
DENATURED ETHYL ALCOHOL AND wire will have contact with saddle bar.
RELUBRICATE WITH PETROLATUM
(FEDERAL SPECIFICATION VV-P-236) AS
d. Tie cable wrap at both ends with lacing
SHOWN IN FIGURE 10–41. DO NOT APPLY
cord or self clinching cable straps.
PETROLATUM TO INSIDE OF GLAND OR
TO SERRATED FACE OF GLAND.
NOTE

Plastic cable straps will not be used on coaxial


cables or bundles containing coaxial cables that
do not have hard dielectrics.

PERFORM ALL SOLVENT CLEANING e. Secure cable to saddle bar with lacing
OPERATIONS IN A WELL VENTILATED cord or self clinching cable straps (see
AREA. AVOID PROLONGED BREATHING Figure 10–37).
OF VAPORS. AVOID EYE AND REPEATED
SKIN CONTACT. KEEP SOLVENTS AWAY Removal of Cable Clamp
FROM SPARKS AND FLAMES.
70. The cable clamp is removed as follows:
c. Assemble wires to connector and tighten
backshell. a. Remove screws from saddle bars and
remove saddle bars from clamp.
d. Push MS3420A bushings, if used,
through gland of MS3057B so that end b. Unscrew cable clamp from connector.
of bushing is flush with serrated face of The strap wrench or padded jaw pliers
gland. listed previously may be used if
necessary.
e. Slide entire assembly toward back shell
and hand tighten. Use strap wrench or Instructions for Assembly and Disassembly of Plug
padded jaw connector pliers to fully Connector
tighten until MS3057B bottoms onto
backshell. While tightening, hold wire 71. Instructions for assembly and disassembly of
bundle and telescoping sleeving until Plug Connector to and from Receptacle Connector are
gland seats on backshell. given in Section 2, Chapter 10.

NOTE Heat Shrinkable Strain Relief Boots for Connectors

Shield braid (and jacket, if present) should end 72. Heat shrinkable strain relief boots are used at
outside of MS3057B cable clamp to retain the rear of connectors to support wiring and to prevent
moisture resistant qualities of clamp. Ground twisting or pulling on crimped or soldered connections.
braid in accordance with standard procedures. They are available for a variety of connectors.

NOTE BOOT REPAIR PROCEDURES

Protect all unmated connectors with protective Rebonding Boot


covers.
73. The following steps should be followed in
rebonding a boot to a connector or harness assembly:

46
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

a. Clean visible bonding surfaces with lint where they enter the connector. Hold in
free cloth dampened with Standard Oil the retracted position until cool and the
Company 265 cleaning solvent (aliphatic boot remains retracted.
petroleum hydrocarbon) or equivalent.
Wipe immediately with clean lint free c. Standard Boots. Heat the boot with heat
cloth. gun until warm to touch, then pull the
adapter and boot back exposing the
b. Prepare Raychem Corporation S-1009 connector backside with enough
adhesive by thoroughly mixing equal clearance to allow repair.
amounts by weight of components A and
B. 75. In some cases the boot may have to be cut off.
When a boot has to be cut off the following procedure
NOTE should be used:

Pot life of mixed epoxy is 1 hour at 21°C r 6°C. a. Score (cut) the boot lengthwise, taking
care not to cut through the boot into the
c. Apply a thin continuous coat of mixed cable jacket.
adhesive on bonding surfaces.
Reassemble boot to connector and/or b. Heat the boot with a heat gun until warm
cable harness. to touch.

d. Allow adhesive to cure at room c. Peel the boot from the cable jacket and
temperature for 24 hours. connector with pliers.

Reinstalling Convoluted and Standard Boots

76. Heat the boot with a heat gun until warm to


touch, slide backshell and boot up to rear of connector
DO NOT BEND OR STRESS BONDED and tighten backshell coupling ring.
CABLE JOINTS DURING ADHESIVE CURE.
IMPROPER BOND(S) COULD RESULT IF New Boot Installation
BONDED JOINTS ARE BENT OR STRESSED
DURING ADHESIVE CURE. 77. The following steps should be followed when
installing a new boot on a connector harness assembly:
Boot Removal
a. Abrade outer jacket on jacketed cable
74. Remove a boot from a cable assembly as with 320 emery cloth. Clean loose
follows: particles from surface with a clean, dry
cloth or paper tissue.
a. Loosen the connector backshell adapter
to gain access to the connector backside. b. Degrease connector backshell or adapter
with suitable cleaning solvent, such as
Isopropyl Alcohol.

c. Apply adhesive to cable and connector


bonding areas if required (some boots
USE ONLY HOT AIR GUN M83521/5-01 OR
are pre-coated with an adhesive in the
EQUIVALENT ON FUELLED AIRCRAFT.
bonding areas).

d. Install new boot over end of cable.

NOTE
USE OF NITROGEN WITH HOT AIR GUN
M83521/5-01 IN AN ENCLOSED AREA CAN Boots can be installed over connectors in most
BE HAZARDOUS. ENSURE AREA IS WELL cases. Occasionally, it may be necessary to
VENTILATED. disassemble a connector to install the repair boot.

b. Convoluted Boots. Heat the boot with e. Shrink the boot starting at the connector
heat gun until warm to touch, and pull end and proceeding to the cable end with
the loosened adapter away from the a heat gun.
connector exposing the wire conductors

47
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

f. Cure the adhesive according to


recommended curing instructions.

RECTANGULAR CONNECTORS

78. Environmental resistant and non-environmental


resistant rectangular connectors are used in electrical
and electronic rack and panel applications. These
connectors are available with front release crimp
contacts, rear-release crimp contacts and solder
contacts. Rectangular connectors most commonly used
in aircraft are covered by military specifications such as
b. Backshell hardware for Series I
MIL-DTL-24308, MIL-DTL-28748, MIL-C-81659 and
(bayonet) and Series III (bayonet and
MIL-DTL-83733.
threaded) is shown in Figure 10–47.
Assembly and Disassembly of Rectangular
Connectors

79. Assembly and disassembly procedures are the


same as those used for circular connectors. Refer to the
appropriate paragraph in the circular connector
instructions for assembly and disassembly procedures.

MIL-DTL-83723 CIRCULAR CONNECTORS

Description

80. The connectors provided by this specification


are miniature environment resisting types with either c. Backshell hardware for Series II
bayonet or threaded couplings (See Table 10–15). MIL- (threaded).
DTL-83723, Series I (bayonet coupling) are replaced by
MIL-C-26482, Series II, and MIL-DTL-83723. Series II
(threaded coupling) are replaced by MIL-DTL-5015.
(See Table 10–6)

NOTE

These connectors will be supplied without


backshell hardware (See paragraph 81).

INSTALLATION AND REMOVAL OF MIL-


DTL-83723 CONTACTS IS FROM THE REAR
OF THE CONNECTORS.

Identification of Connectors and Component Parts d. Series II (threaded) saddle clamp


backshell hardware.
81. For purposes of ordering MIL-DTL-83723
connectors, the part numbers are constructed as follows:

a. Connectors.

48
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

f. Contacts and service tools, Series I and


Series III (rear release contacts).

Bin Contact Contact Insertion/


Codes Size Extraction Tool
/4-110, /5-115 20-20 M81969/14-02
/4-111, /5-116 16-16 M81969/14-03
/4-112, /5-117 16-20 M81969/14-03
e. For shrink hardware (bayonet and /4-113, /5-118 12-12 M81969/14-04
threaded connector series). /4-114, /5-119 12-16 M81969/14-04

49
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–15 MIL-DTL-83723 Connectors

Specification Plug or Mounting Coupling Class Contacts


M83723/XX Receptacle Type (See Note)
Series I (Bayonet)
/1 Receptacle Narrow Flange Bayonet G, R Crimp Socket
/2 Receptacle Narrow Flange Bayonet G, R Crimp Pin
/3 Receptacle Wide Flange Bayonet G, R Crimp Socket
/4 Receptacle Wide Flange Bayonet G, R Crimp Pin
/5 Receptacle Single Hole Bayonet G, R Crimp Socket
/6 Receptacle Single Hole Bayonet G, R Crimp Pin
/7 Receptacle Cable Bayonet G, R Crimp Socket
/8 Receptacle Cable Bayonet G, R Crimp Pin
/9 Receptacle Narrow Flange Bayonet H Solder Pin
/10 Receptacle Wide Flange Bayonet H Solder Pin
/11 Receptacle Solder Flange Bayonet H Solder Pin
/12 Receptacle Single Hole Bayonet H Solder Pin
/13 Plug Cable Bayonet G, R Crimp Socket
/14 Plug Cable Bayonet G, R Crimp Pin
/36 Plug Cable Bayonet G, R Crimp Pin
/37 Plug Cable Bayonet G, R Crimp Socket
/38 Receptacle Narrow Flange Bayonet G, R Crimp Pin
/39 Receptacle Narrow Flange Bayonet G, R Crimp Socket
/40 Receptacle Wide Flange Bayonet G, R Crimp Pin
/41 Receptacle Wide Flange Bayonet G, R Crimp Socket
/42 Plug (R.F.I.) Cable Bayonet G, R, A Crimp Pin
/43 Plug (R.F.I.) Cable Bayonet G, R, A Crimp Socket
/48 Plug (R.F.I.) Cable Bayonet G, R, A Crimp Pin
/49 Plug (R.F.I.) Cable Bayonet G, R, A Crimp Socket
Series II (Threaded)
/17 Receptacle Cable Threaded G, R Crimp Socket
/18 Receptacle Cable Threaded G, R Crimp Pin
/19 Receptacle Wall Mount Threaded G, R Crimp Socket
/20 Receptacle Wall Mount Threaded G, R Crimp Pin
/21 Receptacle Box Mount Threaded G, R Crimp Socket
/22 Receptacle Box Mount Threaded G, R Crimp Pin
/23 Plug Cable Threaded G, R Crimp Socket
/24 Plug Cable Threaded G, R Crimp Pin
/25 Receptacle Square Flange Threaded H Solder Pin
/26 Receptacle Solder Flange Threaded H Solder Pin
/52 Plug Cable Threaded K Crimp Pin
Self-lock
/53 Plug Cable Threaded K Crimp Socket
Self-lock
Series III
/71 Receptacle Flange Bayonet G, R, A Crimp Socket
/72 Receptacle Flange Bayonet G, R, A Crimp Pin
/73 Receptacle Single Hole Bayonet G, R, A Crimp Socket
/74 Receptacle Single Hole Bayonet G, R, A Crimp Pin
/75 Plug Cable Bayonet G, R, A Crimp Socket
/76 Plug Cable Bayonet G, R, A Crimp Pin
/77 Plug (R.F.I.) Cable Bayonet R Crimp Socket
/78 Plug (R.F.I.) Cable Bayonet R Crimp Pin
/79 Receptacle Flange Bayonet H Crimp Pin
/80 Receptacle Solder Flange Bayonet H Crimp Pin
/81 Receptacle Single Hole Bayonet H Crimp Pin
/82 Receptacle Flange Threaded G, K, R, A Crimp Socket
/83 Receptacle Flange Threaded G, K, R, A Crimp Pin

50
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

MIL-DTL-83723 Connectors (Continued)

Specification Plug or Mounting Coupling Class Contacts


M83723/XX Receptacle Type (See Note)
/84 Receptacle Single Hole Bayonet G, K, R, A Crimp Socket
/85 Receptacle Single Hole Bayonet G, K, R, A Crimp Pin
/86 Plug Cable Bayonet G, K, R, A Crimp Socket
/87 Plug Cable Bayonet G, K, R, A Crimp Pin
/88 Receptacle Flange Bayonet H Solder Pin
/89 Receptacle Single Hole Threaded H Solder Pin
/90 Receptacle Solder Flange Threaded H Solder Pin
/93 Receptacle Solder Flange Bayonet H Straight Pin
/94 Receptacle Single Hole Bayonet H Straight Pin
/95 Plug Cable Threaded K, R, A Crimp Socket
Self-lock
/96 Plug Cable Threaded K, R, A Crimp Pin
Self-lock
Note
Classes
R 200qC Aluminium Shell, Conductive Finish
H 200qC Steel Shell, Hermetic, Fluid Resistant Insert
G 200qC Stainless Steel Shell, Passivated, Fluid Resistant Insert
A 200qC Black Anodize (non-conductive)
K 200qC Stainless Steel, Passivated, Fluid Resistant Insert (firewall type)
W 175qC Aluminium Shell, Cadmium Plated Conductive Finish

g. Contacts and service tools, Series II b. Receptacles. Remove backshell and


(rear release contacts). ferrule. Since these are environmentally
sealed connectors, the inserts cannot be
removed from the connector shell.

Crimping of Contacts for MIL-DTL-83723


Connectors

83. Wires may be crimped in sizes 12, 16 and 20


contacts with M22520/1-01 crimp tool with M22520/1-
02 crimp tool turret head assembly. The detail
procedures are given in paragraph 40. To crimp size 0, 4
Bin Contact Contact Insertion/ and 8 contacts, a power crimping tool, M22520/23-01,
Codes Size Extraction Tool with appropriate die set and locator is required. Die set
M22520/23-02 and locator M22520/23-09 are required
/30-217 16S-16 M81969/14-03
for size 8 contacts. Die set M22520/23-04 and locator
/29-212, /30-218 16-16 M81969/14-03
M22520/23-11 are required for size 4 contacts. Die set
/29-213, /30-219 12-12 M81969/14-04
M22520/23-05 and locator M22530/23-13 are required
/29-214, /30-220 8-8 M81969/29-02*
for size 0 contacts. Follow crimping procedures
/29-215, /30-221 4-4 M81969/29-03*
provided with tool. Wire stripping dimensions are as
/29-216, /30-222 0-0 M81969/29-04*
follows:
*Extraction Tool only – sizes 8, 4 and 0 contacts
can be installed without the use of an insertion tool.
Contact Size Stripping Dimensions
20 4.7mm
Disassembly of Connectors
16 6.3mm
12 6.3mm
82. Disassembly of MIL-DTL-83723 connectors is
8 12.7mm
accomplished as follows:
4 12.7mm
0 15.8mm
a. Plugs. Remove backshell, ferrule, and
coupling nut.

51
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

c. Connectors.

IF A SIZE 10 WIRE IS USED IN A SIZE 8-8


CONTACT, A BUSHING, MS3348-8-10,
MUST BE USED TO ENSURE A GOOD
CRIMP JOINT. IF A SIZE 6 WIRE IS USED IN
A SIZE 4-4 CONTACT, A BUSHING, MS3348-
4-6, MUST BE USED. IF A SIZE 2 WIRE IS
USED IN A SIZE 0-0 CONTACT, A
BUSHING, MS3348-0-2, MUST BE USED.

Insertion and Removal of Contacts

84. The crimp type contacts, which are found in all


ut the Class H (hermetic) connectors, are removable.
The procedures for insertion and removal are given
below: d. Contacts and service tools for connector
series MS3450 through MS3459 (Rear
a. Remove backshell, ferrule, and coupling Release Contacts).
nut from plug (backshell and ferrule
from receptacle) and slide back over
wire loom.

b. Follow instructions given in Figure 10–


22 to Figure 10–26 as applicable.

MIL-DTL-5015 CONNECTORS

85. Description. MIL-DTL-5015 covers circular,


electric connectors with solder or removable crimp Bin Contact Contact Insertion/
contacts (both front and rear release). These connectors Codes Size Extraction Tool
are for use in electronic, electrical power, and control /30-217 16S-16 M81969/14-03
circuits. The type designations and class availability are /29-212, /30-218 16-16 M81969/14-03
given in Table 10–16. /29-213, /30-219 12-12 M81969/14-04
/29-214, /30-220 8-8 M81969/29-02*
86. See Figure 10–42 for typical illustrations of /29-215, /30-221 4-4 M81969/29-03*
AN/MS type connectors. Refer to Figure 10–43 for /29-216, /30-222 0-0 M81969/29-04*
insert arrangement. For the purpose of ordering MIL- *Extraction Tool only – sizes 8, 4 and 0 contacts
DTL-5015 connectors, the part numbers of connectors can be installed without the use of an insertion tool.
and component parts are given as follows:

a. Cable clamps for MIL-DTL-5015


e. Contacts and service tools for connector
connectors are described in paragraph 98
series MS3400 through MS3412 (Front
and Figure 10–44.
Release Contacts).
b. Crimping of Contacts: Use same
crimping procedure and tools described
for MIL-DTL-83723 connectors (see
paragraph 83).

52
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Bin Contact Contact Contact


Codes Size Insertion Tool Extraction Tool
/44-287, /45-294 16-22 M81969/17-01 M81969/19-01
/44-288, /45-295 16-16 M81969/17-01 M81969/19-01
/44-289, /45-296 12-16 M81969/17-02 M81969/19-02
/44-290, /45-297 12-12 M81969/17-02 M81969/19-02
/44-291, /45-298 8-8 M81969/17-06 M81969/19-03
/44-292, /45-299 4-4 M81969/17-07 M81969/19-04
/44-293, /45-300 0-0 M81969/17-08 M81969/19-05

Table 10–16 MIL-DTL-5015 Connector Classes

Solder Front Rear


Contacts Release Release
MS3100 Crimp Crimp
Series Contacts Contacts Environ. Fluid Insert Shell
Class Feature Resistant Resistant Material Material Shell Finish
MS3400 MS3400
Series Series
1/
A Solid shell X – – – Limited Neoprene Aluminium Cadmium,
olive drab
B Split shell X – – – Limited Neoprene Aluminium Cadmium,
olive drab
C Pressurized X – – – Limited Neoprene Aluminium Cadmium,
olive drab
D High impact – X – X Partial Silicone Wrought Cadmium,
shock aluminium over nickel
E Without X – – X Limited Neoprene Aluminium Cadmium,
clamp olive drab
F With clamp X – – X Limited Neoprene Aluminium Cadmium,
olive drab
H Hermetic X – – X Complete Silicone Ferrous alloy Electroless
seal nickel
J Gland seal X – – X Limited Neoprene Aluminium Cadmium,
for jacketed olive drab
cable
K Firewall X X X X Complete Silicone Ferrous alloy Electroless
nickel
L Fluid – X X X Complete Silicone Aluminium Electroless
resistant nickel
P Potting seal X – – X Limited Neoprene Aluminium Cadmium,
olive drab
R Grommet X – – X Limited Neoprene Aluminium Cadmium,
seal without olive drab
clamp
U High – X X X Partial Silicone Aluminium Electroless
temperature nickel
W Life – X X X Complete Silicone Aluminium Cadmium,
olive drab
Y Accepts – X – X Partial Silicone Aluminium Cadmium,
large wire olive drab
insulation
O.D.
1/ MS3450 Series is the preferred replacement for MS3100 Series.

53
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–42 Typical AN(MS) Connectors

54
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–43 Insert Arrangements - AN Type Connectors, MIL-DTL-5015 and MIL-DTL-83723, Series
II (Sheet 1 of 2)

55
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–43 Insert Arrangements - AN Type Connectors, MIL-DTL-5015 and MIL-DTL-83723, Series
II (Sheet 2 of 2

56
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

MIL-C-26482, MIL-C-26500 AND MIL-C-81703 a. Contacts and service tools for MIL-C-
CONNECTORS 26482 Series 1, MIL-C-26500 and MIL-
C-81703 Series 2 connectors.
Description

87. MIL-C-26482, MIL-C-26500 and MIL-C-


81703 cover, electric connectors with solder or
removable crimp contacts. The types and classes of
MIL-C-26482, MIL-C-26500 and MIL-C-81703
connectors are listed in Table 10–17.

88. Typical connectors are illustrated in Figure 10–


44. Refer to paragraph 8 and Figure 10–1 for typical
connector identification.

Bin Code Contact Basic Crimp Positioner Contact Contact


Size Tool or Turret Insertion Tool Extraction Tool
/31-223, /31-240 20-20 M22520/1-01 M22520/1-02 M81969/14-02 M81969/19-07
or or
/31-241, /31-448 M22520/2-01 M22520/2-02 M81969/17-03
or
/32-242, /32-250 M22520/7-01 M22520/7-02
/32-260, /32-449
/31-228, /31-229 16-16 M22520/1-01 M22520/1-02 M81969/14-03 M81969/19-08
or or
/32-247, /32-248 M22520/7-01 M22520/7-03 M81969/17-04
/31-243, /31-235 12-12 M22520/1-01 M22520/1-02 M81969/14-04 M81969/19-09
or
/32-253, /32-254 M81969/17-05

b. Contacts and service tools for MIL-C- c. Cable clamps, for MIL-C-26482 Series 1
26482 Series 2 and MIL-C-81703 Series and MIL-C-81703 Series 2 connectors,
3 connectors. are provided with the connectors. Cable
clamps for MIL-C-26482 series 2 and
MIL-C-81703 connectors are described
in paragraph 98 and Figure 10–47.

Bin Code Size Basic Crimp Positioner Contact Insertion/


Tool or Turret Extraction Tool
/4-110, /5-115 20-20 M22520/1-01 M22520/1-02 M81969/14-02
or
M22520/2-01 M22520/2-02
or
M22520/7-01 M22520/7-02
/4-111, /5-116 16-16 M22520/1-01 M22520/1-02 M81969/14-03
or
M22520/7-01 M22520/7-03
/4-112, /5-117 16-20 M22520/1-01 M22520/1-02 M81969/14-03
or or
M22520/7-01 M22520/7-03
/4-113, /5-118 12-12 M22520/1-01 M22520/1-02 M81969/14-04
/4-114, /5-119 12-16 M22520/1-01 M22520/1-02 M81969/14-04

57
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

MIL-C-81511 CONNECTORS a. Contacts and service tools for MIL-C-


81511 Series 1 and 2 connectors.
Description

89. MIL-C-81511 connectors are general-purpose


high-density, environment-resisting connectors similar
to the MS series. The connectors have a quick
disconnect feature, employing bayonet-type locking
ring. The types available are indicated in Table 10–18.

Marking MIL-C-81511 Connectors

90. The connector part number consists of the letter


“M”, the basic number of the specification sheet, and b. Contacts and service tools for MIL-C-
the applicable characteristics as in the following 81511 Series 3 and 4 connectors.
example (See Notes 2, 3, and 4 from Table 10–18):

Bin Code Contact Basic Crimp Positioner Contact Contact


Size Tool or Turret Insertion Tool Extraction Tool
/33-261, /33-262 23-28 M22520/2-01 M22520/2-03 M81969/2-01 M81969/3-01
/33-263, /33-264 23-22 M22520/2-01 M22520/2-03 M81969/2-01 M81969/3-01
/46-301, /46-302 23-28 M22520/2-01 M22520/2-03 M81969/2-01 M81969/3-01
/46-303, /46-304 23-22 M22520/2-01 M22520/2-03 M81969/2-01 M81969/3-01
/47-311, /47-312 23-28 M22520/2-01 M22520/2-03 M81969/2-01 M81969/3-05
/47-313, /47-314 23-22 M22520/2-01 M22520/2-03 M81969/2-01 M81969/3-05
/33-265, /33-266 20-20 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-02
/46-305, /46-306 20-20 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-02
/47-315, /47-316 20-20 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-06
/33-267, /33-268 16-16 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-03
/46-307, /46-308 16-16 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-03
/47-336, /47-337 16-16 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-07
/33-269, /33-270 12-12 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-04
/46-309, /46-310 12-12 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-04
/47-338, /47-339 12-12 M22520/1-01 M22520/1-08 M81969/2-02 M81969/3-08

58
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Bin Code Contact Basic Crimp Positioner Contact Insertion/ Extraction Tool For
Size Tool or Turret Extraction Tool Unwired Contact
/16-166 23-28 M22520/2-01 M22520/2-13 M81969/16-04 M81969/30-01
/16-167 23-22 M22520/2-01 M22520/2-13 M81969/16-04 M81969/30-01
/17-171 23-28 M22520/2-01 M22520/2-16 M81969/16-04 M81969/30-01
/17-172 23-22 M22520/2-01 M22520/2-16 M81969/16-04 M81969/30-01
/18-176 23-28 M22520/2-01 M22520/2-13 M81969/16-04 M81969/30-01
/18-177 23-22 M22520/2-01 M22520/2-13 M81969/16-04 M81969/30-01
/16-168 20-20 M22520/2-01 M22520/2-14 M81969/16-01 M81969/30-02
/17-173 20-20 M22520/2-01 M22520/2-17 M81969/16-01 M81969/30-02
/18-178 20-20 M22520/2-01 M22520/2-14 M81969/16-01 M81969/30-02
/16-169 16-16 M22520/2-01 M22520/2-15 M81969/16-02 M81969/30-03
/17-174 16-16 M22520/2-01 M22520/2-18 M81969/16-02 M81969/30-03
/18-179 16-16 M22520/2-01 M22520/2-15 M81969/16-02 M81969/30-03
/16-170 12-12 M22520/1-01 M22520/1-09 M81969/16-03 M81969/30-04
/17-175 12-12 M22520/1-01 M22520/1-10 M81969/16-03 M81969/30-04
/18-180 12-12 M22520/1-01 M22520/1-09 M81969/16-03 M81969/30-04

Insertion and Removal of Contacts around the holes may consist of nicks or
actual voids due to small portions of the
91. The connector inserts in the MIL-C-81511 rubber being removed or gouged out.
connectors are bonded to the connector shells and are Larger voids will present a serious
not removable. The insertion and/or removal of contacts sealing problem, and the connector will
in these connectors is accomplished as follows: require replacement.

92. Precautionary Measures. These connectors are 93. Insertion of Contacts. The insertion of contacts
built to withstand successfully the anticipated conditions is as follows:
common to the application in which they will be used.
However, certain precautionary measures as listed a. Before attempting any insertion of
below must be followed when working with these contacts, determine if the rear nut
connectors. assembly is in the unlocked position. A
coloured stripe will appear when the rear
a. Do not attempt to remove the inserts nut assembly is rotated
from the shell. These components are counterclockwise. At this point, the
permanently bonded to the shells and connector is in position for both
cannot be removed without destroying insertion and removal of contacts. This
them. Also, do not attempt to remove the can also be determined by checking the
face seal from the pin insert. space between the rear nut knurled
diameter and the shell. The space should
b. When working with these connectors, be between 2.5 to 4 mm.
always choose a clean, dry, smooth
working surface, to prevent foreign b. Place the contact into the desired hole in
matter from collecting on the sealing the rear of the connector by hand; then,
surfaces and/or the electrical using the appropriate insertion tool (see
components. This is necessary also to Table 10–19), place the crimped contact
prevent abrasion of sealing surfaces. It is in the front of the tool. The mating end
also important to avoid sliding the should extend out of the tool and the
resilient components along working wire into the tool. The tool is in its
surfaces. proper position when it grasps the rear
of the contact behind the contact
c. Occasionally some damage to the wire shoulder.
holes in the resilient grommet may occur
during insertion of the contacts. This c. The contact and the tool should be
damage may be limited to small slash or aligned within the desired hole as
knife-blade type cuts resulting in cracks straight as possible to avoid serious
that radiate between the wire holes. The damage to the connector.
grommet will seal satisfactorily in this
case. On the other hand, the damage

59
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–17 Miniature MS Connector Type and Class Availability

Connector Contact Class


Type Description Type Series Availability
MIL-C-26482F – Bayonet Coupling
MS3110 Wall Mounting Receptacle Solder 1 E, F, J
MS3111 Cable Connecting Plug Solder 1 E, F, J, P
MS3112 Box Mounting Receptacle Solder 1 E
MS3113 Solder Mounting Receptacle Solder 1 H
MS3114 Single Hole Mounting Receptacle Solder 1 E, F, P, H
MS3115 Dummy Stowage Receptacle Solder 1
MS3116 Straight Plug Solder 1 E, F, P, J
MS3119 Bulkhead Mounting Receptacle Solder 1 E
MS3120 Wall Mounting Receptacle Crimp 1 E, F
MS3121 Cable Connecting Plug Crimp 1 E, F, P
MS3122 Box Mounting Receptacle Crimp 1 E
MS3124 Single Hole Mounting Receptacle Crimp 1 E, F, P
MS3126 Straight Plug Crimp 1 E, F, P
MS3127 Box Mounting Receptacle crimp 1 E
MS3128 Wall Mounting Receptacle Crimp 1 E, F, P
MS3440 Narrow Flange Mounting Receptacle Solder 2 H
MS3442 Wide Flange Mounting Receptacle Solder 2 H
MS3443 Solder Flange Mounting Receptacle Solder 2 H
MS3449 Single Hole Mounting Receptacle Solder 2 H
MS3470 Narrow Flange Mounting Receptacle Crimp 2 E, L, W, A
MS3471 Cable Connecting Receptacle Crimp 2 E, L, W, A
MS3472 Wide Flange Mounting Receptacle Crimp 2 E, L, W, A
MS3474 Rear Mounting Jam Nut Receptacle Crimp 2 E, L, W, A
MS3475 RFI Shielded Plug Crimp 2 E, L, W
MS3476 Plug Crimp 2 E, L, W, A
MIL-C-81703 – Push-Pull Coupling
MS3130 Wall Mounting Receptacle Solder 1 E, P, J
MS3132 Box Mounting Receptacle Solder 1 E, H
MS3134 Single Hole Mounting Receptacle Solder 1 E, P, J, H
MS3135 Wall Mounting Dummy Stowage Receptacle Solder 1,2
MS3137 Short Plug Solder 1 E, P, J
MS3138 Lanyard Plug Solder 1 E, P, J
MS3139 Bulkhead Receptacle Solder 1 E
MS3140 Wall Mounting Receptacle Crimp 2 E, J
MS3144 Single Hole Mounting Receptacle Crimp 2 E, J
MS3147 Straight Plug Crimp 2 E, J
MS3148 Lanyard Plug Crimp 2 E, J
MS3424 Wall Mounting Flange Receptacle Crimp 3 E, L
MS3445 Rack and Panel Plug Crimp 2 E
MS3446 Rack and Panel Plug Crimp 3 E, L
MS3463 Hermetic Solder Mounting Receptacle Solder 3 H
MS3464 Jam Nut Mounting Receptacle Crimp 3 E, L
MS3466 Hermetic Box Mounting Receptacle Solder 3 H
MS3467 Plug Crimp 3 E, L
MS3468 Lanyard Plug Crimp 3 E, L
MS3469 Hermetic Jam Nut Mounting Receptacle Solder 3 H
MIL-C-26500 – Threaded and Bayonet Couplings
MS24266 Straight Plug Crimp F. H, R
MS27562 Flange Mounting Receptacle Crimp F, H, R
MS27563 Single Hole Mounting Receptacle Crimp F, H, R
MS27564 Straight Plug (Hard Insert) Crimp F, H. R

60
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–44 Typical MS Connectors – Miniature

d. Push the contact into the connector. The on the wire of rear-release contacts to be sure
shoulder on the contact provides a they are locked into position.
positive stop. At this point, the contact is
fully inserted. Slide the tool back along e. A contact should be inserted in all
the wire insulation until it clears the unwired holes in the receptacle to
grommet. provide for proper sealing on the
equipment. Sealing plugs must be placed
NOTE behind all unwired contacts.

For rear-release contacts (series 3 and 4 crimp-


type), tines will lock into place behind the
contact shoulder. A light pull should be exerted

61
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

f. After all contacts and sealing plugs have NOTE


been inserted into the connector, tighten
the rear nut by turning clockwise until To maintain seal, all holes behind unused
the locking nut is tight. contacts must be filled with the proper size
sealing plugs.
Table 10–18 MIL-C-81511 Connectors

Specification Plug or Mounting Series Classes Contacts


(M81511/XX) Receptacle Type (Note 1) (Note 2)
/01 Receptacle Square flange 2 A, F, E Crimp
/02 Receptacle Solder flange 2 B, G, H Solder (pins only)
/03 Receptacle Single hole 2 A, F, E Crimp
/04 Receptacle Single hole 2 B, G, H Solder (pins only)
/05 Receptacle Cable 2 A, F, E Crimp
/06 Plug Cable 2 A, F, E Crimp
/21 Receptacle Square flange 1 A, F, E Crimp
/22 Receptacle Solder flange 1 B, G, H Solder (pins only)
/23 Receptacle Single hole 1 A, F, E Crimp
/24 Receptacle Single hole 1 B, G, H Solder (pins only)
/25 Receptacle Cable 1 A, F, E Crimp
/26 Plug Cable 1 A, F, E Crimp
/27 Receptacle Single hole 1 B, G, H Non-removable
/28 Receptacle Single hole 2 B, G, H Non-removable
/31 Receptacle Square flange 2 C, T, P Crimp
/32 Receptacle Single hole 2 C, T, P Crimp
/33 Plug Cable 2 C, T, P Crimp
/34 Plug Cable 2 C, T, P Crimp
/35 Receptacle Square flange 1 C, T, P Crimp
/36 Receptacle Single hole 1 C, T, P Crimp
/37 Plug Cable 1 C, T, P Crimp
/38 Plug Cable 1 C, T, P Crimp
/41 Receptacle Square flange 3 A, E, F Crimp
/42 Receptacle Solder flange 3 D Solder (pins only)
/44 Receptacle Single hole 3 D Solder (pins only)
/45 Receptacle Cable 3 A, E, F Crimp
/46 Plug 3 A, E, F Crimp
/47 Receptacle Solder flange 3 L Crimp (pins only)
/48 Receptacle Single hole 3 L Crimp (pins only)
/49 Receptacle Single hole 3 A, E, F Crimp
/50 Receptacle Single hole 4 L Crimp (pins only)
/51 Receptacle Square flange 4 A, E, F Crimp
/52 Receptacle Solder flange 4 D Solder (pins only)
/53 Receptacle Single hole 4 A, E, F Crimp
/54 Receptacle Single hole 4 D Solder (pins only)
/55 Receptacle Cable 4 A, E, F Crimp
/56 Plug Cable 4 A, E, F Crimp
/57 Receptacle Solder flange 4 L Crimp (pins only)

62
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–18 MIL-C-81511 Connectors (Continued)

NOTES
(1) Series are defined as follows:
Series 1 & 3 – Long shell
Series 2 & 4 – Light weight, short shell
(2) Series defined as follows:
Operating Temperature
Type 150qC 175qC 200qC
Grommet seal E F A
Hermetic seal H G B
Potting seal P T C
(3) The shell size and insert arrangement are identified by a two-part code. The first part
consists of a single letter indicating the shell size in accordance with the following code. The
second part should be two digits indicating the insert arrangement in accordance with the
applicable insert arrangement.
Shell Size Code
Shell Size Code Letter
8 A
10 B
14 D
16 E
18 F
20 G
22 H
24 J
(4) The following designators are used to indicate a full complement of applicable power
contacts:
P – Pin contacts
S – Socket contacts
C – Feedthrough contacts
The following designators are used to indicate a connector less contacts. They will be used
only when other than power contacts are to be installed in the connector. Examples of this
are shielded, thermocouple, and coaxial contacts:
A – Less pin contacts
B – Less socket contacts

Figure 10–45 Colour Marking for Individual Release MIL-C-81511 Connectors

63
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

94. Connector Disassembly and Removal of


Contacts. Carry out connector disassembly and removal
of contacts as follows:
GOOD AXIAL ALIGNMENT SHOULD BE
MAINTAINED DURING REMOVAL OF
SERIES 1 AND 2 CONTACTS.
MISALIGNMENT CAN BEND THE
THE NEWER TYPE MIL-C-81511 (SERIES 3 CONTACT AND DAMAGE THE
AND 4) CONNECTORS HAVE INDIVIDUAL CONNECTOR.
RELEASE CONTACTS WHICH MUST BE
REMOVED (AND INSTALLED) FROM THE e. Series 3 and 4 (individual release)
REAR OF THE CONNECTOR. THESE contacts are removed from the rear of
CONNECTORS ARE IDENTIFIED BY A the connector as follows:
SPECIAL BLUE BAND ON BOTH FRONT
AND REAR AS SHOWN IN FIGURE 10–45. (1) With the rear of the connector
facing you, lay the wire of the
a. Remove any adapters from the rear of contact to be removed along the
the connector. slot of the tool. Squeeze the wire
firmly into the tool between the
b. Loosen the rear nut assembly by turning thumb and forefinger about
it counterclockwise when viewed from 1.2mm from the tool tip, and snap
the wire end. Approximately 1.5mm of the wire into the tool. (A quick
axial movement unlocks the contacts. pull on the tool away from the
The coloured stripe will fully appear. connector may be necessary to
The connector is now in position for snap the wire into place).
removal of contacts.
(2) With the wire in place in the tool,
c. Select the proper contact removal tool slide the tool down along the wire
from Table 10–19. and into the rear cavity and
slowly into the connector until a
d. Series 1 and 2 (gang release) contacts positive resistance is felt. At this
are removed from the front of the time, the contact retaining
connector as follows: mechanism is in the unlocked
position.
(1) The pin contact removal tool has
a hole to accept the pin contact.
The socket removal tool has a pin
tip to insert in the socket.

(2) Grasp the tool by the handle. WHEN USING MINIMUM DIAMETER WIRE,
Locate the contact to be removed THE TOOL MAY HAVE A TENDENCY TO
by the numbers on the insert face. STOP AGAINST THE REAR OF THE
CONTACT CRIMP BARREL. IF THIS
SHOULD OCCUR, CAREFUL
(3) Mate the tool with the contact
MANIPULATION OF THE TOOL WILL
and, holding the tool at right
PERMIT IT TO RIDE OVER THE CRIMP
angles with the insert face, push
BARREL AND INTO THE PROPER
axially against the tip of the
POSITION TO UNLOCK THE CONTACT.
contact until the contact appears
at the grommet (rear) end of the
connector. The removal tools are (3) Press the wire of the contact
designed to bottom against the against the serrations of the
insert face when the contact is plastic tool, and pull both the tool
completely released and pushed and the wired contact out of the
out. connector.

(4) The wire and contact can now be


removed from the connector.

64
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

(2) When plunger butts against


contact barrel, release plunger
and grasp tool using probe hand
grip. Push probe in so that
INDIVIDUAL RELEASE CONTACTS ARE contact barrel slides into hollow
EASILY REMOVED. THE USE OF TOO centre of probe and pushes
MUCH FORCE MAY DAMAGE THE plunger back. Hollow probe
CONNECTOR INSERT. diameter is slightly less than
contact barrel diameter so contact
f. Unwired series 3 and 4 (individual will stick in probe.
release) contacts are removed from the
rear of the connector as follows: (3) When probe bottoms in
connector, contact locking tines
(1) Remove sealing plug and insert will be released, and contact may
appropriate size MS3159 tool be pulled out.
into rear of cavity. Extended
plunger in MS3159 tool can be (4) Plunger may then be used to push
used to guide tool through cavity removed contact from removal
to rear of contact crimp barrel. tool.

Table 10–19 MIL-C-81511 Contact Insertion and Removal Tools

Series 1 & 2 (Gang Release) Contacts Series 3 & 4 (Individual Release) Contacts
Contact Insertion Pin Removal Socket Insertion and Unwired Contact
Size Tool Tool Removal Tool Removal Tool Removal Tool
22 & 23 MS3323-23 MS3342-23 MS3344-23 MS3160-22 MS3159-22
20 MS3323-20 MS3342-20 MS3344-20 MS3160-20 MS3159-20
16 MS3323-16 MS3342-16 MS3344-16 MS3160-16 MS3159-16
12 MS3160-12 MS3159-12

MIL-DTL-38999 CONNECTORS (3) III – Grounded, Scoop-proof;


Threaded Coupling.
General Description
(4) IV – Grounded, Scoop-proof;
95. Connectors manufactured under this Breech Coupling.
specification are miniature, high-density, environment-
resisting types. They are available with removable NOTE
crimp type contacts, except for the hermetic sealing
types which have non-removable solder contacts. The The series I, II, III and IV connectors are not
availability of MIL-DTL-38999 is indicated in Table interchangeable or intermatable.
10–20. Typical MIL-DTL-38999 connectors are
illustrated in Figure 10–46. b. Types:

Classification (1) Plugs:

96. These connectors are classified as follows: (a) Straight.

a. Series: (b) Straight, Grounded.

(1) I – Grounded, Scoop-proof; (c) Lanyard Release.


Bayonet Coupling.
(2) Receptacles:
(2) II – Low Silhouette; Bayonet
Coupling. (a) Box Mounting.

(b) Wall Mounting.

65
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

(c) Jam-nut Mounting. f. Finishes (Series III & IV):

(d) Solder Mounting. (a) C – Anodic.

c. Classes (Series I & II): (b) F – Electroless Nickel.

(a) E – Environment resisting. (c) K – Corrosion Resistant


Steel Shell.
(b) P – For potting; includes
potting form. (d) W – Olive-drab cadmium
plate.
(c) T – Environment resisting.
(e) Y – Corrosion resistant
(d) Y – Hermetically sealed. steel shell.

d. Classes (Series III & IV): g. Shell Size Code – Series III & IV only:

(a) C – Environment resisting Shell Code Shell Code


nonconductive finish. Size Letter Size Letter
9 A 17 E
(b) F – Environment resisting
11 B 19 F
conductive finish.
13 C 21 G
(c) K – Environment resisting 15 D 23 H
firewall barrier. 25 I

(d) W – Environment
h. Cable Clamps for MIL-DTL-38999
resisting corrosion
connectors are described in paragraph 98
resistant plating.
and Figure 10–48.
(e) Y – Hermetically Sealed.
i. Contact Styles:
e. Finishes (Series I & II):
(a) P – Pin.
(a) A – Bright cadmium plate.
(b) S – Socket.
(b) B – Olive-drab cadmium
plate.

(c) C – Anodic.

(d) D – Fused tin plate.

(e) E – Stainless steel,


unplated.

(f) F – Electroless nickel.

66
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Socket Bin Code Socket Bin Pin Bin Code Contact Contact Contact
(Series I, III & IV) Code (Series (Series I, II, III & IV) Size Insertion Tool* Extraction Tool*
II)
/56-348 /57-354 /58-360 22-22D M81969/14-01 M81969/14-01
or or
M81969/8-01 M81969/8-02
/56-349 /57-355 /58-361 22-22M M81969/14-01 M81969/14-01
or or
M81969/8-01 M81969/8-02
/56-350 /57-356 /58-362 22-22 M81969/8-03 M81969/8-04
/56-351 /57-357 /58-363 20-20 M81969/14-02 M81969/14-02
or or
M81969/8-05 M81969/8-06
/56-352 /57-358 /58-364 16-16 M81969/14-03 M81969/14-03
or or
M81969/8-07 M81969/8-08
/56-353 /57-359 /58-365 12-12 M81969/14-04 M81969/14-04
or or
M81969/8-09 M81969/8-10
/56-327 N/A /58-528 10-10 M81969/14-05 M81969/14-05
* M81969/8-XX is a metal tool.
M81969/14-XX is a double ended plastic insertion/extraction tool.

Bin Code Contact Size Basic Crimp Tool Positioner or


Turret
/56-348, 56/349 22-22D M22520/2-01 M22520/2-07
and /56-350 22-22M or or
22-22 M22520/7-01 M22520/7-05
/56-354, 56/355 22-22D M22520/2-01 M22520/2-06
and /56-356 22-22M or or
22-22 M22520/7-01 M22520/7-06
/56-360, 56/361 22-22D M22520/2-01 M22520/2-09
and /56-362 22-22M or or
22-22 M22520/7-01 M22520/7-07
/56-351, 56/357 20-20 M22520/1-01 M22520/1-04
and /56-363 or or
M22520/2-01 M22520/2-10
or or
M22520/7-01 M22520/7-08
/56-352, 56/358 16-16 M22520/1-01 M22520/1-04
and /56-364 or or
M22520/7-01 M22520/7-04
/56-353, 56/359 12-12 M22520/1-01 M22520/1-04
and /56-365

67
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–20 Availability of MIL-DTL-38999 Connectors

Spec (MSxxxxx) Type Mounting Series Class**


27466 Receptacle Wall Flange I E,P,T
27467 Plug Straight I E,P,T
27468 Receptacle Jam Nut I E,P,T
27469 Receptacle Wall Flange I Y
27470 Receptacle Jam Nut I Y
27471 Receptacle Solder I Y
*27472 Receptacle Wall Flange II E,P,T
*27473 Plug Straight II E,P,T
*27475 Receptacle Wall Flange II Y
*27476 Receptacle Box Flange II Y
*27477 Receptacle Jam Nut II Y
*27478 Receptacle Solder II Y
*27479 Receptacle Wall Flange II E,P,T
*27480 Plug Straight II E,P
*27481 Receptacle Jam Nut II E,P,T
*27482 Receptacle Wall Flange II Y
*27483 Receptacle Jam Nut II Y
*27484 Plug Straight II E,P,T
Grounding
27496 Receptacle Box Flange I E,P,T
*27497 Receptacle Back Panel Wall II E,P,T
*27498 Plug 90q Elbow I E,P
*27499 Receptacle Box Flange II E
*27500 Receptacle Box Flange II E
*27503 Receptacle Solder II Y
*27504 Receptacle Box Flange II E,P,T
27505 Receptacle Box Flange I E
*27508 Receptacle Back Panel Box II E,P,T
*27513 Receptacle Box Flange II E
*27515 Receptacle Back Panel Wall I E,P,T
*Inactive for new design. **Class E and P inactive for new design.
Spec (D38999/) Type Mounting Series Class
20 Receptacle Wall Mount Flange III F, G, J, K, M, S, W
21 Receptacle Box Mount Flange III N, Y
22 Receptacle Dummy Stowage III G, J, M, W
23 Receptacle Jam Nut III N, Y
24 Receptacle Jam Nut III F, G, J, K, M, S, W
25 Receptacle Solder III N, Y
26 Plug (EMI) Straight III F, G, J, K, M, S, W
27 Receptacle Weld III N, Y
28 Nut Connector Mounting III, IV C, F, G, H, J, K, M, W
29 Plug (Pins) Lanyard Release III F, K, S, W
30 Plug (Sockets) Lanyard Release III F, K, S, W
31 Plug Lanyard Release III W
32 Cover Plug Protective III G, J, M, W
33 Cover Receptacle Protective III G, J, M, W
34 Receptacle Breakaway Jam Nut III W
35 Receptacle Breakaway Wall Mount III W
40 Receptacle Wall Mount Flange IV C, F, K, S, W
41 Receptacle Box Mount Flange IV N, Y
42 Receptacle Box Mount Flange IV C, F, W
43 Receptacle Jam Nut IV N, Y
44 Receptacle Jam Nut IV C, F, K, S, W
45 Receptacle Solder IV N, Y
46 Plug (EMI) Straight IV F, K, S, W
47 Plug Breech Coupling IV C, W
48 Receptacle Weld Mount IV N, Y
49 Receptacle Breech Coupling IV C, F, W
50 Receptacle Dummy Stowage IV W

68
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–46 Typical MIL-DTL-38999 Connectors

Marking

97. The connectors are marked as follows:

a. Series I and II:

69
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

b. Series III and IV:

M and MS Connector Cable Clamps

98. Connector cable clamps are used on the back


end of M and MS connectors to support wiring and to
prevent twisting or pulling on wire terminations.
Standard cable clamps that fit MIL-DTL-5015 (MS3400
and MS3450 Series), MIL-C-26482 (Series 2), MIL-C-
81703, (Series 3) and MIL-DTL-83723 (Series I and III)
are shown in Figure 10–47. Standard cable clamps for
MIL-DTL-38999 connectors are shown in Figure 10–
48. See Table 10–21 for connector accessory installation
torque values.

Table 10–21 Installation Torque Values For MIL-C-85049 Circular Electrical Connector Accessories

Accessory Thread Torque r 5 inch pounds


Group 1 Group 2
MIL-C-85049 Part Numbers: MIL-C-85049 Part Numbers:
/17, 27, 29, 30, 32, 33, 34, 35, /1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,
Shell Sizes 36, 37, 41, 42, 45, 46, 47, 49, 14, 15, 16, 18, 19, 20, 21, 23,
56, 57, 61, 62, 63, 64, 65, 76, 24, 25, 26, 31, 38, 39, 43, 51,
77, 82, 83, 84, 85, 86, 87, 88, 52, 53, 54, 55, 59, 60, 66, 67,
89, 90, 91, 92 69, 78, 79
8, 9, A 40 70
3, 10, 10SL, 11, B 40 95
7, 12, 12S, 13, C 40 135
14, 14S, 15, D 40 145
16, 16S, 17, E 40 145
18, 19, 27, F 40 145
20, 21, 37, G 80 170
22, 23, H 80 170
24, 25, 61, J 80 170
28, 29 120 185
32, 33 120 185
36 120 185
40 170 205
44 170 205
48 170 205
Note: The above values are recommended.

70
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–47 Typical Cable Clamps For MIL-DTL-5015 (MS3400 & MS3450 Series), MIL-C-26482
(Series 2), MIL-C-81703 (Series 3) and MIL-DTL-83723 (Series I and Series II) Connectors

71
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–48 Typical Cable Clamps For MIL-DTL-38999 Series I, II, III & IV Connectors

72
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

MIL-C-81659 CONNECTORS various combinations of insert arrangements


are listed in Table 10–24 with their
Description corresponding designation numbers.

99. MIL-C-81659 environment-resistant, c. The polarization positions and the


rectangular connectors are used in electrical and corresponding polarization numbers
electronic rack and panel applications. These are explained in Table 10–25.
connectors are available with front release contacts Normally the plugs and receptacles are
(Series 1) or rear-release contacts (Series 2). Series 1 furnished with 01 polarization, i.e., all
and Series 2 connectors are available in two types and plug polarizing posts up and all
classes. Type I has a short grommet seal and Type II receptacle polarizing insert holes up. If
has a standard grommet seal. Class 1 is built for a the polarization must be changed to
temperature range from -65qC to 125qC. Class 2 will prevent connection of similar plugs to
operate at a higher temperature, its range being from the wrong receptacles, the polarization
-65qC to 200qC. The connectors are furnished with number from Table 10–25 must be
standard contacts sizes 22, 20 and 16, and coaxial marked on the connector shell
contacts sizes 1, 3, 5, 7 and 9. The connectors have following the connector part number.
crimp type removable standard contacts and crimp
type coaxial contacts, some of which are rear- MIL-C-81659 Assembly and Disassembly
releasable and others non-releasable. Their availability
is indicated in Table 10–22. 101. The method of assembling and disassembling
MIL-C-81659 connectors with standard contacts or
Marking of MIL-C-81659 Connectors with rear-release coaxial contacts is shown in Figure
10–50. The method of disassembling the polarizing or
100. The connector part number consists of the keying assembly to change the polarization position is
letter “M”, the basic number of the specification sheet, shown in Figure 10–51. The method of assembling
and the coded numbers or letters as in the following and disassembling MIL-C-81659 connectors with non-
example: releasable coaxial contacts is shown in Figure 10–52.

a. Installing Non-releasable Coaxial


Socket Contacts. (See Figure 10–52).

(1) Select the plug shell needed for


your application. A double shell
is shown in Figure 10–52 to
illustrate the possible
combination of a C2 coaxial
contact insert and a standard
contact insert.

(2) Insert two socket contacts into


the rear insert. Position this
assembly on a horizontal
a. Shells with size designator A have a support with the back of the
key stone shape and a mounting flange contacts resting on the support.
width of 50mm. Shells with size
designator B have a rectangular shape (3) Slide the retention springs over
and a mounting flange width of 6.3cm. the front of the contacts.
b. The insert arrangements are described (4) Install the retaining rings by
in MS3157. There are fifteen different insert using a suitable tool to spread
arrangements shown in MS3157 Sheets 1 each ring and slide it over the
through 14. Table 10–23 lists the number, front of the contact. Push the
size, and type (standard or coaxial) of contacts ring down until it locks behind
in each insert arrangement. In a given insert, the shoulder of the contact.
the contacts may be all pins, in which case Ensure the ring is properly
they are housed in a receptacle (See Figure seated behind the shoulder.
10–49). The insert arrangements may be
housed in single, double, triple, or quadruple
(5) Slide the retaining plate over
plugs or receptacles. Any combination of
the cables. Then slide the
insert arrangements may be used in the
contact ferrules over the
multiple plugs or receptacles. Some of the
unstripped cables.

73
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

(6) Strip the cables and crimp the illustrates a semi-rigid coaxial
contacts. cable.)

(7) Insert the front insert into the (3) Insert the front insert into the
back of the connector as back of the receptacle shell as
indicated in Figure 10–52. shown in Figure 10–52. Make
sure the recessed cavities in the
(8) Insert the contacts into the front front insert are facing the back
insert by hand until the back of the shell.
insert is flush with the back of
the plug shell. (4) Slide the retainer plate over the
crimped contacts and cable.
(9) Slide the retainer plate over the
cables and position it on the (5) Insert the contacts by hand into
back of the shell. Secure the the front insert. Make sure the
plate with the four screws and contacts seat in the recessed
washers supplied with the cavities.
connector.
(6) Slide the rear insert over the
b. Installing Non-releasable Coaxial Pin rear portion of the contacts.
Contacts. (See Figure 10–52.) Push the rear insert in until it is
flush with the back of the shell.
(1) Select the receptacle shell that
mates with the plug shell used (7) Slide the retainer plate over the
above. cables and position the plate on
the back of the shell. Secure the
(2) Strip and crimp the coaxial plate with the four screws and
cable to the contacts using the washers supplied with the
procedure described in connector.
paragraph 40. (Figure 10–52

74
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–22 MIL-C-81659 Connectors

Specification Plug or Type Class Series Shell Size Insert Plug


(MIL-C-81659/xx) Receptacle Types
/1 Plug II 1 1 A Single
/2 Plug II 2 1 A Single
/3 Receptacle II 1 1 A Single
/4 Receptacle II 2 1 A Single
/5 Receptacle I 1 1 A Single
/6 Receptacle I 2 1 A Single
/7 Plug II 1 1 A Double
/8 Plug II 2 1 A Double
/9 Receptacle II 1 1 A Double
/10 Receptacle II 2 1 A Double
/11 Receptacle I 1 1 A Double
/12 Receptacle I 2 1 A Double
/21 Plug II 1 1 B Double
/22 Plug II 2 1 B Double
/23 Plug I 1 1 B Double
/24 Plug I 2 1 B Double
/25 Receptacle II 1 1 B Double
/26 Receptacle II 2 1 B Double
/27 Receptacle I 1 1 B Double
/28 Receptacle I 2 1 B Double
/29 Plug II 1 2 A Single
/30 Plug II 2 2 A Single
/31 Receptacle II 1 2 A Single
/32 Receptacle II 2 2 A Single
/33 Plug II 1 2 A Double
/34 Plug II 2 2 A Double
/35 Receptacle II 1 2 A Double
/36 Receptacle II 2 2 A Double
/37 Plug II 1 2 A Triple
/38 Plug II 2 2 A Triple
/39 Receptacle II 1 2 A Triple
/40 Receptacle II 2 2 A Triple
/41 Plug II 1 2 A Quadruple
/42 Plug II 2 2 A Quadruple
/43 Receptacle II 1 2 A Quadruple
/44 Receptacle II 2 2 A Quadruple
/45 Plug II 1 2 B Single
/46 Plug II 2 2 B Single
/47 Receptacle II 1 2 B Single
/48 Receptacle II 2 2 B Single
/49 Plug II 1 2 B Double
/50 Plug II 2 2 B Double
/51 Receptacle II 1 2 B Double
/52 Receptacle II 2 2 B Double
/53 Plug II 1 2 B Triple
/54 Plug II 2 2 B Triple
/55 Receptacle II 1 2 B Triple
/56 Receptacle II 2 2 B Triple
/57 Plug II 1 2 B Quadruple
/58 Plug II 2 2 B Quadruple
/59 Receptacle II 1 2 B Quadruple
/60 Receptacle II 2 2 B Quadruple

75
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–23 Contact Insert Arrangements for MIL-C-81659 Connectors

Position Insert Total Number Number, Size and Type of Shell MS3157
Arrangement of Contact Contacts Size Sheet
Positions Number
26 26 26 size 16 A 1
40 40 40 size 20 A 2
45 45 45 size 20 A 3
57 57 57 size 20 A 3
67 67 64 size 20, 3 size 16 A 4
106 106 106 size 20 A 5
124 124 124 size 20 B 6
C2 2 2 size 1 coaxial A 7
C3 3 2 size 7 coaxial, 1 size 3 coaxial A 8
C8 8 8 size 9 coaxial A 9
D8 8 4 size 16, 4 size 12 A 10
10C3 10 7 size 20, 3 size 11 coaxial A 11
32C2 32 30 size 20, 2 size 5 coaxial A 12
33C4 33 25 size 20, 4 size 16, 4 size 5 coaxial A 13
40C1 40 39 size 20, 1 size 5 coaxial A 14

Figure 10–49 Typical MIL-C-81659 Duplex Connector

Figure 10–50 Assembly of MIL-C-81659 Connectors With Standard Contacts

76
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Crimping and Assembly of Standard Contacts in


MIL-C-81659 Connectors

102. Crimping of standard contacts and their


insertion and removal in the MIL-C-81659 connectors CONTACTS ARE EASILY INSERTED. THE
are accomplished with the tools listed in Table 10–26. USE OF TOO MUCH FORCE MAY DAMAGE
THE CONNECTOR INSERT.
a. Installation of Rear-Release Standard
Pin or Socket Contacts. b. Removal of Rear-Release Standard Pin
or Socket Contacts.
(1) Select the insertion tool MS3156
corresponding to the size of the (1) Select the extraction tool
contact barrel (-22, -20, or -16). MS3156 corresponding to the
(See Table 10–26) Place the wire size of the contact barrel (-22, -
from the contact over the wire 20, or -16). (See Table 10–26)
slot of the coloured insertion tip Place the wire from the contact
and hold it in this position with over the wire slot of the white
your thumb. extraction tip and hold it in this
position with your thumb.
(2) While applying light pressure on
the wire, slide your thumb toward (2) Apply light pressure on the wire
the tip of the tool. The tip will and slide your thumb toward the
spread, allowing the wire to enter tip of the tool. The tip will
the tip. spread, allowing the wire to enter
the tip.
(3) Position the tool tip against the
shoulder of the contact as shown (3) Insert the tool tip straight into the
in Figure 10–53. (Note that the cavity until it bottoms. This will
bevelled tip of the insertion tool release the locking tines.
is smaller than the outside
diameter of the contact shoulder. (4) Hold the wire against the tool
This allows the locking tines in handle. Pull the tool and contact
the cavity to grip the shoulder of straight out the back of the
the contact.) connector cavity. (See Figure 10–
54).
(4) Press the wire against the tool
handle to hold the contact in
position.

(5) Align the contact with the cavity CONTACTS ARE EASILY REMOVED. THE
and insert the contact straight into USE OF TOO MUCH FORCE MAY DAMAGE
the cavity until it bottoms and the THE CONNECTOR INSERT.
locking tines in the cavity click
into position behind the contact NOTE
shoulder.
To remove unwired rear-release contacts, remove
(6) Remove the tool. Pull back sealing plug, insert the appropriate size removal
lightly on the wire to make tool, MS3156, to grasp the rear of the contact
certain the contact is locked in and release the locking tines. Then push on the
the cavity. front of the contact with tool MS3344 (or the
appropriate size variation of this tool). After the
contact has been released from the insert, remove
the extraction tool, grasp rear of contact, and pull
from the connector.

77
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–24 Insert Arrangements, MIL-C-81659 Connector, Series 1 and 2

Insert Shell Insert Arrangement Insert Shell Insert Arrangement


Designation Designation
Number A B C D Number A B C D
0001 26 P 0070 C8S 33 C4S
0002 26 S 0071 67 P 106 S
0003 26 P 26 P 0072 67 S 106 P
0004 26 S 26 S 0073 67 P 67 P C8P
0005 26 P 26 P 26 P 0074 67 S 67 S C8S
0006 26 S 26 S 26 S 0075 67 P 67 P 106 S
0007 26 P 26 P 26 P 26 P 0076 67 S 67 S 106 P
0008 26 S 26 S 26 S 26 S 0077 67 P 106 S 33 C4P
0009 40 P 0078 67 S 106 P 33 C4S
0010 40 S 0079 67 P 106 S 67 P
0011 40 P 40 P 0080 67 S 106 P 67 S
0012 40 S 40 S 0081 67 P 67 P 33 C4P 33 C4P
0013 40 P 40 P 40 P 0082 67 S 67 S 33 C4S 33 C4S
0014 40 S 40 S 40 S 0083 D8P
0015 40 P 40 P 40 P 40 P 0084 D8S
0016 40 S 40 S 40 S 40 S 0085 C8P C8P 67 P 67 P
0017 45 P 0086 C8S C8S 67 S 67 S
0018 45 S 0087 106 S C8P
0019 45 P 45 P 0088 106 P C8S
0020 45 S 45 S 0089 106 S 67 P
0021 45 P 45 P 45 P 0090 106 P 67 S
0022 45 S 45 S 45 S 0091 106 S 106 S 67 P
0023 45 P 45 P 45 P 45 P 0092 106 P 106 P 67 S
0024 45 S 45 S 45 S 45 S 0093 106 S 106 S 33 C4P
0025 57 P 0094 106 P 106 P 33 C4S
0026 57 S 0095 106 S C8P 106 S 106 S
0027 57 P 57 P 0096 106 P C8S 106 P 106 P
0028 57 S 57 S 0097 106 S 67 P 106 S C8P
0029 57 P 57 P 57 P 0098 106 P 67 S 106 P C8S
0030 57 S 57 S 57 S 0099 106 S 67 P C8P C8P
0031 57 P 57 P 57 P 57 P 0100 106 P 67 S C8S C8S
0032 57 S 57 S 57 S 57 S 0101 106 S 106 S 67 P 67 P
0033 67 P 0102 106 P 106 P 67 S 67 S
0034 67 S 0103 33 C4P
0035 67 P 67 P 0104 33 C4S
0036 67 S 67 S 0105 33 C4P 106 S
0037 67 P 67 P 67 P 0106 33 C4S 106 P
0038 67 S 67 S 67 S 0107 33 C4P C8P
0039 67 P 67 P 67 P 67 P 0108 33 C4S C8S
0040 67 S 67 S 67 S 67 S 0109 C2P 40 C1P
0041 106 S 0110 C2S 40 C1S
0042 106 P 106 P 0111 C2P 57 P
0043 106 S 106 S 0112 C2S 57 S
0044 106 S 106 S 0113 C3P 67 P
0045 106 P 106 P 106 P 0114 C3S 67 S
0046 106 S 106 S 106 S 0115 C3P 106 S
0047 106 P 106 P 106 P 106 P 0116 C3S 106 P
0048 106 S 106 S 106 S 106 S 0117 C8P 106 S
0049 124 P 0118 C8S 106 P
0050 124 S 0119 10 C3P 32 C2P
0051 124 P 124 P 0120 10 C3S 32 C2S
0052 124 S 124 S 0121 32 C2P 40 C1P
0053 124 P 124 P 124 P 0122 32 C2S 40 C1S
0054 124 S 124 S 124 S 0123 32 C2P 45 P
0055 124 P 124 P 124 P 124 P 0124 32 C2S 45 S
0056 124 S 124 S 124 S 124 S 0125 32 C2P 57 P
0057 106 S 26 P 0126 32 C2S 57 S
0058 106 P 26 S 0127 32 C2P 67 P
0059 26 P 106 S 0128 32 C2S 67 S
0060 26 S 106 P 0129 32 C2P 106 S
0061 26 P 26 P 26 P 26 S 0130 32 C2S 106 P
0062 26 S 26 S 26 S 26 P 0131 40 C1P 40 C1P
0063 10 C3P 10 C3P C8P 67 P 0132 40 C1S 40 C1S
0064 10 C3S 10 C3S C8S 67 S 0133 57 P 106 S
0065 C8P C8P C8P 0134 57 S 106 P
0066 C8S C8S C8S 0135 C8P
0067 C8P C8P 106 S 0136 C8S
0068 C8S C8S 106 P 0137 10 C3P
0069 C8P 33 C4P 0138 10 C3S

78
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–24 Insert Arrangements, MIL-C-81659 Connector, Series 1 and 2 (Continued)

Insert Shell Insert Placement Insert Shell Insert Placement


Designation Designation
Number A B C D Number A B C D
0139 32 C2P 0144 67 C3S
0140 32 C2S 0145 C8P 57 P
0141 40 C1P 0146 C8S 57 S
0142 40 C1S 0147 57 P 26 P
0143 67 C3P 0148 57 S 26 S

Table 10–25 Polarization (Keying) Positions

# PLUG RECEPTACLE # PLUG RECEPTACLE


KEY KEYING POST KEY KEYING INSERT KEY KEYING POST KEY KEYING INSERT
CODE CODE CODE CODE
L C R L C R L C R L C R
00 00 50 2 2 5 50 6 3 3
01 1 1 1 01 4 4 4 51 3 2 5 51 6 3 2
02 2 1 1 02 4 4 3 52 4 2 5 52 6 3 1
03 3 1 1 03 4 4 2 53 5 2 5 53 6 3 6
04 4 1 1 04 4 4 1 54 6 2 5 54 6 3 5
05 5 1 1 05 4 4 6 55 1 2 4 55 1 3 4
06 6 1 1 06 4 4 5 56 2 2 4 56 1 3 3
07 1 1 6 07 5 4 4 57 3 2 4 57 1 3 2
08 2 1 6 08 5 4 3 58 4 2 4 58 1 3 1
09 3 1 6 09 5 4 2 59 5 2 4 59 1 3 6
10 4 1 6 10 5 4 1 60 6 2 4 60 1 3 5
11 5 1 6 11 5 4 6 61 1 2 3 61 2 3 4
12 6 1 6 12 5 4 5 62 2 2 3 62 2 3 3
13 1 1 5 13 6 4 4 63 3 2 3 63 2 3 2
14 2 1 5 14 6 4 3 64 4 2 3 64 2 3 1
15 3 1 5 15 6 4 2 65 5 2 3 65 2 3 6
16 4 1 5 16 6 4 1 66 6 2 3 66 2 3 5
17 5 1 5 17 6 4 6 67 1 2 2 67 3 3 4
18 6 1 5 18 6 4 5 68 2 2 2 68 3 3 3
19 1 1 4 19 1 4 4 69 3 2 2 69 3 3 2
20 2 1 4 20 1 4 3 70 4 2 2 70 3 3 1
21 3 1 4 21 1 4 2 71 5 2 2 71 3 3 6
22 4 1 4 22 1 4 1 72 6 2 2 72 3 3 5
23 5 1 4 23 1 4 6 73 1 3 1 73 4 2 4
24 6 1 4 24 1 4 5 74 2 3 1 74 4 2 3
25 1 1 3 25 2 4 4 75 3 3 1 75 4 2 2
26 2 1 3 26 2 4 3 76 4 3 1 76 4 2 1
27 3 1 3 27 2 4 2 77 5 3 1 77 4 2 6
28 4 1 3 28 2 4 1 78 6 3 1 78 4 2 5
29 5 1 3 29 2 4 6 79 1 3 6 79 5 2 4
30 6 1 3 30 2 4 5 80 2 3 6 80 5 2 3
31 1 1 2 31 3 4 4 81 3 3 6 81 5 2 2
32 2 1 2 32 3 4 3 82 4 3 6 82 5 2 1
33 3 1 2 33 3 4 2 83 5 3 6 83 5 2 6
34 4 1 2 34 3 4 1 84 6 3 6 84 5 2 5
35 5 1 2 35 3 4 6 85 1 3 5 85 6 2 4
36 6 1 2 36 3 4 5 86 2 3 5 86 6 2 3
37 1 2 1 37 4 3 4 87 3 3 5 87 6 2 2
38 2 2 1 38 4 3 3 88 4 3 5 88 6 2 6
39 3 2 1 39 4 3 2 89 5 3 5 89 6 2 6
40 4 2 1 40 4 3 1 90 6 3 5 90 6 2 5
41 5 2 1 41 4 3 6 91 1 3 4 91 1 2 4
42 6 2 1 42 4 3 5 92 2 3 4 92 1 2 3
43 1 2 6 43 5 3 4 93 3 3 4 93 1 2 2
44 2 2 6 44 5 3 3 94 4 3 4 94 1 2 1
45 3 2 6 45 5 3 2 95 5 3 4 95 1 2 6
46 4 2 6 46 5 3 1 96 6 3 4 96 1 2 5
47 5 2 6 47 5 3 6 97 1 3 3 97 2 2 4
48 6 2 6 48 5 3 5 98 2 3 3 98 2 2 3
49 1 2 5 49 6 3 4 99 3 3 3 99 2 2 3
# L – LEFT C – CENTRE R – RIGHT

79
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–26 Tools For MIL-C-81659 Standard Contacts

Contact Crimp Tool Insertion Tool Removal Tool


Size
Series 1 Front Release
22 MIL-DTL-22520/2 AMP 91039-1 AMP 91040-1
20 MIL-DTL-22520/2 (or /1) AMP 91039-1 AMP 91040-1
16 MIL-DTL-22520/1 MS 90455-1 MS 90456-1
Series 2 Rear Release
22 MIL-DTL-22520/2 MS 3156-22 (Black End) MS 3156-22 (White End)
20 MIL-DTL-22520/2 (or /1) MS 3156-20 (Green End) MS 3156-20 (White End)
16 MIL-DTL-22520/1 MS 3156-16 (Blue End) MS 3156-16 (White End)

Figure 10–51 Assembly of MIL-C-81659 Connectors Polarization (Keying) Posts and Inserts

Crimping of Coaxial Contacts in MIL-C-81659 shown in Figure 10–52. Size 5 and 9 connectors are
Connectors equipped with rear-release contacts that may be released
and removed from the rear of the connector with the use
103. Table 10–27 lists the type of contact, type of of special tool MS3178-001.
coaxial cable, crimping tools, selector position setting,
and contact positioner used with inner contact crimping 104. Centre Contact Crimping Procedure. The
tool, crimping die opening used with ferrule crimping centre contacts of MIL-C-81659 coaxial connectors are
tool, and cable stripping lengths for each of the MIL-C- crimped with either the MS22520/2-01 standard
81659 coaxial connectors. These connectors are crimping tool or the AMP 220015-1 crimping tool as
described in MS drawings 3168 through 3177. Sizes 1, listed in Table 10–27. If the MS22520/2-01 tool is used,
3 and 7 connector contacts are non-releasable. They can a special AMP contact positioner (also listed in Table
only be removed by disassembling the connector as 10–27) must be employed.

80
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–52 Assembly of MIL-C-81659 Connectors with Coaxial Connectors

Figure 10–54 Removal of Standard Contacts in


MIL-C-81659 Connectors
Figure 10–53 Insertion of Standard Contacts in
MIL-C-81659 Connectors

81
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

a. The procedure to be used with the (9) Insert contact into indentor
MS22520/2-01 crimping tool is as opening so that contact rests in
follows: positioner and wire barrel is
between indentor jaws.
(1) Select the special AMP positioner
to use from Table 10–27. (10) Insert stripped centre conductor
into centre contact until cable
(2) Open the tool handles. (If not dielectric butts against rim of
already open. The tool handles wire barrel. Then close crimp tool
must be fully closed to release the handles until ratchet releases.
ratchet). Handles will then return to open
position, allowing crimped
(3) Install the positioner by inserting contact to be removed.
it into the crimping tool retainer
ring and turning 90q to the right
until the bayonet pin locks.

(4) Install the safety clip in retainer


ring.

(5) Raise selector knob on crimping


tool, and rotate it until selector
position number from Table 10–
27 is opposite index mark. Figure 10–55 Installation of Sealing Boot and
Ferrule on Coaxial Cable Before Crimping
(6) Slip sealing boot (when used) Contacts
over cable. The end of the sealing
boot with the rounded lip should
face the end of the cable.

NOTE

Sealing boots are needed with all size 5 and size


9 coaxial contacts. Sealing rings are needed for
all size 3 and size 7 coaxial contacts and for
some size 1 contacts. In general, the
manufacturer will furnish the parts needed to seal
the connector from the environment and to keep
moisture from getting into the cable. Make sure Figure 10–56 Stripping Dimensions for Coaxial
all seals furnished with the contacts are properly Cable in Table 10–27
installed. (See Figure 10–55)
b. The procedure to be used with AMP
(7) Slip ferrule (when used) over 220015-1 crimping tool is as follows:
cable. The crimp end of the
ferrule should face the end of the (1) Slip sealing boot (when used)
cable and the shoulder end of the over cable. The end of the sealing
ferrule should face away from the boot with the rounded lip should
end of the cable. (See Figure 10– face the end of the cable. (See
55). Figure 10–55)
NOTE NOTE
A crimping ferrule is not used with semi-rigid Sealing boots are needed with all size 5 and size
coaxial cable. 9 coaxial contacts. Sealing rings are needed for
all size 3 and size 7 coaxial contacts and for
(8) Strip cable using stripping some size 1 contacts. In general, the
lengths given in Table 10–27 and manufacturer will furnish the parts needed to seal
illustrated in Figure 10–56. For the connectors against the environment and to
braided cable, flare braid. (See keep moisture from getting into the cable. Make
Figure 10–55.) sure all seals furnished with the contacts are
properly installed.

82
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–27 Stripping Lengths, Crimping Tools, Contacts, and Cables for MIL-C-81659 Coaxial
Connectors

Stripping Lengths and Crimping Tools


Stripping Length, mm r 0.4
Contact Braid Wire Braid + Total Centre Contact Selector Outer Die
MS A B Insul. Jacket Crimp Tool Setting Contact
Number C D Crimp Tool
3168 1.2 4.8 1.2 6.7 M22520/2-01 8 220066-1 B
AMP-1-601966-9
3169 12.7 4.8 12.7 17.5 AMP-220015-1 220015-1
3170 5.5 3.2 5.5 11.0 M22520/2-01 8 220066-1 B
AMP-1-601966-8
3171 12.7 4.8 12.7 17.5 AMP-220015-1 5 220015-1
3172 5.5 3.2 7.9 11.0 M22520/2-01 5 220066-1 B
AMP-1-601966-6
3173 5.5 3.2 7.9 11.0 M22520/2-01 5 220066-1 B
AMP-1-601966-6
3174 5.5 3.2 7.9 11.0 M22520/2-01 4 220066-1 C
AMP-1-601966-7
3175 5.5 3.2 7.1 10.3 M22520/2-01 5 220066-1 B
AMP-1-601966-7
3176 1.2 4.8 1.2 6.7 M22520/2-01 5 220066-1 B
AMP-1-601966-6
3177 5.5 3.2 7.9 11.0 M22520/2-01 5 220066-1 B
AMP-1-601966-6
Contacts and Cables
Contact Outer Contact Cable Type Exit Arrangement Removal Tool
MS Contact Size
Number Type
3168 Pin 1 141S.R. Straight Non-releasable
3169 Socket 1 RG214 Straight Non-releasable
3170 Pin 3 RG142 Straight or 90q Non-releasable
3171 Socket 3 RG214 Straight Non-releasable
3172 Pin 5 RG58C Straight MS3178-001
RG223 Straight MS3178-001
3173 Socket 5 RG58C Straight MS3178-001
RG223 Straight MS3178-001
3174 Pin 7 RG188 Straight or 90q Non-releasable
3175 Socket 7 RG58C Straight Non-releasable
3176 Pin 9 141S.R. Straight MS3178-001
3177 Socket 9 RG58C Straight MS3178-001

(2) Slip ferrule (when needed) over braided cable, flare braid. (See
cable. The crimp end of the Figure 10–55.)
ferrule should face the end of the
cable and the shoulder end of the (4) With crimping tool handles fully
ferrule should face away from the open, rotate contact locator-stop
end of the cable. (See Figure 10– knob (on back of tool head) to
55) open position. (See Figure 10–
57)
NOTE
(5) Insert centre conductor of coaxial
A crimping ferrule is not used with semi-rigid cable into centre contact wire
coaxial cable. barrel until cable dielectric butts
against rim of wire barrel. Then
(3) Strip cable using stripping place contact in tool head as
lengths given in Table 10–27 and shown in Figure 10–57.
illustrated in Figure 10–56. For

83
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

NOTE

When crimped centre contact of size 1 contact is


inserted into the size 1 contact body, an internal
locking feature should engage and hold the
centre contact captive. Pull back lightly on cable
to deter mine if contact is being held captive by
the internal locking feature. This locking feature
is not present in the smaller size contacts.

(3) Position ferrule over braid and


against shoulder on contact.

(4) Place the assembly in crimping


die of tool with shoulder of
contact against die. (See Figure
10–60)

(5) Close tool handles until ratchet


releases to form braid crimp.

b. The procedure for crimping braided


coaxial cable to outer contacts with the
AMP 220066-1 tool is as follows:

(1) Install seal ring (if used) over


Figure 10–57 Crimping Centre Contacts with braid support section of contact.
AMP 220015-1 Crimping Tool (See Figure 10–58)

(2) Insert crimped centre contact into


(6) Close tool handles until ratchet contact body until cable dielectric
releases. Tool ratchet will not bottoms against dielectric inside
release and handles will not open contact body. Braid should fit
until full crimping cycle has been over braid support section of
completed, assuring proper depth contact. (See Figure 10–59)
of crimp indent.
NOTE
105. Outer Contact Crimping Procedure. The outer
contacts of MIL-C-81659 coaxial connectors are When crimped centre contact of size 1 contact is
crimped with either the AMP 220066-1 crimping tool or inserted into the size 1 contact body, an internal
the AMP 220015-1 crimping tool as listed in Table 10– locking feature should engage and hold the
27. The 220015-1 tool has only one outer contact centre contact captive. Pull back lightly on cable
crimping die, but the 220066-1 tool has three. The to determine if contact is being held captive by
correct die to use is given in Table 10–27. internal locking feature. This locking feature is
not present in the smaller size contacts.
a. The procedure for crimping braided
coaxial cable to outer contacts, with the (3) Position ferrule over braid and
AMP 220015-1 tool is as follows: against shoulder on contact.

(1) Install seal ring (if used) over (4) Place the contact-ferrule
braid support section of contact assembly in the appropriate
against shoulder on contact. (See crimping die (from Table 10–27)
Figure 10–58) of the tool, with the shoulder of
the contact against the tool jaw.
(2) Insert crimped centre contact into (See Figure 10–61 and Figure
contact body until cable dielectric 10–62)
bottoms against dielectric inside
contact body. Braid should fit (5) Close tool handles until ratchet
over braid support section of releases to from braid crimp.
contact. (See Figure 10–59)

84
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

c. The procedure for crimping semi-rigid


coaxial cable contacts with the AMP
220066-1 ferrule crimping tool is as
follows:

(1) Insert crimped centre contact into


contact body until cable dielectric
bottoms against dielectric inside
contact body. Outer conductor of
cable should slip inside contact
backshell. (See Figure 10–63)

NOTE Figure 10–60 Contact-Ferrule Assembly in


Ferrule Crimping Die of Crimping Tool AMP
When crimped centre contact of size 1 contact is 220015-1 Ready for Crimping
inserted into the size 1 contact body, an internal
locking feature should engage and hold the
centre contact captive. Pull back lightly on cable
to determine if contact is being held captive by
internal locking feature. This locking feature is
not present in the smaller size contacts.

(2) Place the cable-contact assembly


in the appropriate crimping die
(from Table 10–27) of AMP
220066-1 ferrule crimping tool so
that the contact backshell is in the
crimping die and the shoulder of
the contact body (adjacent to the
backshell) butts against the die.
(See Figure 10–64)
Figure 10–61 AMP 220066-1 Ferrule Crimping
(3) Close tool handles until ratchet Tool Showing the Three Crimping Dies
releases to form backshell crimp.

Figure 10–62 Contact-Ferrule Assembly in


Figure 10–58 Contact Assembly Using Seal Crimping Die of AMP 220066-1 Ferrule
Ring Crimping Tool Ready for Crimping

Figure 10–63 Crimped Centre Contact of Semi-


Rigid Coaxial Cable Inserted in Contact Body

Figure 10–59 Crimped Centre Contact of


Braided Coaxial Cable Inserted in Contact Body

85
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

e. Pull the cable and tool out of the contact


cavity.

108. Sealing Plugs. All unused cavities in circular


and rectangular connectors should be filled with
unwired contacts and appropriate MS27488 sealing
plugs (see Table 10–28). The unwired contacts and
sealing plugs are required to preserve the environmental
sealing characteristics of the connectors.

Figure 10–64 Semi-Rigid Cable-Contact


Assembly in Crimping Die of AMP 220066-1
Ferrule Crimping Tool Ready for Backshell
Crimping

Insertion and Removal of Rear Release Coaxial


Contacts in MIL-C-81659 Connectors

106. Inserting Contacts. An insertion tool is not


required for inserting these contacts. To insert a contact,
align it with the back of the contact cavity and push it
straight into the connector until it bottoms. Pull back
lightly on the cable to make certain the contact is locked
in the cavity. Slide the sealing boot over the cable and
into the contact cavity until the collar of the seal butts
against the insert as shown in Figure 10–65. Slight Figure 10–65 Insertion of Rear-Release Coaxial
rotation of the seal will ease insertion. Contacts in MIL-C-81659 Connectors

107. Extracting Contacts. Removal tool MS3178-


001 is designed to remove size 5 and 9 contacts from
MIL-C-81659 connectors. The procedure is as follows:

a. Slide the sealing boot back over the


cable a minimum distance of 8.2cm
before extracting the contact. Do not cut
or otherwise damage the sealing boot.

b. Place the cable over the “V” notch of the


extraction tool handle. Then press the
cable into the notch. The tool handle will
spread open and allow the cable to enter.
Make certain the cable is seated in the
full length of the tool as shown in Figure
10–66. Figure 10–66 Removal of Rear-Release Coaxial
Contacts From MIL-C-81659 Connectors
c. Grip the tool handle firmly and insert the
tip to the contact cavity until it bottoms.

d. Maintain slight inward pressure on the


back of the tool handle and pull back on
the cable to release the contact.

86
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Table 10–28 MS27488 Sealing Plugs and Superseded Part Numbers

Connector
or Module
Contact Superseding
Cavity Size Part Number Superseded Military Specification Part Number
22 & 23 MS27488-22 M81511/39-22
20 MS27488-20 M81511/39-20 M83723/28-20 MS25251-20 MS27186-1 MS27187-3 MS3187-20-2
16 MS27488-16 M81511/39-16 M83723/28-16 MS25251-16 MS27186-2 MS27187-1 MS3187-16-2
12 MS27488-12 M81511/39-12 M83723/28-12 MS25251-12 MS27186-3 MS27187-2 MS3187-12-2
8 MS27488-8 M83723/28-8 MS25251-8 MS3187-8-2
4 MS27488-4 M83723/28-4 MS27187-4 MS3187-4-2
0 MS27488-0 M83723/28-0 MS3187-0-2

MULTIPLE TERMINATION CONNECTORS e. Use the M83521/5-01 heater and direct


(MTCS) hot air at the solder joint only. When the
solder melts pull the wire and the sleeve
109. MTCs are rectangular, flat and high density material straight off with tweezers.
connectors used in making environmentally protected
electrical connections between round wire harnesses f. To prevent electrostatic discharge
(see Figure 10–67). damage to sensitive electronic
components when working on installed
Wire Removal Procedure harnesses, the static grounding bus must
be used whenever any solder sleeve
110. The wire removal procedure for MTCs is as terminators are installed, either on the
follows: wafer or anywhere on the wires.

a. Insert wafer removal tool in the rear of Wire Connection Procedure


the MTC connector and gently pull the
cable to release the wafer from the shell. 111. The wire connection procedure for MTCs is as
follows:
b. Clamp the appropriate wafer holding
fixture in a convenient position and a. Clamp appropriate wafer holding fixture
insert wafer into holding fixture. in a convenient position and insert wafer
into holding fixture.
c. If working on installed harnesses, attach
the static grounding bus to the wafer b. Install a connector solder sleeve
contacts. It attaches by clipping onto the terminator back over the wire flue end
contacts of either pin or socket wafers. first.
Do not force the grounding bus rightly
onto the wafer. Very gentle insertion is c. Strip wire back 3.8 – 4.3mm.
sufficient for static grounding.
d. Position stripped wire over solder tab
d. Isolate the wire and sleeve terminator and slide sleeve terminator over wire
with the sleeve isolator on the holding and tab until it touches the wafer.
fixture.
e. Isolate sleeve with the sleeve isolator in
holding fixture.

USE ONLY HOT AIR GUN M83521/5-01 OR


EQUIVALENT ON FUELLED AIRCRAFT.
USE ONLY HOT AIR GUN M83521/5-01 OR
EQUIVALENT ON FUELLED AIRCRAFT.

USE OF NITROGEN WITH HOT AIR GUN


M83521/5-01 IN AN ENCLOSED AREA CAN
BE HAZARDOUS. ENSURE AREA IS WELL
VENTILATED.

87
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

NOTE

Allow terminator to cool before disturbing.

USE OF NITROGEN WITH HOT AIR GUN g. Remove assembly from fixture and
M83521/5-01 IN AN ENCLOSED AREA CAN inspect in accordance with Figure 10–
BE HAZARDOUS. ENSURE AREA IS WELL 68.
VENTILATED.
h. Insert wafer into rear of MTC shell.
f. Using a M83521/5-01 hot air gun, direct
hot air at the solder until it melts and
flows.

Figure 10–67 Multiple Termination Connector

88
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10

Figure 10–68 Inspection Criteria

89

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