Connectors, Contacts & Tooling
Connectors, Contacts & Tooling
Connectors, Contacts & Tooling
CRIMP CONTACTS
10
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
11
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
12
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
13
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
14
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
15
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
16
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
17
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
18
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
19
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
20
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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.
21
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
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
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
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).
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
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
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
28
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
Figure 10–21 Removing Crimp Type Contacts From Front Release Connectors
29
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
(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.
30
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
31
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
32
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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.
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:
33
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
34
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
CONTINUITY TEST
35
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
36
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
37
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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).
NOTE
38
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
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.
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).
42
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
43
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
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):
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.
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.
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.
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
RECTANGULAR CONNECTORS
Description
NOTE
a. Connectors.
48
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
49
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
50
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
51
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
c. Connectors.
MIL-DTL-5015 CONNECTORS
52
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
53
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
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.
57
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
60
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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.
61
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
62
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
63
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
(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.
64
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
65
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
d. Classes (Series III & IV): g. Shell Size Code – Series III & IV only:
(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.
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.
67
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
68
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
Marking
69
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
Table 10–21 Installation Torque Values For MIL-C-85049 Circular Electrical Connector Accessories
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
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
75
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
76
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
(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
78
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
79
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
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.
NOTE
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
(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
(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
85
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
86
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
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
87
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
NOTE
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.
88
AC 21-99 Aircraft Wiring and Bonding Sect 2 Chap 10
89