MIL-DTL-26500 Features and Application MS2426*/AE66* Features and Application AE66 connectors are widely used on commercial, military and aerospace systems requiring general-purpose, miniature cylindrical bayonet or threaded coupling connectors. Connector Sealing - A pressure seal at the connector interface is accomplished through the aid of a coupling device which compresses the front resilient insulators and thus offers a seal around each contact preventing the passage of moisture through the contact cavity. Rear resilient insulators are designed with a triple wire seal in each cavity to offer positive sealing and prevent wicking of moisture through the connector without the use of external clamping devices or adapters. In addition, a dynamic O'ring seal in the receptacles engages the front of the plug shell when connectors are mated and offers yet another barrier to moisture and contaminants. This family (bayonet as well as threaded) of connectors is offered in wall mount receptacles, jam nut mounted receptacles which incorporate O'ring seals, designed for rear panel "D" hole mounting, and straight plugs. Superior Contact Stability - Front release crimp contact system features a beryllium-copper retaining clip completely encased in a tough dielectric wafer, thus protecting the clip tines from damage. Twenty-one insert arrangements per MIL-STD-1554 are tooled and qualified to MIL-DTL-26500, utilizing 3 to 57 M39029 contacts. Contacts come in sizes 20, 16 and 12, terminating wire sizes from 24 to 12 gauge. Closed Entry Socket Contacts Closed-entry socket contacts facilitate positive mating. MIL-DTL-26500 family offers connectors with bayonet coupling as well as threaded coupling. These connectors are intermateable with correspondingly coupled MIL-DTL-83723 Series III connectors (except shell size 8, threaded coupling only). These connectors are only available in aluminum shells with anodic plating to the MS number. In addition, we offer connectors with passivated stainless steel shells to commercial callouts only. Insert Polarization Alternate insert positions documented in the original specification, positions 1 through 5, are still available (except in shell size 8), but are not approved for new design. These alternate insert clocking positions aid in mating of adjacent connectors having identical insert arrangement. Shell Polarization - Alternate key/keyway positions prevent cross mating of adjacent connectors having same insert arrangement. 26500 www.conesys.com - 150 - sales@aero-electric.com MIL-DTL-26500 Performance Specifications MS2426*/AE66* Performance Specifications Shock and Vibration Requirements Wired, mated connectors shall not be damaged, coupling ring shall not loosen, and there shall be no interruption of electrical continuity longer than one microsecond when subjected to the following: Operating Temperature Range Class R: -55C to +200C (-67F to +392F) Class E*: -55C to +200C (-67F to +392F) Shock Mated connectors withstand a pulse of approximate half sine wave of 100 G magnitude with duration of 6 milliseconds applied in each of the three major axes. Material and Finish Data (Class) R - aluminum shell, black anodized finish E*- stainless steel shell, passivated Corrosion Resistance Classes R and E* withstand 48-hour salt spray. Vibration Mated connectors withstand the following vibration levels: * Vibration per EIA-364, test procedure 28 conducted at a low temperature ambient of -55C (-67F) and high ambient of +200C (392F). Environmental Seal Wired, mated connectors shall meet the altitude-immersion test specified by MIL-DTL-26500. Shell-to-Shell Conductivity * Class R is non-conductive. * Maximum potential drop shall not exceed 200 millivolts for class E*. Fluid Resistance Unmated connectors resist specified immersions in MIL-PRF-5606 (hydraulic fluid), MIL-PRF-23699 (lubricating oil), MIL-PRF-7808 (lubricating oil), MIL-DTL-5624 (JP-5) and glycol. Durability Bayonet Coupling - 500 cycles Threaded Coupling - 200 cycles Voltage Rating Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) 26500 Service Rating Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft. AC (RMS) DC V RMS V RMS V RMS V RMS I 600 850 1500 450 275 200 * Class E only available to commercial callouts. Consult factory for drawings. Pages 153 thru 158 apply to class R only. ** To be used by designer only as a guide. www.conesys.com - 151 - sales@aero-electric.com MIL-DTL-26500 Part Number Development Bayonet & Threaded Coupling Part Number Development Mil. Prefix Aero Prefix MS AE 24266 666 R R 12 12 T T 12 12 P P N N -340 Shell type 24264 = Wall mount receptacle = 664 (Aero p/n) 24265 = Jam nut receptacle = 665 (Aero p/n) 24266 = Straight plug = 666 (Aero p/n) Class (Material and Finish) R = Aluminum shell, black anodized finish E* = Stainless steel shell, passivated Shell Size (SS) 8, 10, 12, 14, 16, 18, 20, 22 or 24 Coupling Mechanism B = Bayonet Coupling T = Threaded Coupling Insert Arrangement See pages 164 Contact Style P = Pin S = Socket Polarization (Keying) N = Normal 6, 7, 8, 9 or Y (Alternate keyed positions, Y is not availabe in SS 8) 1, 2, 3, 4 or 5 (Clocked insert polarizations within normally keyed shell, not approved for new design, n/a in SS 8) Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 341 = Connector kitted with MS27291-XX straight clamp Consult factory for other modifications * Class E only available to commercial callouts. Consult factory for drawings. Pages 153 thru 158 apply to class R only. www.conesys.com Note 2: Proper part number marking has no "0" in front of single digit shell size (8), and no "0" in front of single digit layouts. Example: MS24264R8B3SN and MS24264R18B8P6. Please note that in this series "N" for normal is included in part number marking. - 152 - sales@aero-electric.com 26500 Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: Two spare contacts for each size contact utilized and at least 15% of the number of contacts but no less than three sealing plugs are provided. No insertion/removal tools are provided. No spares are required for shielded contacts. MS24264R**B Wall Mounting Receptacle AE664R**B Bayonet Coupling, Crimp Removable, Front Release A 1.421(36.09) MAX B .728(18.49) .708(17.98) MASTER KEYWAY 4x C MOUNTING HOLES .072(1.83) .052(1.32) F D MAX GROMMET E ACCESSORY THREAD 3 ORANGE COLOR STRIPES EQUALLY SPACED 4 MINOR KEYWAYS Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 PANEL THICKNESS: .125(3.18)MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A Shell Size .306(7.77) MIN FULL THREAD B .005 .13 inch mm O (TP) inch mm C O D E +.000 -.009 +.00 -.23 +.000 -.005 +.00 -.13 inch mm inch mm Accessory Thread Class 2A O F Maximum inch mm 8 .812 20.62 .594 15.09 .125 3.18 .536 13.61 7/16-28UNEF .328 8.33 10 .937 23.80 .719 18.26 .125 3.18 .659 16.74 9/16-24UNEF .420 10.67 12 1.031 26.19 .812 20.62 .125 3.18 .829 21.06 3/4-20UNEF .580 14.73 14 1.125 28.58 .906 23.01 .125 3.18 .898 22.81 13/16-20UNEF .664 16.87 16 1.250 31.75 .969 24.61 .125 3.18 1.025 26.04 15/16-20UNEF .769 19.53 26500 18 1.343 34.11 1.062 26.97 .125 3.18 1.131 28.73 1-1/16-18UNEF .902 22.91 20 1.437 36.50 1.156 29.36 .125 3.18 1.256 31.90 1-3/16-18UNEF 1.033 26.24 22 1.562 39.67 1.250 31.75 .125 3.18 1.381 35.08 1-5/16-18UNEF 1.152 29.26 24 1.703 43.26 1.375 34.93 .154 3.91 1.506 38.25 1-7/16-18UNEF 1.282 32.56 www.conesys.com - 153 - sales@aero-electric.com MS24265R**B Jam Nut Receptacle AE665R**B Bayonet Coupling, Crimp Removable, Front Release 1.421(36.09) MAX B .781(19.84) .761(19.33) C MASTER KEYWAY MOUNTING FLAT .306(7.77) MIN FULL THREAD D F MAX GROMMET A MAX 3 ORANGE COLOR STRIPES EQUALLY SPACED E ACCESSORY THREAD G JAM-NUT THREAD "O" RING HEX NUT WITH 3 TEFLON PLUGS EQUALLY SPACED Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 PANEL THICKNESS: .125(3.18) MAX Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O A B inch 8 1.068 O D E .005 .13 .003 .08 +.000 -.005 +.00 -.13 mm inch mm inch mm inch mm 27.13 .979 24.87 .593 15.06 .536 13.61 Maximum Shell Size C Accessory Thread Class 2A O F G Maximum inch mm 7/16-28UNEF .328 8.33 Jam Nut Thread Class 2A 5/8-20UN 1.192 30.28 1.104 28.04 .718 18.24 .659 16.74 9/16-24UNEF .420 10.67 3/4-20UNEF 1.380 35.05 1.291 32.79 .905 22.99 .829 21.06 3/4-20UNEF .580 14.73 15/16-20UNEF 14 1.505 38.23 1.391 35.33 .968 24.59 .898 22.81 13/16-20UNEF .664 16.87 1-20UNEF 16 1.630 41.40 1.516 38.51 1.093 27.76 1.025 26.04 15/16-20UNEF .769 19.53 1-1/8-20UN 18 1.740 44.20 1.641 41.68 1.217 30.91 1.131 28.73 1-1/16-18UNEF .902 22.91 1-1/4-20UN 20 1.860 47.24 1.766 44.86 1.342 34.09 1.256 31.90 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF 22 2.040 51.82 1.954 49.63 1.467 37.26 1.381 35.08 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN 24 2.160 54.86 2.079 52.81 1.592 40.44 1.506 38.25 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF www.conesys.com - 154 - sales@aero-electric.com 26500 10 12 MS24266R**B Straight Plug AE666R**B Bayonet Coupling, Crimp Removable, Front Release A MAX COUPLING NUT 1.375(34.93) MAX MASTER KEY .306(7.77) MIN FULL THREAD B C MAX GROMMET 3 ORANGE STRIPES EQUALLY SPACED D ACCESSORY THREAD 4 MINOR KEYS Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O Shell Size A O Maximum inch mm B O +.000 -.005 +.00 -.13 inch mm C D Accessory Thread Class 2A Maximum inch mm 8 .776 19.71 .424 10.77 .328 8.33 7/16-28UNEF 10 .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF 12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF 14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF 16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF 26500 18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF 20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF 22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF 24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF www.conesys.com - 155 - sales@aero-electric.com MS24264R**T Wall Mounting Receptacle AE664R**T Threaded Coupling, Crimp Removable, Front Release A 1.421(36.09) MAX B 4x C .728(18.49) .708(17.98) MASTER KEYWAY MOUNTING HOLES .072(1.83) .052(1.32) F MAX GROMMET D MATING THREAD 4 MINOR KEYWAYS E ACCESSORY THREAD FULL MATE INDICATOR COLOR: ORANGE .306(7.77) MIN FULL THREAD PANEL THICKNESS: .125(3.18) MAX Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Shell Size .005 .13 inch mm inch O C +.000 -.009 +.00 -.23 mm inch mm (TP) D E Mating Thread Class 2A Accessory Thread Class 2A O F Maximum inch mm 8 .812 20.62 .594 15.09 .125 3.18 9/16-24UNEF 7/16-28UNEF .328 8.33 10 .937 23.80 .719 18.26 .125 3.18 11/16-24UNEF 9/16-24UNEF .420 10.67 12 1.031 26.19 .812 20.62 .125 3.18 7/8-20UNEF 3/4-20UNEF .580 14.73 14 1.125 28.58 .906 23.01 .125 3.18 15/16-20UNEF 13/16-20UNEF .664 16.87 16 1.250 31.75 .969 24.61 .125 3.18 1-1/16-18UNEF 15/16-20UNEF .769 19.53 1.343 34.11 1.062 26.97 .125 3.18 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91 1.437 36.50 1.156 29.36 .125 3.18 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24 22 1.562 39.67 1.250 31.75 .125 3.18 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26 24 1.703 43.26 1.375 34.93 .154 3.91 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56 www.conesys.com - 156 - sales@aero-electric.com 26500 18 20 MS24265R**T Jam Nut Receptacle AE665R**T Threaded Coupling, Crimp Removable, Front Release 1.421(36.09) MAX B .781(19.84) .761(19.33) C MOUNTING FLAT MASTER KEYWAY .306(7.77) MIN FULL THREAD F MAX GROMMET A D MATING THREAD MAX FULL MATE INDICATOR COLOR: ORANGE E ACCESSORY THREAD G JAM-NUT THREAD "O" RING HEX NUT WITH 3 TEFLON PLUGS EQUALLY SPACED Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O Shell Size PANEL THICKNESS: .125(3.18) MAX A B Maximum inch mm C .005 .13 .003 .08 inch mm inch mm D E Mating Thread Class 2A Accessory Thread Class 2A O F G Jam Nut Thread Class 2A Maximum inch mm 8 1.068 27.13 .979 24.87 .593 15.06 9/16-24UNEF 7/16-28UNEF .328 8.33 5/8-20UN 10 1.192 30.28 1.104 28.04 .718 18.24 11/16-24UNEF 9/16-24UNEF .420 10.67 3/4-20UNEF 12 1.380 35.05 1.291 32.79 .905 22.99 7/8-20UNEF 3/4-20UNEF .580 14.73 15/16-20UNEF 14 1.505 38.23 1.391 35.33 .968 24.59 15/16-20UNEF 13/16-20UNEF .664 16.87 1-20UNEF 16 1.630 41.40 1.516 38.51 1.093 27.76 1-1/16-18UNEF 15/16-20UNEF .769 19.53 1-1/8-20UN 26500 18 1.740 44.20 1.641 41.68 1.217 30.91 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91 1-1/4-20UN 20 1.860 47.24 1.766 44.86 1.342 34.09 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF 22 2.040 51.82 1.954 49.63 1.467 37.26 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN 24 2.160 54.86 2.079 52.81 1.592 40.44 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF www.conesys.com - 157 - sales@aero-electric.com MS24266R**T Straight Plug AE666R**T Threaded Coupling, Crimp Removable, Front Release A MAX COUPLING NUT 1.375(34.93) MAX MASTER KEY .306(7.77) MIN FULL THREAD B C MAX GROMMET E MATING THREAD D ACCESSORY THREAD 4 MINOR KEYS Page 152 Page 161 Page 164 Page 151 Page 163 Page 160 Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization O A O inch O +.000 -.005 +.00 -.13 mm inch mm inch Maximum Shell Size B C Maximum D E Accessory Thread Class 2A Mating Thread Class 2B mm .776 19.71 .424 10.77 .328 8.33 7/16-28UNEF 9/16-24UNEF .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF 11/16-24UNEF 12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF 7/8-20UNEF 14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF 15/16-20UNEF 16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF 1-1/16-18UNEF 18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF 1-3/16-18UNEF 20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF 1-5/16-18UNEF 22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF 1-7/16-18UNEF 24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF 1-9/16-18UNEF www.conesys.com - 158 - sales@aero-electric.com 26500 8 10 MIL-DTL-26500 Polarization (Shell Keying, Insert Clocking) Bayonet and Threaded Shell Keying D B Insert Clocking A E MASTER KEYWAY(KEY) OF SHELL MASTER KEYWAY C ENGAGING FACE VIEW FOR RECEPTACLE SHELL KEYWAYS (PLUG SHELL KEYS, OPPOSITE) INSERT VERTICAL CENTERLINE SOCKET INSERT MATING FACE (PIN INSERT IS OPPOSITE) Notes: 1. In the normal position (N), the insert centerline coincides with the centerline of the master keyway (key) of the shell: E = 0. 2. In the alternate keying positions (6, 7, 8, 9 and Y), the minor keyways (keys) are positioned with reference to master key/keyway as indicated in the keying position table below. Polarizing Shell Size 8*, 10 10 only 12 thru 24 10 thru 24 3. In the alternate insert clocking positions (1, 2, 3, 4 and 5), the socket insert (viewing from the mating side) is rotated counter-clockwise relative to the centerline of the master keyway (key) of the shell. The pin insert is rotated clockwise. Key/Keyway Positions Insert Position 26500 Position A B C D E N 6 7 8 9 Y** N 6 7 8 9 Y** 1 2 3 4 5 105 102 80 35 64 25 105 18 92 84 24 98 105 105 105 105 105 140 132 118 140 155 115 140 149 152 152 135 152 140 140 140 140 140 215 248 230 205 234 220 215 192 222 204 199 268 215 215 215 215 215 265 320 312 275 304 270 265 259 342 334 240 338 265 265 265 265 265 0 0 0 0 0 0 0 0 0 0 0 0 10 20 30 40 50 * Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5 are not available in shell size 8. Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Alterate positions "Z" and "10" are cancelled and superseded by Position "Y". www.conesys.com - 159 - sales@aero-electric.com MIL-DTL-26500 Bayonet and Threaded Flange and Jam Nut Receptacles Panel Cutouts Panel Cutouts S LL J Z L Note: Maximum panel thickness of .125 inch (3.18 mm). Flange and Jam Nut Mounting Dimensions L O J O For Back Mounting Minimum (TP) J O inch mm inch mm inch S O Z +.000 -.009 +.00 -.23 .005 .13 .005 .13 mm inch mm inch mm inch mm For Front Mounting Minimum Shell Size LL 8 .594 15.09 .620 15.75 .447 11.35 .125 3.18 .605 15.37 .635 16.13 10 .719 18.26 .748 19.00 .572 14.53 .125 3.18 .730 18.54 .760 19.30 12 .812 20.62 .913 23.19 .760 19.30 .125 3.18 .917 23.29 .947 24.05 14 .906 23.01 .980 24.89 .822 20.88 .125 3.18 .980 24.89 1.010 25.65 16 .969 24.61 1.107 28.12 .948 24.08 .125 3.18 1.105 28.07 1.135 28.83 1.062 26.97 1.209 30.71 1.072 27.23 .125 3.18 1.225 31.12 1.260 32.00 1.156 29.36 1.337 33.96 1.192 30.28 .125 3.18 1.350 34.29 1.385 35.18 22 1.250 31.75 1.452 36.88 1.322 33.58 .125 3.18 1.475 37.47 1.510 38.35 24 1.375 34.93 1.577 40.06 1.442 36.63 .154 3.91 1.600 40.64 1.635 41.53 www.conesys.com - 160 - sales@aero-electric.com 26500 18 20 MIL-DTL-26500 Contacts, Tools and Seal Plugs MS2426*/AE66* Contacts, Plastic Insertion/Removal Tools and Seal Plugs Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Military No. Military No. Military No. Military No. 20 Power/Signal M39029/31-241 M39029/32-260 MS27488-20-1 N/A 16 Power/Signal M39029/31-229 M39029/32-248 MS27488-16-1 N/A 12 Power/Signal M39029/31-235 M39029/32-254 MS27488-12-1 N/A 8 Coax Coax M39029/54-343 M39029/55-345 MS27488-8-1 N/A Contact Size Plastic Crimping and Metal Insertion/Extraction Tools Crimp Tool Contact Size/Type Positioner Positioner Insertion Tool Extraction Tool For Pin Contacts For Socket Contacts Metal Metal Military No. Military No. M81969/17-03 M81969/19-07 Military No. Military No. Military No. M22520/1-01 M22520/1-02 M22520/1-02 M22520/2-01 M22520/2-02 M22520/2-02 16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-04 M81969/19-08 12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-05 M81969/19-09 M81969/17-06 M81969/19-03 20 8 Coax Inner M22520/2-01 M22520/2-24 M22520/2-24 8 Coax Outer M22520/5-01 M22520/5-10 M22520/5-10 Contact and Wire Data Contact Size Test Current Potential DC Test Drop Crimp Well Data Well Dia. Wire Range Minimum Well Dept Finished Wire O Range Minimum Maximum mm2 inch mm inch mm Amps Millivolts inch inch mm AWG 20 7.5 55 .049 .001 .267 6.78 24-20 .20-.52 .040 1.02 .090 2.29 16 13.0 49 .067 .001 .236 5.99 20-16 .52-1.31 .068 1.73 .130 3.30 12 23.0 42 .100 .002 .236 5.99 14-12 2.08-3.31 .106 2.69 .170 4.32 26500 Note 1: Test Current and Maximum Voltage Drop when tested with silver-plated wire at 25C. www.conesys.com Note 2: No plastic Insertion/Removal tools are supplied as part of contact packages when ordering 26500 connectors. Metal insertion and extraction tools must be ordered separately. - 161 - sales@aero-electric.com MIL-DTL-26500 Contact Installation Instructions MS2426*/AE66* Contact Installation Instructions 4. Beginning with a center cavity, insert the contact into the insulator with a slow, even pressure until the contact snaps into position. Make sure the contact and tool are held perpendicular to the face of the insert during the contact installation or the grommet could be damaged. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 4.1 If contacts are not inserted all the way prior to removing insertion tool, do not try to reinsert the insertion tool. Instead, remove the contact and try again; otherwise reinserting the insertion tool may damage the inside of the contact cavity. 2. Cycle the tool to be sure the indentors are open. 3. Determine the correct selector setting for the wire size from the data plate on the positioner (turret head assembly) and set the selector knob on the crimp tool to match. 5. Remove tool and check the face of the connector for proper contact installation. Proper installation may also be checked by pulling back lightly on the wire to make sure the contact is properly seated. 4. Place the contact, mating end first, into the tool. 5. Insert the stripped wire into the hollow end of the contact. Be sure the wire is inserted as far as it will go. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 6. Close the tool completely to crimp. Unless the tool is closed completely, the tool will not release the contact. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 7. Remove the crimped contact from the tool. Check the inspection hole to verify that the wire is fully inserted. 2. Select the appropriate tool. Place tool over the contact on mating side and insert into the cavity. Insertion of Contacts 1. Before inserting the contacts, unscrew the accessories (clamps, backshells or adapters) from rear of plug or receptacle. Slide the hardware over the wire bundle in the proper order for reassembly after all the contacts are inserted. 3. Exert nominal force axially to release retention clip. Spacer sleeve will shoulder at face of insulation when tool is inserted to proper depth. 4. Push extraction plunger to force the contact out of the rear of the insert. 2. To assist insertion of contacts, lubricate insulator (grommet) cavities with isopropyl alcohol. Alcohol will evaporate and will not leave a conductive film. Caution: Never use any lubricant other than isopropyl alcohol. 5. Grasp contact or wire and pull the wired contact out of the rear of the insulator. 6. Remove extraction tool axially. 3. Place the correct insertion tool on the contact so that the wire runs along the groove in the tool. (Tool tip will butt against the shoulder.) Hold the plug or receptacle body firmly. Pin Contact Socket Contact 20 M39029/31-241 M39029/32-260 16 12 M39029/31-229 M39029/31-235 M39029/32-248 M39029/32-254 www.conesys.com Basic Crimp Tool M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 - 162 - Positioner M22520/1-02 Red M22520/2-02 M22520/1-02 Blue M22520/1-02 Yellow Insertion Tool Removal Tool M81969/17-03 M81969/19-07 M81969/17-04 M81969/17-05 M81969/19-08 M81969/19-09 sales@aero-electric.com 26500 Size 7. After using the extraction tool, the spacer sleeve should be set forward in the last notch to protect the end of the plunger guide. MIL-DTL-26500 Bayonet and Threaded Insert Availability and Contact Information per MIL-STD-1554 Insert Availability and Contact Information Insert Arrangement Aero-Electric Total Quantity of Contacts Status No. of (by Size) Alternate Positions (Insert Rotation in Degrees) QPL'd Tooled Contacts 20 Rating 1* 2* 3* 4* 5* 8-3 Yes Yes 3 3 I N/A N/A N/A N/A N/A 10-5 Yes Yes 5 5 I 10 20 30 40 50 12-3 Yes Yes 3 12-12 Yes Yes 12 Yes Yes 7 Yes Yes 12 9 14-15 Yes Yes 15 15 Yes Yes 10 Yes Yes 24 20 30 40 50 20 30 40 50 I 10 20 30 40 50 10 24 8 11 10 18-14 Yes Yes 14 31 16 8 20-25 Yes Yes 25 19 Yes Yes 39 37 20-41 Yes Yes 41 41 22-19 Yes Yes 19 22-55 Yes Yes 55 N/A Yes 30 Yes Yes 43 23 24-57 Yes Yes 57 55 20 30 40 50 20 30 40 50 10 20 30 40 50 10 20 30 40 50 14 I 10 20 30 40 50 I 10 20 30 40 50 16 I 10 20 30 40 50 6 2 19 24-30** 10 10 I 55 24-43 I I I 1 31 20-39 50 50 10 Yes Yes 40 40 10 Yes Yes 30 30 I Yes Yes 20 20 I Yes Yes 10 10 7 18-8 18-31 I I 3 18-11 20-16 # 8 Coax 3 14-7 16-10 12 12 14-12 16-24 16 Service I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 I 10 20 30 40 50 30 I 10 20 30 40 50 20 I 10 20 30 40 50 I 10 20 30 40 50 2 * Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Non MIL-STD-1554 layout, available to Aero-Electric part number only. 26500 www.conesys.com - 163 - sales@aero-electric.com MIL-STD-1554 Insert Arrangements (Socket Front View) for MIL-DTL-26500 Connectors Insert Arrangement Views 7 1 5 1 1 1 1 12 3 2 8-3 3 # 20 I 10-5 5 # 20 I 3 12-3 3 # 16 I 12-12 12 # 20 I 14-7 7 # 16 I 8 10 15 1 1 1 1 12 1 24 14-12 9 # 20, 3 # 16 I 14-15 15 # 20 I 16-10 10 # 16 I 16-24 24 # 20 I 16 14 11 18-8 8 # 12 I 31 25 1 1 1 1 18-14 14 # 16 I 18-11 10 # 16, 1 # 8 Coax. I 1 18-31 31 # 20 I 20-16 16 # 16 I 41 20-25 19 # 20, 6 # 12 I 19 55 39 1 1 20-39 37 # 20, 2 # 16 I 1 20-41 41 # 20 I 1 22-19 19 # 16 I 22-55 55 # 20 I 43 57 1 30 1 24-43 23 # 20, 20 # 16 I 26500 24-30 30 # 16 I 1 24-57 55 # 20, 2 # 12 I Non MIL-STD-1554 layout, available to Aero-Electric part number only. www.conesys.com - 164 - sales@aero-electric.com