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26500
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MIL-DTL-26500
Features and Application
MS2426*/AE66*
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 oers 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 oer 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 oers yet another barrier to
moisture and contaminants.
Superior Contact Stability - Front release crimp contact
system features a beryllium-copper retaining clip completely
encased in a tough dielectric wafer, thus protecting the clip
tines from damage.
Closed Entry Socket Contacts
Closed-entry socket contacts facilitate positive mating.
Features and Application
MIL-DTL-26500 family oers connectors with bayonet
coupling as well as threaded coupling. ese connectors are
intermateable with correspondingly coupled MIL-DTL-83723
Series III connectors (except shell size 8, threaded coupling
only).
AE66 connectors are widely used on commercial, military
and aerospace systems requiring general-purpose, miniature
cylindrical bayonet or threaded coupling connectors.
is family (bayonet as well as threaded) of connectors
is oered in wall mount receptacles, jam nut mounted
receptacles which incorporate O’ring seals, designed for
rear panel “D” hole mounting, and straight plugs.
Twenty-one insert arrangements per MIL-STD-1554 are
tooled and qualied 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.
ese connectors are only available in aluminum shells
with anodic plating to the MS number. In addition, we oer
connectors with passivated stainless steel shells to commercial
callouts only.
Insert Polarization
Alternate insert positions documented in the original
specication, positions 1 through 5, are still available (except
in shell size 8), but are not approved for new design. ese
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.
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26500
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MIL-DTL-26500
Performance Specications
MS2426*/AE66*
Performance Specications
Operating Temperature Range
Class R: -55°C to +200°C (-67°F to +392°F)
Class E*: -55°C to +200°C (-67°F to +392°F)
Material and Finish Data (Class)
R – aluminum shell, black anodized nish
E*– stainless steel shell, passivated
Corrosion Resistance
Classes R and E* withstand 48-hour salt spray.
Environmental Seal
Wired, mated connectors shall meet the altitude-immersion
test specied by MIL-DTL-26500.
Fluid Resistance
Unmated connectors resist specied immersions in
MIL-PRF-5606 (hydraulic uid), MIL-PRF-23699 (lubricating
oil), MIL-PRF-7808 (lubricating oil), MIL-DTL-5624 (JP-5)
and glycol.
Durability
Bayonet Coupling – 500 cycles
readed Coupling – 200 cycles
Voltage Rating
Shock and Vibration Requirements
Wired, mated connectors shall not be damaged, coupling
ring shall not loosen, and there shall be no interruption of
electrical continuity longer than one microsecond when
subjected to the following:
Shock
Mated connectors withstand a pulse of approximate
half sine wave of 100 G magnitude with duration of
6 milliseconds applied in each of the three major axes.
Vibration
Mated connectors withstand the following vibration levels:
• Vibration per EIA-364, test procedure 28 conducted at
a low temperature ambient of -55°C (-67°F) and high
ambient of +200°C (392°F).
Shell-to-Shell Conductivity
• Class R is non-conductive.
• Maximum potential drop shall not exceed 200 millivolts
for class E*.
*Class E only available to commercial callouts. Consult factory for
drawings. Pages 153 thru 158 apply to class R only.
** To be used by designer only as a guide.
Service
Rating
Suggested Operating Voltage** Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 110,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
I 600 850 1500 450 275 200
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26500
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MIL-DTL-26500
Part Number Development
Bayonet & Threaded Coupling
Part Number Development
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: Two spare contacts
for each size contact utilized and at least 15% of the number
of contacts but no less than three sealing plugs are provid-
ed. No insertion/removal tools are provided. No spares are
required for shielded contacts.
Note 2: Proper part number marking has no “0” in front of
single digit shell size (8), and no “0” in front of single digit
layouts. Example: MS24264R8B3SN and MS24264R18B8P6.
Please note that in this series “N” for normal is included in
part number marking.
Mil. Prex MS 24266 R 12 T 12 P N
Aero Prex AE 666 R 12 T 12 P N -340
Shell type
24264 = Wall mount receptacle = 664 (Aero p/n)
24265 = Jam nut receptacle = 665 (Aero p/n)
24266 = Straight plug = 666 (Aero p/n)
Class (Material and Finish)
R = Aluminum shell, black anodized nish
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)
Modication (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 modications
*Class E only available to commercial callouts. Consult factory for
drawings. Pages 153 thru 158 apply to class R only.
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26500
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1.421(36.09)
MAX
4x C
MOUNTING
HOLES
3 ORANGE COLOR STRIPES
EQUALLY SPACED
PANEL THICKNESS:
.125(3.18)MAX
D
KEYWAY
MASTER
B
.728(18.49)
.708(17.98)
A
E ACCESSORY THREAD
F
MAX
GROMMET
.072(1.83)
.052(1.32)
.306(7.77) MIN FULL THREAD
4 MINOR KEYWAYS
MS24264R**B
Wall Mounting Receptacle
AE664R**B
Bayonet Coupling, Crimp Removable, Front Release
Page 152 Completed Part Number
Page 161 Contacts, Sealing Plugs and Tools
Page 164 Insert Arrangements
Page 151 Performance Specications
Page 163 Insert Availability and Contact Information
Page 160 Polarization
Shell
Size
A B Ø C Ø D EØ F
+.000 +.00 +.000 +.00 Accessory Thread
±.005 ±.13 (TP) -.009 -.23 -.005 -.13 Class 2A Maximum
inch mm inch mm inch mm inch mm inch mm
8 .812 20.62 .594 15.09 .125 3.18 .536 13.61 7/16-28UNEF .328 8.33
10 .937 23.80 .719 18.26 .125 3.18 .659 16.74 9/16-24UNEF .420 10.67
12 1.031 26.19 .812 20.62 .125 3.18 .829 21.06 3/4-20UNEF .580 14.73
14 1.125 28.58 .906 23.01 .125 3.18 .898 22.81 13/16-20UNEF .664 16.87
16 1.250 31.75 .969 24.61 .125 3.18 1.025 26.04 15/16-20UNEF .769 19.53
18 1.343 34.11 1.062 26.97 .125 3.18 1.131 28.73 1-1/16-18UNEF .902 22.91
20 1.437 36.50 1.156 29.36 .125 3.18 1.256 31.90 1-3/16-18UNEF 1.033 26.24
22 1.562 39.67 1.250 31.75 .125 3.18 1.381 35.08 1-5/16-18UNEF 1.152 29.26
24 1.703 43.26 1.375 34.93 .154 3.91 1.506 38.25 1-7/16-18UNEF 1.282 32.56
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26500
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MOUNTING
FLAT
3 ORANGE COLOR STRIPES
EQUALLY SPACED E ACCESSORY THREAD
JAM-NUT THREAD
G
HEX NUT WITH
3 TEFLON PLUGS
EQUALLY SPACED
"O" RING
PANEL THICKNESS:
.125(3.18) MAX
F
MAX
GROMMET
D
.781(19.84)
.761(19.33)
1.421(36.09)
MAX
.306(7.77)
MIN FULL THREAD
A
MAX
B
C
MASTER
KEYWAY
MS24265R**B
Jam Nut Receptacle
AE665R**B
Bayonet Coupling, Crimp Removable, Front Release
Page 152 Completed Part Number
Page 161 Contacts, Sealing Plugs and Tools
Page 164 Insert Arrangements
Page 151 Performance Specications
Page 163 Insert Availability and Contact Information
Page 160 Polarization
Shell
Size
Ø A B C Ø D EØ F G
+.000 +.00 Accessory Thread Jam Nut Thread
Maximum ±.005 ±.13 ±.003 ±.08 -.005 -.13 Class 2A Maximum Class 2A
inch mm inch mm inch mm inch mm inch mm
8 1.068 27.13 .979 24.87 .593 15.06 .536 13.61 7/16-28UNEF .328 8.33 5/8-20UN
10 1.192 30.28 1.104 28.04 .718 18.24 .659 16.74 9/16-24UNEF .420 10.67 3/4-20UNEF
12 1.380 35.05 1.291 32.79 .905 22.99 .829 21.06 3/4-20UNEF .580 14.73 15/16-20UNEF
14 1.505 38.23 1.391 35.33 .968 24.59 .898 22.81 13/16-20UNEF .664 16.87 1-20UNEF
16 1.630 41.40 1.516 38.51 1.093 27.76 1.025 26.04 15/16-20UNEF .769 19.53 1-1/8-20UN
18 1.740 44.20 1.641 41.68 1.217 30.91 1.131 28.73 1-1/16-18UNEF .902 22.91 1-1/4-20UN
20 1.860 47.24 1.766 44.86 1.342 34.09 1.256 31.90 1-3/16-18UNEF 1.033 26.24 1-3/8-18UNEF
22 2.040 51.82 1.954 49.63 1.467 37.26 1.381 35.08 1-5/16-18UNEF 1.152 29.26 1-1/2-20UN
24 2.160 54.86 2.079 52.81 1.592 40.44 1.506 38.25 1-7/16-18UNEF 1.282 32.56 1-5/8-18UNEF
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26500
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MS24266R**B
Straight Plug
AE666R**B
Bayonet Coupling, Crimp Removable, Front Release
Page 152 Completed Part Number
Page 161 Contacts, Sealing Plugs and Tools
Page 164 Insert Arrangements
Page 151 Performance Specications
Page 163 Insert Availability and Contact Information
Page 160 Polarization
D ACCESSORY THREAD
3 ORANGE STRIPES
EQUALLY SPACED
.306(7.77)
MIN FULL THREAD
B
C
MAX
GROMMET
A
MAX COUPLING NUT 1.375(34.93)
MAX
4 MINOR KEYS
MASTER KEY
Shell
Size
Ø A Ø B Ø C D
+.000 +.00 Accessory Thread
Maximum -.005 -.13 Maximum Class 2A
inch mm inch mm inch mm
8 .776 19.71 .424 10.77 .328 8.33 7/16-28UNEF
10 .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF
12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF
14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF
16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF
18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF
20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF
22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF
24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF
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26500
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FULL MATE
INDICATOR
COLOR: ORANGE
4x C
MOUNTING
HOLES
D MATING THREAD E ACCESSORY THREAD
MASTER
KEYWAY
F
MAX
GROMMET
A
B
1.421(36.09)
MAX
.728(18.49)
.708(17.98)
.306(7.77) MIN FULL THREAD
.072(1.83)
.052(1.32)
4 MINOR KEYWAYS
PANEL THICKNESS:
.125(3.18) MAX
MS24264R**T
Wall Mounting Receptacle
AE664R**T
Threaded Coupling, Crimp Removable, Front Release
Page 152 Completed Part Number
Page 161 Contacts, Sealing Plugs and Tools
Page 164 Insert Arrangements
Page 151 Performance Specications
Page 163 Insert Availability and Contact Information
Page 160 Polarization
Shell
Size
A B Ø C D E Ø F
+.000 +.00 Mating Thread Accessory Thread
±.005 ±.13 (TP) -.009 -.23 Class 2A Class 2A Maximum
inch mm inch mm inch mm inch mm
8 .812 20.62 .594 15.09 .125 3.18 9/16-24UNEF 7/16-28UNEF .328 8.33
10 .937 23.80 .719 18.26 .125 3.18 11/16-24UNEF 9/16-24UNEF .420 10.67
12 1.031 26.19 .812 20.62 .125 3.18 7/8-20UNEF 3/4-20UNEF .580 14.73
14 1.125 28.58 .906 23.01 .125 3.18 15/16-20UNEF 13/16-20UNEF .664 16.87
16 1.250 31.75 .969 24.61 .125 3.18 1-1/16-18UNEF 15/16-20UNEF .769 19.53
18 1.343 34.11 1.062 26.97 .125 3.18 1-3/16-18UNEF 1-1/16-18UNEF .902 22.91
20 1.437 36.50 1.156 29.36 .125 3.18 1-5/16-18UNEF 1-3/16-18UNEF 1.033 26.24
22 1.562 39.67 1.250 31.75 .125 3.18 1-7/16-18UNEF 1-5/16-18UNEF 1.152 29.26
24 1.703 43.26 1.375 34.93 .154 3.91 1-9/16-18UNEF 1-7/16-18UNEF 1.282 32.56
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26500
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E ACCESSORY THREAD
D MATING THREAD
FULL MATE
INDICATOR
COLOR: ORANGE
HEX NUT WITH
3 TEFLON PLUGS
EQUALLY SPACED
"O" RING
F
MAX
GROMMET
G JAM-NUT THREAD
A
MAX
B
C
MOUNTING
FLAT
.306(7.77)
MIN FULL THREAD
1.421(36.09)
MAX
.781(19.84)
.761(19.33)
PANEL THICKNESS:
.125(3.18) MAX
MASTER
KEYWAY
MS24265R**T
Jam Nut Receptacle
AE665R**T
Threaded Coupling, Crimp Removable, Front Release
Page 152 Completed Part Number
Page 161 Contacts, Sealing Plugs and Tools
Page 164 Insert Arrangements
Page 151 Performance Specications
Page 163 Insert Availability and Contact Information
Page 160 Polarization
Shell
Size
Ø A B C D E Ø F G
Mating Thread Accessory Thread Jam Nut Thread
Maximum ±.005 ±.13 ±.003 ±.08 Class 2A Class 2A Maximum Class 2A
inch mm inch mm inch mm inch mm
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
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
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26500
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MS24266R**T
Straight Plug
AE666R**T
Threaded Coupling, Crimp Removable, Front Release
Page 152 Completed Part Number
Page 161 Contacts, Sealing Plugs and Tools
Page 164 Insert Arrangements
Page 151 Performance Specications
Page 163 Insert Availability and Contact Information
Page 160 Polarization
1.375(34.93)
MAX
A
MAX COUPLING NUT
B
D ACCESSORY THREAD
C
MAX
GROMMET
.306(7.77)
MIN FULL THREAD
E MATING THREAD
4 MINOR KEYS
MASTER KEY
Shell
Size
Ø A Ø B Ø C D E
+.000 +.00 Accessory Thread Mating Thread
Maximum -.005 -.13 Maximum Class 2A Class 2B
inch mm inch mm inch mm
8 .776 19.71 .424 10.77 .328 8.33 7/16-28UNEF 9/16-24UNEF
10 .906 23.01 .526 13.36 .420 10.67 9/16-24UNEF 11/16-24UNEF
12 1.078 27.38 .696 17.68 .580 14.73 3/4-20UNEF 7/8-20UNEF
14 1.141 28.98 .765 19.43 .664 16.87 13/16-20UNEF 15/16-20UNEF
16 1.266 32.16 .892 22.66 .769 19.53 15/16-20UNEF 1-1/16-18UNEF
18 1.375 34.93 .998 25.35 .902 22.91 1-1/16-18UNEF 1-3/16-18UNEF
20 1.510 38.35 1.123 28.52 1.033 26.24 1-3/16-18UNEF 1-5/16-18UNEF
22 1.625 41.28 1.248 31.70 1.152 29.26 1-5/16-18UNEF 1-7/16-18UNEF
24 1.760 44.70 1.373 34.87 1.282 32.56 1-7/16-18UNEF 1-9/16-18UNEF
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26500
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MIL-DTL-26500
Polarization (Shell Keying, Insert Clocking)
Bayonet and Threaded
Shell Keying Insert Clocking
Notes:
1.In the normal position (N), the insert centerline
coincides with the centerline of the master keyway (key)
of the shell: E = 0°.
2.In the alternate keying positions (6, 7, 8, 9 and Y), the
minor keyways (keys) are positioned with reference to
master key/keyway as indicated in the keying position
table below.
3.In the alternate insert clocking positions (1, 2, 3, 4 and
5), the socket insert (viewing from the mating side) is
rotated counter-clockwise relative to the centerline of the
master keyway (key) of the shell. e pin insert is rotated
clockwise.
*Per MIL-STD-1554, keyed position Y and clocked positions 1, 2, 3, 4 and 5 are
not available in shell size 8.
** Alterate positions “Z” and “10” are cancelled and superseded by Position “Y”.
†Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design.
Shell
Size
Polarizing Key/Keyway Positions Insert Position
Position A° B° C° D° E°
8*, 10
N 105 140 215 265 0
6 102 132 248 320 0
7 80 118 230 312 0
8 35 140 205 275 0
9 64 155 234 304 0
10 only Y** 25 115 220 270 0
12 thru 24
N 105 140 215 265 0
6 18 149 192 259 0
7 92 152 222 342 0
8 84 152 204 334 0
9 24 135 199 240 0
Y** 98 152 268 338 0
10 thru 24
1† 105 140 215 265 10
2† 105 140 215 265 20
3† 105 140 215 265 30
4† 105 140 215 265 40
5† 105 140 215 265 50
INSERT
VERTICAL
CENTERLINE
SOCKET INSERT
MATING FACE
(PIN INSERT IS OPPOSITE)
ENGAGING FACE VIEW FOR
RECEPTACLE SHELL KEYWAYS
(PLUG SHELL KEYS, OPPOSITE)
MASTER
KEYWAY(KEY)
OF SHELL
E°
C°
B°
D°
A°
MASTER
KEYWAY
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26500
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MIL-DTL-26500 Bayonet and Threaded
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
Note: Maximum panel thickness of .125 inch (3.18 mm).
Flange and Jam Nut Mounting Dimensions
L
S
LL J
Z
Shell
Size
LØ J Ø J Ø LL SØ Z
For Back Mounting For Front Mounting +.000 +.00
(TP) Minimum Minimum -.009 -.23 ±.005 ±.13 ±.005 ±.13
inch mm inch mm inch mm inch mm inch mm inch mm
8 .594 15.09 .620 15.75 .447 11.35 .125 3.18 .605 15.37 .635 16.13
10 .719 18.26 .748 19.00 .572 14.53 .125 3.18 .730 18.54 .760 19.30
12 .812 20.62 .913 23.19 .760 19.30 .125 3.18 .917 23.29 .947 24.05
14 .906 23.01 .980 24.89 .822 20.88 .125 3.18 .980 24.89 1.010 25.65
16 .969 24.61 1.107 28.12 .948 24.08 .125 3.18 1.105 28.07 1.135 28.83
18 1.062 26.97 1.209 30.71 1.072 27.23 .125 3.18 1.225 31.12 1.260 32.00
20 1.156 29.36 1.337 33.96 1.192 30.28 .125 3.18 1.350 34.29 1.385 35.18
22 1.250 31.75 1.452 36.88 1.322 33.58 .125 3.18 1.475 37.47 1.510 38.35
24 1.375 34.93 1.577 40.06 1.442 36.63 .154 3.91 1.600 40.64 1.635 41.53
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26500
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MIL-DTL-26500
Contacts, Tools and Seal Plugs
MS2426*/AE66*
Note 1: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
Note 2: No plastic Insertion/Removal tools are supplied as part
of contact packages when ordering 26500 connectors. Metal
insertion and extraction tools must be ordered separately.
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
20 Power/Signal M39029/31-241 M39029/32-260 MS27488-20-1 N/A
16 Power/Signal M39029/31-229 M39029/32-248 MS27488-16-1 N/A
12 Power/Signal M39029/31-235 M39029/32-254 MS27488-12-1 N/A
8 Coax Coax M39029/54-343 M39029/55-345 MS27488-8-1 N/A
Contact
Size/Type
Crimp Tool Positioner Positioner Insertion Tool Extraction Tool
For Pin Contacts For Socket Contacts Metal Metal
Military No. Military No. Military No. Military No. Military No.
20 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-03 M81969/19-07
M22520/2-01 M22520/2-02 M22520/2-02
16 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-04 M81969/19-08
12 M22520/1-01 M22520/1-02 M22520/1-02 M81969/17-05 M81969/19-09
8 Coax Inner M22520/2-01 M22520/2-24 M22520/2-24 M81969/17-06 M81969/19-03
8 Coax Outer M22520/5-01 M22520/5-10 M22520/5-10
Contact
Size
Test Current Potential Crimp Well Data Wire Range Finished Wire Ø Range
DC Test Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWG mm2inch mm inch mm
20 7.5 55 .049 ±.001 .267 6.78 24-20 .20-.52 .040 1.02 .090 2.29
16 13.0 49 .067 ±.001 .236 5.99 20-16 .52-1.31 .068 1.73 .130 3.30
12 23.0 42 .100 ±.002 .236 5.99 14-12 2.08-3.31 .106 2.69 .170 4.32
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26500
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MIL-DTL-26500
Contact Installation Instructions
MS2426*/AE66*
Contact Installation
Instructions
Crimping Contacts
1. Select the appropriate crimp tool and ensure that the
proper crimp head positioner is used.
2. Cycle the tool to be sure the indentors are open.
3. Determine the correct selector setting for the wire size
from the data plate on the positioner (turret head
assembly) and set the selector knob on the crimp tool
to match.
4. Place the contact, mating end rst, into the tool.
5. Insert the stripped wire into the hollow end of the
contact. Be sure the wire is inserted as far as it will go.
6. Close the tool completely to crimp. Unless the tool is
closed completely, the tool will not release the contact.
7. Remove the crimped contact from the tool. Check the
inspection hole to verify that the wire is fully inserted.
Insertion of Contacts
1. Before inserting the contacts, unscrew the accessories
(clamps, backshells or adapters) from rear of plug or
receptacle. Slide the hardware over the wire bundle in
the proper order for reassembly aer all the contacts
are inserted.
2. To assist insertion of contacts, lubricate insulator
(grommet) cavities with isopropyl alcohol. Alcohol will
evaporate and will not leave a conductive lm. Caution:
Never use any lubricant other than isopropyl alcohol.
3. Place the correct insertion tool on the contact so that the
wire runs along the groove in the tool. (Tool tip will butt
against the shoulder.) Hold the plug or receptacle body
rmly.
4. Beginning with a center cavity, insert the contact into
the insulator with a slow, even pressure until the contact
snaps into position. Make sure the contact and tool are
held perpendicular to the face of the insert during the
contact installation or the grommet could be damaged.
4.1 If contacts are not inserted all the way prior to removing
insertion tool, do not try to reinsert the insertion tool.
Instead, remove the contact and try again; otherwise
reinserting the insertion tool may damage the inside of
the contact cavity.
5. Remove tool and check the face of the connector for
proper contact installation. Proper installation may also
be checked by pulling back lightly on the wire to make
sure the contact is properly seated.
Completion
Aer all the cavities have been lled, slide the hardware back
into position on the connector and tighten.
Extraction of Contacts (Rework)
1. Slide the hardware back over the wire bundle.
2. Select the appropriate tool. Place tool over the contact
on mating side and insert into the cavity.
3. Exert nominal force axially to release retention clip.
Spacer sleeve will shoulder at face of insulation when tool
is inserted to proper depth.
4. Push extraction plunger to force the contact out of the
rear of the insert.
5. Grasp contact or wire and pull the wired contact out of
the rear of the insulator.
6. Remove extraction tool axially.
7. Aer using the extraction tool, the spacer sleeve should
be set forward in the last notch to protect the end of the
plunger guide.
Size Pin Contact Socket Contact Basic Crimp Tool Positioner Insertion Tool Removal Tool
20 M39029/31-241 M39029/32-260 M22520/1-01 M22520/1-02 Red M81969/17-03 M81969/19-07
M22520/2-01 M22520/2-02
16 M39029/31-229 M39029/32-248 M22520/1-01 M22520/1-02 Blue M81969/17-04 M81969/19-08
12 M39029/31-235 M39029/32-254 M22520/1-01 M22520/1-02 Yellow M81969/17-05 M81969/19-09
163www.conesys.com sales@aero-electric.com
26500
– –
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 Service Alternate Positions
Status No. of (by Size) (Insert Rotation in Degrees)
QPL’d Tooled Contacts 20 16 12 # 8 Coax Rating 1* 2* 3* 4* 5*
8-3 Yes Yes 3 3 I N/A N/A N/A N/A N/A
10-5 Yes Yes 5 5 I 10 20 30 40 50
12-3 Yes Yes 3 3 I 10 20 30 40 50
12-12 Yes Yes 12 12 I 10 20 30 40 50
14-7 Yes Yes 7 7 I 10 20 30 40 50
14-12 Yes Yes 12 9 3 I 10 20 30 40 50
14-15 Yes Yes 15 15 I 10 20 30 40 50
16-10 Yes Yes 10 10 I 10 20 30 40 50
16-24 Yes Yes 24 24 I 10 20 30 40 50
18-8 Yes Yes 8 8 I 10 20 30 40 50
18-11 Yes Yes 11 10 1 I 10 20 30 40 50
18-14 Yes Yes 14 14 I 10 20 30 40 50
18-31 Yes Yes 31 31 I 10 20 30 40 50
20-16 Yes Yes 16 16 I 10 20 30 40 50
20-25 Yes Yes 25 19 6 I 10 20 30 40 50
20-39 Yes Yes 39 37 2 I 10 20 30 40 50
20-41 Yes Yes 41 41 I 10 20 30 40 50
22-19 Yes Yes 19 19 I 10 20 30 40 50
22-55 Yes Yes 55 55 I 10 20 30 40 50
24-30** N/A Yes 30 30 I 10 20 30 40 50
24-43 Yes Yes 43 23 20 I 10 20 30 40 50
24-57 Yes Yes 57 55 2 I 10 20 30 40 50
*Per MIL-STD-1554, insert positions 1 thru 5 are inactive for new design. ** Non MIL-STD-1554 layout, available to Aero-Electric part number only.
164www.conesys.com sales@aero-electric.com
26500
– –
8-3
3#20
I
1
3
10-5
5#20
I
1
5
12-3
3#16
I
1
23
14-7
7#16
I
1
7
18-8
8#12
I
1
8
12-12
12 #20
I
1
12
14-12
9#20, 3#16
I
1
12
14-15
15 #20
I
1
15
16-10
10#16
I
1
10
18-14
14 #16
I
1
14
18-31
31 #20
I
1
31
20-39
37 # 20, 2#16
I
1
39
16-24
24 #20
I
1
24
20-16
16 #16
I
1
16
20-25
19 #20, 6#12
I
1
25
20-41
41#20
I
1
41
18-11
10 # 16, 1#8Coax.
I
1
11
22-19
19 #16
I
19
1
22-55
55 #20
I
1
55
24-43
23 # 20, 20 #16
I
1
43
24-57
55 #20, 2#12
I
1
57
130
24-30
30 #16
I
MIL-STD-1554
Insert Arrangements (Socket Front View)
for MIL-DTL-26500 Connectors
Insert Arrangement Views
∆ Non MIL-STD-1554 layout, available to Aero-Electric part number only.