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GOVERNMENT - INDUSTRY DATA EXCHANGE PROGRAM

ALERT

1. TITLE (Class, Function, Type, etc.) 2. DOCUMENT NUMBER

PE2-A-17-02 ITT Cannon to MIL-DTL-83733E Specification 3. DATE (DD-MMM-YY)

07-JUN-17 4. MANUFACTURER AND ADDRESS 5. PART NUMBER 6. NATIONAL STOCK NUMBER

ITT Cannon, LLC M83733/XX (See Database) See Database 56 Technology Drive 7. SPECIFICATION 8. GOVERNMENT PART NUMBER Irvine, CA 92618 MIL-DTL-83733E M83733/XX 9. LOT DATE CODE START 10. LOT DATE CODE END

2008 Present 11. MANUFACTURER’S POINT OF CONTACT 12. CAGE 13. MANUFACTURER'S FAX

Michael Savage 71468 (714) 628-2369 14. MFR. POC PHONE 15. MANUFACTURER’S E-MAIL

(714) 628-2329 [email protected] 16. SUPPLIER 17. SUPPLIER ADDRESS 18. SUPPLIER CAGE

Not Applicable Not Applicable Not Applicable 19. PROBLEM DESCRIPTION / DISCUSSION / EFFECT

ITT Cannon (ITT) is not current on MIL-DTL-83733E retention of qualification testing. For the period 2008 to present, ITT observed the following test failures during retention of qualification testing:

• Gauge retention: requirements para. 3.6.11, test method para. 4.7.12 • Contact retention: requirements para 3.6.13, test method para. 4.7.14 • Visual and mechanical examination (out of tolerance dimensions): requirements para. 3.1, test method para.

4.7.2 • Mating and unmating forces: requirements para. 3.6.4, test method para. 4.7.5 • Altitude - low temperature: requirements para. 3.6.14, test method para. 4.7.15 • Maintenance aging: requirements para. 3.6.23, test method para. 4.7.3

ITT is also reporting on this GIDEP changes in process, material, construction, sourcing or design incorporated in the construction of MIL-SPEC connectors for the period 2008 to present. Block 19 continued on page 2.

20. ACTION TAKEN/PLANNED

DLA has imposed a stop production and stop shipment on ITT Cannon (ITT) and its Category C (Value-Add) Distributors relative to the subject MIL-SPEC. In addition, DLA has required that ITT disclose instances of using unapproved or non-conforming materials in the construction of the subject MIL-SPEC products for the period 2008 to present. Further GIDEP notifications beyond this one will be issued if additional non-conformances are identified.

21. DATE MFR. NOTIFIED/ SUPPLIER NOTIFIED

22. MFR./SUPPLIER RESPONSE 23. ORIGINATOR ADDRESS/POINT OF CONTACT

REPLY ATTACHED Michael Savage, ITT Cannon, LLC Not Applicable Not Applicable 56 Technology Drive NO REPLY Irvine, CA 92618 [email protected] (714) 628-2329 24. GIDEP REPRESENTATIVE 25. SIGNATURE 26. DATE

Michael Regola Signature on File 07-JUN-17

GIDEP Form 97-1 (September 2009)

Block 19 Continued:

Retention of Qualification and Initial Qualification Testing

The following problems occurred during retention of qualification testing of this specification for the period from 2008 to the present. The test problems are summarized below:

1. Gauge retention and contact retentionRequirements para. 3.6.11, test method para. 4.7.12

ITT observed the following test problem in the 36-month requalification of ITT Cannon DPK class R, shell size A and B connectors due August 2009.

Gauge retention: Per the specification’s retention of qualification testing requirements, contacts in three randomly selected cavities were replaced with the applicable test gauges per the specification. An axial load of 25 lbs was applied at a rate of 1 lb per second until the full load was reached. The displacement was measured, and the displacement of each one of the three contacts was above the 0.012 inch-limit required.

Contact retention: Per the specification’s retention of qualification testing requirements, an axial load of 25 lbs was applied at a rate of 1 lb per second until the full load was reached to 20% of the contacts in unmated connectors. A preload of 3 lbs maximum was initially applied to fully seat the contacts. The displacement was measured, and the displacement in several contacts in two samples exceeded the 0.012 inch displacement limit required by the specification.

ITT determined that both failures were the consequence of the axial displacement of the entire insulator subassembly. The cause of the insulator movement was an insufficient amount of adhesive in the insulator groove of the shell housing. ITT determined that the problem was found to be an isolated incident resulting from the assembler applying the specified adhesive in the incorrect area. The appropriate training was given to the operators in the insulator bonding process.

Risk Assessment • This was an isolated issue.• ITT is not aware of field failures attributed to this issue.

2. Visual and mechanical examination (out of tolerance dimensions)Requirements para. 3.1, test method para. 4.7.2

ITT observed the following test problems relating to visual and mechanical examination (out of tolerance dimensions):

A. ITT observed the following test problem in the Group B 36-month requalification of ITT Cannon DPK, shell size A andB connectors due August 2012.

Various dimensions were out of tolerance. Investigation revealed 2 causes – the assembly process and the mold. The assembly issues related to the bonding and final assembly operations. The oversized internal width dimension of the mating side of the receptacle shell occurred during the sub assembly process (bonding of peripheral seal to the shell). The oversized external width dimension of the mating side of the plug shell occurred during the insulator to shell assembly at the final assembly process. The mold was found to be out of specification per the drawing.

An internal CAR was issued, CAR 2013-002429. Fixtures were built that ensure the assembly process maintains the dimensions within specification. Monitoring of the new process indicates no dimensional rejections. New inserts for the die cast tool for shells family 248-2102-XXX were built.

Risk Assessment • Eleven dimensions were out of tolerance on the connectors, driven by 4 common components with out of tolerance

dimensions used in the assembly. Three of the 4 were determined to have no impact on the performance of theconnectors (non-critical dimensions) per the M83733 specification. An engineering analysis was performed on theremaining dimension relating to an oversized plug shell (+.003” per side) which verified that the mating receptacleshell/seal design would accommodate the increased seal compression caused by this oversized condition without anyimpact on performance to the M83733 specification. See Page 9, Detail B of the M83733 specification for moreinformation regarding this dimension.

• As part of the company’s corrective actions, ITT improved the tooling for use after assembly to verify that the shellmeets the correct dimensions, and if it is not, to bring it back into the M83733 dimension.

• Monitoring of the new process indicates no dimensional rejections.• ITT is not aware of field failures attributed to this issue.

B. ITT observed the following test problem in the Group B 12-month inspection of ITT Cannon DPK, shell size A and Bconnectors due August 2014

During first article inspection ITT observed that the internal radius dimension at the receptacle interface was not in conformance with MIL-DTL-83733.

Upon review of the current MIL-DTL-83733 rev E specification and previous rev D specification, ITT identified a significant difference in the internal radius dimension at the receptacle interface when compared to the MIL-DTL-83733 rev C specification. ITT believes that this was an oversight that occurred during the revision updates. This internal receptacle shell radius affects both the size A and size B shell interface. ITT had previously sent a request alerting DLA to the likely error in the specification in 2014.

Risk Assessment • This is an error in the specification that was acknowledged by DLA.

C. ITT observed the following test problem in the Group B 12-month inspection of ITT Cannon DPK, shell size A and Bconnectors due August 2014

During first article inspection ITT observed that the internal radius dimension at the receptacle interface was not in conformance with MIL-DTL-83733.

MIL-DTL-83733/12D has a flange bushing diameter dimension on the receptacle of 0.213 – 0.223”. MIL-DTL- 83733/12C shows the measurement as a radius. Upon review of the current MIL-DTL-83733/12E the dimension returns to 0.213 – 0.233” radius.

ITT believe that this was an oversight that occurred when the specification was being revised.

Risk Assessment • This is an error in the specification that was acknowledged by DLA.

D. ITT observed the following test problems on samples supplied by our value-add distributor during retention ofqualification testing that is currently in progress for the requalification due 2016.

Initial analysis indicated that for test sample M83733/3RA131, the shell was out of tolerance. For test sample M83733/4RB101, a grommet tool was out of tolerance and a slight bowing occurred on the shell lead-in after assembly.

In both cases, mold tools were out of specification with the M83733 specifications. Contributing to the molding tools conditions were:

1. Inadequate control of tool usage and repairs to allow prevention and timely detection of tool problems; and2. No established requirement to verify all critical dimensions included in the specification.

For test sample M83733/3RA131, the following actions were taken: 1. Implemented a database for tool control which outlines requirements for tracking tool usage, service and

repairs, including applicable actions depending on its record.2. Provided training to all Tooling technicians on the added requirements regarding tool time life tracking.

For test sample M83733/4RB101, the following actions were taken: 1. All DPKB-101 grommet molding tools placed on tooling hold status to prevent their use until the tools were

validated.2. Developed a plan to verify dimensions on all DPKB-101 grommet molding tools prior to releasing them to

production.

As part of the company’s corrective actions, defective tools were removed from production for disposal (grommet, M83733/4RB101) or for repair and subsequent replacement with a new tool (Shell, M83733/3RA131). All defective inventories of shells and insulators related to the issues identified above were scrapped.

ITT provided oral notification in 2017 to the quality personnel at the value-add distributor, who provided the sample, of the possibility of shell bowing after assembly and the tooling required to correct this issue.

Risk Assessment • Four dimensions were out of tolerance. One, on the receptacle, was corrected through mold changes and

involved a non-critical exterior dimension. Two others were on the mating plug and were due to an oversizedgrommet, also corrected through a mold change, and both involved non-critical dimensions. An engineeringanalysis was performed on the fourth remaining dimension relating to an oversized plug shell (+.003” per side)which verified that the mating receptacle shell/seal design would accommodate the increased sealcompression caused by this oversized condition without any impact on performance to the M83733specification. See Page 9, Detail B of the M83733 specification for more information regarding this dimension.

• Monitoring of the new process indicates no dimensional rejections.• ITT is not aware of field failures attributed to this issue.

E. ITT observed the following test problem during retention of qualification testing that is currently in progress for therequalification due 2016

During mechanical inspection, the engineer could not seat the contact into cavity 1 on sample 1-1R. Initial analysis showed adhesive in the cavity. Upon further inspection it was determined that a piece of the plastic insertion tool had broken off in the cavity. Lab personnel were re-trained on the proper use of insertion tools and were instructed to note the condition of the insertion tool before and after use.

The sample was replaced and testing continued, and there were no issues with the replacement sample.

Risk Assessment • This test problem was the result of an error in the test set-up that is not attributable to the connector sample.

• The replacement sample passed contact retention testing.

3. Mating and unmating forcesRequirements para. 3.6.4, test method para. 4.7.5ITT observed the following test problem during retention of qualification testing that is currently in progress for therequalification due 2015.

Samples 1-1P/1R through 1-6P/6R from the 2015 retention of qualifications failed mating forces per MIL-DTL-83733E.

The specification requires that all shell size A connectors be under 70lb of forces and all shell size B connectors be under 95lb of forces without mounting accessories. The samples all had forces above these values when testing to average mating dimensions. As a result, the parts could not be fully mated.

During engineering examination, the receptacle insulator was noted to be offset to the side relative to the front portion of the receptacle shell resulting in high forces when mating with the plug. The cause is that the rear tool core that creates the rear shell cavity retaining the insulator was not in alignment with the front half of the tooling that creates the front portion of the shell, rendering the tool out of compliance with the design intent as controlled by the ITT tooling drawing.

ITT determined that the cause for this was wear on the guide pins used to align the die cast tooling for the shell and a lack of core locating pins that produce the rear cavity of the shell. The corrective action was to repair the existing alignment pins and add alignment pins for the rear core to better align these two features moving forward.

Risk Assessment • This is an isolated issue.• Such a defect would have been recognizable due the inability to mate the connectors, and ITT is not aware of field

failures reported since 2016 attributed to this issue.

4. Altitude – low temperatureRequirements para. 3.6.14, test method para. 4.7.15ITT observed the following test problem in the Group B 36-month requalification of ITT Cannon DPK, shell size A and Bconnectors due August 2009.

The specification requires that connectors shall withstand a dielectric withstanding voltage (DWV) of 625 V rms for 1 minute after stabilizing at an atmospheric pressure equivalent to an altitude of 80,000 feet (21 mm Hg) and a temperature of -54ºC +4/-0ºC for 1 hour.

Group 2 connectors were subjected to DWV at -54°C and 80,000 feet in accordance with the specification. Five out of 6 connectors showed dielectric breakdown at the 625V test voltage. Additional techniques were used to isolate the failing locations and to test various root causes.

Risk Assessment • DWV problems were seen during altitude immersion testing, most likely due to a test set-up issue, not a defect

in the connector.• The same parts were subsequently re-tested and passed this requalification test, as indicated in the final Test

Report filed with DLA in 2010.• ITT is not aware of field failures attributed to this issue.

5. Maintenance agingRequirements para. 3.6.23, test method para. 4.7.3ITT observed the following test problem in the Group B 36-month requalification of ITT Cannon DPK, shell size A and Bconnectors due August 2012.

The applicable specification requires that each contact shall be inserted, removed, and reinserted using applicable insertion and removal tools, and that at least 10 of the contacts in both plugs and receptacles shall be inserted and removed 9 times. During Group One testing, one contact would not seat and lock into place in one cavity.

On a follow-up attempt to insert the contact during test setup, the contact seated successfully. Testing then proceeded appropriately.

Risk Assessment • This was a test set-up error, not a defect in the connector, which was corrected on a follow-up attempt

to insert the contact properly.• The test data in the final Test Report filed with the DLA in 2014 demonstrates that all cavities met the applicable

specification during retention of qualification testing.

6. Damaged PlatingDuring 2015 DLA approved plating qualification testing, one test connector was dropped and damaged duringhumidity test set-up. The sample was replaced and testing proceeded without incident. The error wasattributed to operator handling.

Risk Assessment Due to the nature of this event involving a test technician handling error, ITT does not believe there is risk of failure for product in the field relating to this test problem.

******************

Changes in process, materials, construction, sourcing or design

ITT is reporting in Appendix B of this GIDEP certain changes in process, material, construction, sourcing or design in the construction of MIL-SPEC connectors for the period 2008 to present.

******************

Summary of Field Failures and Corrective Actions

ITT is reporting in Appendix C of this GIDEP field failures for the period from 2008 to the present.

APPENDIX A LOT DATE CODE START and LOT DATE CODE END

Retention of Qualification and Initial Qualification Testing:

1-Gauge retention and contact retention (Test Group 2)Requirements para. 3.6.11, test method para. 4.7.12

Affected P/N 83733/3RA032- Start Date 0708 End Date 0939

2-Visual and mechanical examination (out of tolerance dimensions) Test Group 1, Group 2, Group 3 & Group 4Requirements para. 3.1, test method para. 4.7.2

a) Affected P/N’s Start Date End Date

M83733/7RB048 1121 1332 M83733/11RA051 1111 1332 M83733/2RA032 1123 1332 M83733/9RB071 1122 1332 M83733/3RA131 1111 1332 M83733/12RA051 1123 1332 M83733/8RB048 1121 1332 M83733/4RA032 1123 1332 M83733/6RB101 1141 1332 M83733/4RA018 1123 1332 M83733/2RA131 1123 1332

Table 2 Test Group 2 Specimens

Test Group 2 Service , " '" , Military Part Number

ITT Cannon Part Number

S~ell Rating Contact s.,_,, Date Code Size Size Wire Type Wire Diameter

Snmple Number - ~ - (inch)

1---2_._1_P __ -+ __ M8:3_?~~~~~- E£'~~~-S_:<_:?___ 0830-08 .. A ·=~T- : __ 32 #16 _ M16878/5-16 ,:n• x _ o .o~_ 1---2_-1_R __ -+ __ M8373313RA032 t OPKA-32PX-7 _ I 0930. 10 , A l-1 , 32 ; 16 I M16878/5-16 I "."ax_ o.o~_

2·2P M8373312RA032 OPKA·32SX·7 0830-08 1 · A - I -1 ··- 32 ; 16 - I M22759/9·20 I min 0.072

2·2R M8373313RA032 OPKA-32PX-7 0830-10 A I i 32 ; 16 M22759/9-20 min -o.on-1---2--3-P---+-M- 83- 733/_ 1_2_R_B0_7_1-+-0- P_K_B_-7_1_S_H_-7_ -+-_0_8_38_-0_5_1-_B ...... --I - -- 56 #20-- M22759i9-20" ,;, .. -o.oer 1---2---3R---rM-83- 7331_ 9_R_B_0_7_1-+-0-P_K_B_-7_1_P_M_-7 _ _.,_0_9_2_8--1-4-1 -+- 8-1--1--+- ~~ =~~ ----~};~~:~~--~;; ~:6rs-1-------r------+------r----+--1----t-·.,,;~~-~i-- ~;;;;:,~~~! :.~: -~:6E-

2-4P M83733/12RB071 OPKB-71SH-7 0838-05 B I 15

;12

M2275919_14 min 0

_098

2-4R M83733/9RB071 OPKB-71PM-7 0928-141

2-5P ! M83733/2RA1 31 ! OPKA-G131SX-7 ! 0830-12

l---2-_5_R __ -;! __ M8373313RA131 ! OPKA-G131PX-7 ! 0831-18

2·6P M8373312RA131 T OPKA-G131SX-7 I 0830-12 2-SR M8373313RA131 j OPKA-G131PX-7 j 0831-18

B 56 ; 20 M22759/11·24 min 0.043 15 #12 M22759/9-14 min 0 .098

! A ! M ! 131 #220 ! M22759/11·22 ! max 0.048

! A ! M ! 131 #220 ! M22759/11·22 ! ,:n•x _ 0.0~

I A j M l 131 #220 I M81381/44-26 I min 0.031 j A j M j 131 #220 j M81381/44-26 j min 0.031

Test Group 1 Specimens

! MT Test Group 1 i I llary I Pan Number

Sample tJumber ! I-IP M8373312RA032

1-1R M83733/3RA032 -------~-- . .. .. . .. 1-2P M8373312RA032

>---1- --2R ___ .. _M837:i'313RA032

I 1rr Cannon j Part t-lumber

L .... . DPKA-32SX-7

DPKA-32PX-7

DPKA-32SX-7

o Pi<A:32Px :, ·

1-3P l.183733/12RB071 DPKB-71SH-7

i ! Sh 11 !service! Contac1 ! j Date Code j ~ j Ra1ing j Q1y & Size j ! ! 1ze ! ;

! I

W ire Type iwire Diameter

(inch)

0830-08 A --------- · 0830-10 A

0830-08 A

0830-10 A

08~5 B

I I

~ · I

I

I

32 #16

32 #16

32 #16

32 #16

56 #20 15 # 12

t-----+-· . ----1.116878/5-16 max 0.083

t-----+-- -------M16878/5-16 max 0.083

t-----+-- - - --M22759/9-20 min 0.072

M22759/9.20 min ""om"" M22759/9-20 max 0.069 M22759/9-12 .'!!8~-~1__

1-3R M83733/9RB071 : DPKB-71PM-7 0928-141 B ··56rn

15#12 .. 56 #20

: M22759/9.20 : max 0.069 : M22759/9-12 : max 0.119

----1-.:-:----.::::::::::::nt::::::::::: j 0°9

82:5, •--------<--• . .. .. . .. .. . ....... .. .. . .. .. . L ________ J

B ·r~1· B I I J 15 #12

.. 56 #20 15 #12

131 #220

131 #220

M221sS111. 24 · miri -a:off ~;;J;!~--~: -~:;; - ~ :t-M22759/9-14 ~ in. _ 0.09~-

I-SP : M8373312RA131 : DPKA-G131SX-7 0830-12 : 1--------- A M : M2275S/11-22 : max 0.048 ------- -1-SR . M83733/3RA131 . DPKA-G131PX-7 0831-18 A M . M2275S/11-22 · max 0.048

~======·-6= P= =====:: M's37j'3nRA 1'31 ·~ OPKA'.G131SX:7 '"• - 08_3_0-_1_2--:

1-6R :·M·s:ii-i313RA1.31 foPi<.o.'.ci1:i1Px:1 0831-18

A M ·~·

131 #220 ; M81381/44-26 ; min 0.031

131 #220 M81381/44-26 l min 0.031

Test Group 2

Sample Number

2-1P

Test Group 3 i S.1me:le Number . j

3-1P 3-1R 3-2P 3-2R 3-3P 3-3R 3-4P I 3-4R ! 3-5P 3-5R

3-6P -·-·-

3-6R

3-7P

3-7R

3-8P

3-8R

3-9P 3-9R 3-10P 3-10R 3-11P

------ 3-1-1R

3-12P

3-12R

Military Pan Number

. .... ' .. .. ' M8373312RA032

Military P.1rt Number I

M83733/4RA018 I M83733/5RA018 , M83733/4RA018 , M83733/5RA018 I M8373317RA032 I M83733/8RA032 I M83733l 12RA051 I M83733111RA051 i M83733/4RA131 M83733/1RA131

M8373317RB048

M83733/8RB048

M8373317RB048

M83733/8RB048

M83733/12RB071

M83733/9RB071

M83733/4RB101 ' M83733/6R8101 M83733/4R8101 M83733/6RB101 M83733/4RA018 M83733/5RA018 -

M8373317RB048

M83733/8RB048

A


ITT Cannon Part Number

I s . I Shell t-;•c• contact~ I Date Code Size !1ill!!!Q. Size Wire T ype W ire Diameter

(inch) .. "" . .. .. DPKA-32SX-7

DPKA-32PX-7

DPKA-32SX-7 .. .... . "" OPKA-32PX-7

DPKB-71PM-7

DPKB-71SH-7

DPKB-71PM-7 .. .... .. ..

I 32 #16 . j 0830-08 . A I

t: 0830-10:~ < :~.I : 32 #16 j 0830-08 I A I 32 #16

:c: 0830-10] : A :c I ,: .. ~ : ; 6 . i 08=5 i 6 i i 15 #12

; 0928-141 : B

.Lo8~5.J. s ! 0928-141 i B

·,---,. .. 56#20

:~1: 15 #12

.. 56 #20 15 #12

.. 56 i:iii

OPKA-G131SX-7 , 0830-12 1

j I j . L __ 1 •

i F~ i .. 1,?~!7 . 131 #220

DPKA:G13i PX:7 ri,aJi°:is"- . 0Pi<A'.ci1:i1s X:1 1 0530-12 ·

DPKA'.G1:i1PX:7 I 0831-18


ITT C .1nnon

I Ifill!!!!~ !

P.1n Number 0.1te Code I Size. I R.1ting I DPKA-18SK-7 0837-02 A I I DPKA-18PC-7 ··0830-05 A I

131 #220

131 #220

131 #220

Cont.1ct Qty & Size

· · · is ili2- · · ··· is 11;2 · ·

M16878/5-16 max 0.083

M16878/5-16 max 0.083

M22759/9-20 mil 0.072 i------+---

M22759/9.20 nun 0.072 !-:-M"2"'2"'75'"'9"'19'"."'20:-t-m-a-x - 0.069

M22759/9-12 max 0.1 19 M22759/9.20 max 0.069

..... ~~i~i1~1;~!-~-;-~~2-4---~~.~-x -t~~ i-,,M.,.2,.2.,75.,,9,.,19.,.--.14,-t~n~m~ 0 .098

M2275S/11-24 m"1 - 0.043 ,_M.,_2-"2_75'-'9_/9'---14-f-'-n'-"111" _J!:9.i~

M2275S/11-22 max 0.048

M2275S/11-22 max 0.048

M81381/44-26

M81381/44-26

I Wire Type

mil 0.031

mil 0.031

1 W ire Oi.1meter I inch

I M22759/7-14 ( .114 • M22759/7-14 , .114

DPKA-18SK-7 .. 0837-02 . A I : . - is #12. - '. M22759/7-14 , .114 DPKA-18PC-7 i 0830-05 I A I I .. - is ili i . - I M22759/7-14 I .114 DPKA-32SK-7 .•. 0830-07 A I I .. - 32 #16 .. - M22759/9-18 I .081 DPKA-32PC-7 0830-09 A I I . - - 32 ili6" - - M22759/9-18 I .081 DPKA-51SH-7 i 0830-11 I A I I I · · • 51 il:io- · · I M22759l9-22 ! 058 DPKA-51PZ-7 ! 0928-139 i A i I i .. - 51 #20 . - i M22759l9-22 i 058

DPKA-G131SK-7 ---083 7 -03. A M . . i:i{ il:iiti - M22759/11-24 .042 DPKA-G131PG-7 0831-17 A M .. i:i1 i:iiti - M22759l 11-24 .042

DPKB-48SY-7 I 0832-06 B M .. - 30 #16 M22759/9-18 .081

18 #12 M22759/7-14 114 - --30 #16 M16878l5/18 .078

OPKB-48PY-7 I 0928-119 B I 18 #12 M22759/7-14 114

DPKB-48SY-7 0832-06 B I . . ":id iliff" - . M22759l9-18 -iisi·--

18 #12 M22759/7-14 .114

DPKB-48PY-7 I 0928-119 B I · · - :io ili6 . - M1687815/18 078

' 18 #12 M22759/7-14 114 - - - · ·· - 56 #20 - M22759/9-22 058 DPKB-71SH-7 0838-05 B I 15 #12 M22759/7-14 .114

DPKB-71PM-7 0928-141 B I .. - 56 #20- . M22759l9-22 058

15 #12 M22759/7-14 .114 DPKB-101SK-7 0831-14 B I . - · 10·1·#2 0 · - ' M22759/9-22 ' .058 DPKB-101PF-7 0830-06 B I .. · 101 ·#2 0 · - M22759l9-22 058 DPKB-101SK-7 0831-14 B I .. · ,-0·1 ·#2ii " - M22759l9-22 .058 DPKB-101PF-7 .•.. 0830-06. B I .. · 101 ·#2 0 · - M22759/9-22 058 OPKA-18SK-7 0837-02 A I · ·· is ilii ·-- M22759/7-14 114 DPKA-18PC-7 .•. 0830-05 --· A I ··· ,a 1112· · - M22759/7-14 - .114

DPKB-48SY-7 0832-06 B I . - - 30 ili6" - - . M16878l5/18 .078

18 #12 M22759/7-14 .114

DPKB-48PY-7 0928-119 B I .. - 30 #16- . - M16878l5/18 078

18 #12 M22759/7-14 114

d) Affected P/N’s Start Date End Date

M83733/3RA131 1529 1639 M83733/4RB101 1441 1639 M83733/4RB101 1441 1639 M83733/4RB101 1441 1639

3-Mating and unmating forcesRequirements para. 3.6.4, test method para. 4.7.5

No affected product.

Unapproved Materials:

Requirements para. 3.5.1 Shielded Contacts

Shipment Information by date code M83733/2RB71C M83733/4RB71C

Qty Date Code Qty Date Code 7 1425-1150 8 1032-234

10 1405-1494 5 1019-348 1 1225-688 5 1022-1032 9 1224-318 10 0931-375

1 0934-175


T est Group 4 I M ilitary I ITT Connon ; I Shell I Service Contoct I w· T I Wire Oiometer

Sample Number J Part Number j - - .. p.~~-~~~~~r- - 1~ j .fil!!. i ~ -~-~ ~-~i:~j !!!!!..!YE! j l!l£h

t---:,...:,.,;:,,.-- -'-,' ~"'~,.,~,..;~""t"":":~g.,.;~,,......--g~~N~~g I g~~b:g; 1 : 1 : !--m:-;-~-m~~:;: ~ ;;: 4-2P M83733/4RA018 . .. bi>i<J>.:18s'i(i . ·. 0837-02 A I , 18 #12 , M22759l7-14 , .1 14

t---4--2=R- - - ~I M_8_3=73_3/_5=RA~0-18~1 -··oPKA:18PC:f · ·1 0830-05 A I I I" ·1sfiff" M22759/7-14 I .1 14 4-3P I M83733/7RA032 .. "bpi<J1::i2si<:f I 0830-07 A I I . " j i ti1"6- M22759/9-18 I 081 4-3R , M83733/8RAo32 · ·· 01>i<i>.: :i21>c:i · ·, 0830-09 A , , · ·12 #16· - M22159/9-18 , .081 4-4P . M83733/12RA051 . .. bpi<J1:s 1s H:i . . 0830-11 A ! I ,- ·g, ilio" -. M22759/9-22 ! .058 4-4R · M8373311 1RA051 1 · - b1>i<i>.:s 11>z :f · 0928-139 · A 1 ;· · s1ti20· · M2215919.22 ; .o58 4-5P M83733/4RA131 . b "pki1:G1:i1·s i<:f . 0837-03 A M . i:ff lii:ib" M22759/1 1-24 .042

o----4--5~R- - -+-~M=8~3-73~3/~1~RA~1~31-'-+-·· OPKA:c;13"1p c;: f . 0831-17 A M . i:i1" #220- M22759/11-24 .042

4-6P M83733/7RB048 . - .. - - . . . .. . . . . . "36 :i1"6- - M22759/11-18 .081

DPKB-48SY-7 0832-06 B M 18 #12 M22759/7-14 .114

1ci ii1s i>1221591f 1:18 .069 18 # 12 M22759/7-14 .114 · -------· -· · · ·>----+-- >-----1-· 36 :He- - M221ss111-1 a .069

t---:-::- :- - -+--:-:-:-::-:-8-:-:-:-::-+--::~~::::~:> +-:-982-

3

:--~-016

-9-+--:-+--:---<--~rn-~--~~f,~~i,.~~ iii 4-6R M83733/8RB048 DPKB-48PY-7 0928-119 B

.. 5li ii20 M22759!9-22 .058 15 #12 M22759l7-14 114 · "' · · --· · · '" · · · ·>----+-- +----I· . 56 #io'" - M22759/9-22 .058

4-8R M83733/9RB071 DPKB-71PM-7 0928-141 B I 15 #l2 M2275917_14 _114

4-8P M83733/12RB071 DPKB-71SH-7 0838-05 B

4-9P M83733/4RB101 . "'6ri<s -·1ois1<-7 " . 0831-14 B I ,- "101 i:i o "• M22759/9-22 ' 058 t---4;--_9,;;R,,.-- -,-...;Mc,;8,.,3"'73""31"'6"R"'B;.;1-:-01,....,.. . . 6 Pi<Ei."1iJi PF-7 . ·t-1 -i0-:-83"'0,--0i,.,6;-,.l-;,s,--,-I - ;--, - i" ·101 i:io · r M22759/9-22 . .058

4-10P M83733/4RB101 . "6ri<s -·1oi s 1<-7 . 0831-14 B I . ·101 #20 - M22759/9-22 .058 t-- ...;4-,_1"'o""R--+-,Mc,;8;-,3"'73""31"'6"R"'B;.;1-:-01'""+ ·· "6 1'>i<Ei."1i)fpf'.7 . . 0830-06 B I . ·101 #20 °M22759/9-22 .058

~====:=:;=;=:====:=~=~~~=;~~t~:=~=A:g=;~~:::::: g~~i::~~M: •,_g_~3_3b_:g_;-+_:_+-_:---I: :i~~;:r -~;;;~~~:;: . ;;: 4-12P M83733/7RB048 DPKB-48SY-7 0832-06 B 1 . . 30 fi{6- - M22759/11-18 .069

t---- - - t------+ - ·· - - - - - - - ·· · - - ·t----+-- t-----i· -1~ ;;-~--·-ltNNl~,-1,~ ~~: 4-12R M83733/8RB048 DPKB-48PY-7 0928-119 B I 18 # 12 M2275917_14 _114

APPENDIX B Changes in process, materials, construction, sourcing or design

ITT is also reporting on this GIDEP the following changes in process, material, construction, sourcing or design in the construction of MIL-SPEC connectors for the period 2008 to present.

1. Supply Source Changes - Unless otherwise noted, ITT has not been able to locate documentation confirmingthat it notified DLA Land and Maritime of these changes before they were implemented. It is important tonote however, that any source change made by ITT goes through a first article inspection (inclusive ofmaterial certification) prior to being used in production.

Item Number Material Type Material Description of Change

1 Mil Hardware 980-0000-513, 980-003-422, 980-0006-

333

In 2013 and 2017, ITT changed its domestic suppliers for hardware. In 2013, the change was made on M519233 and M5678 hardware. In 2017, the change was made on M45938 hardware.

2 Screw 990-0000-237 In 2015, ITT changed its domestic suppliers for 4-40 stainless steel fillister head screws.

3 Contact Machining

030-2001-000 XXX In 2012, ITT changed domestic suppliers of the center contact for size 12 coaxial termini.

4 Bushing 012-0504-000 In 2011, ITT changed its machining source for a bushing from a domestic supplier to a foreign supplier in Taiwan.

5 Insert Machining

120-1666-000 In 2013, ITT added a domestic supplier as an approved machined component supplier.

6 Post 230-0132-000 In 2012, ITT changed domestic suppliers for posts.

7 PTFE plug Installation

012-0515-000 X10 In 2011, ITT added a domestic source for installing PTFE plugs into its bushings.

2. Changes to Design, Process, or Materials - Unless otherwise noted, ITT has not been able to locatedocumentation confirming that it notified DLA Land and Maritime of these changes before they wereimplemented.

Item Components Affected Year Description of Change

1 Washer 2013 Engineering error to add washer. 2 Shells 2017 Updated pre-plate thread pitch.

3. Unapproved materials

The following unapproved material was found on shipments of M83733/2RB71C and M83733/4RB71C connectors since 2008:

The connector part numbers above contain shielded contacts specified as AS39029/51 under MIL-DTL-83733 which were manufactured and qualified by ITT as the sole source until 2007. In 2007, ITT outsourced its contact manufacturing and was removed from the qualified products list for these contacts. Since 2007, ITT has supplied these contacts as a component of M83733/2RB71C and /4RB71C connector assemblies under an ITT part number.

Risk Assessment • ITT has manufactured and assembled these contacts to the same specifications using the same materials

and processes employed prior to 2007. ITT is not aware of field failures attributed to this issue.

APPENDIX C Summary of Field Failures and Corrective Actions

ITT observed the following field failures for the period from 2008 to the present. The field failures and associated corrective actions are summarized below. Unless otherwise noted, ITT has not been able to locate documentation confirming that it notified DLA Land and Maritime of such failures.

Item Year Report/RMA Number Description of Failure Description of Corrective Action

Lot and Date

Codes 1 2009 60027971-10 Mounting hardware reversed

– shell damagedConnector scrapped and rebuilt 0922-

866 2 2009 60029029-10 Contact cannot be inserted

into cavity # 25 Insulator replaced 0931-

375 3 2013 60040216-10 Guide post tab bent Root cause was an assembly

error. The following corrective actions were taken: - Assembly fixture was

improved to add polarity forconnector 042941-0831

- MCIs and router wereupdated to include properuse of the new fixture

- Operators were trained onthe new instructions

- Stock was checked – no WIPor FG in inventory

1320-769

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