3M 2540-60K2UG Equivalent & Substitute Parts

Part Overview

The 3M 2540-60K2UG is a rectangular connector header with vertical orientation, 40 positions, and 2.54mm pitch designed for through-hole mounting. This connector features shrouded 4-wall construction with male pins, kinked solder termination, and gold-plated mating contacts. The part is classified as obsolete, making equivalent substitutes necessary for ongoing production and maintenance applications. Active alternatives from 3M, Molex, and TE Connectivity provide functional equivalence while offering improved compliance status and availability.

Key Parameters

Parameter	Value
Connector Type	Header
Contact Type	Male Pin
Number of Positions	40
Number of Rows	2
Pitch - Mating	0.100" (2.54mm)
Row Spacing - Mating	0.100" (2.54mm)
Shrouding	Shrouded - 4 Wall
Mounting Type	Through Hole
Fastening Type	Push-Pull
Contact Finish - Mating	Gold
Material Flammability Rating	UL94 V-0
Operating Temperature	-55°C ~ 105°C
Current Rating	1.75A
Moisture Sensitivity Level	1 (Unlimited)

Substitute Part Grouping Explanation

Substitution eligibility is determined by strict alignment with the following core parameters: connector type (header), contact type (male pin), number of positions (40), number of rows (2), mating pitch (0.100"/2.54mm), row spacing (0.100"/2.54mm), shrouding (shrouded 4-wall), mounting type (through hole), fastening type (push-pull), contact finish on mating surface (gold), and flammability rating (UL94 V-0).

All substitute parts listed meet these mandatory criteria. Variations in secondary parameters such as contact material, insulation material, contact finish thickness, post finish composition, and packaging format do not preclude substitution when core electrical and mechanical parameters align. Product status transitions from obsolete to active improve supply chain reliability and compliance posture.

Parameter Comparison

Parameter	2540-60K2UG	D2540-6002-AR	N2540-6002-RB	0702464001	0702464002	0702464004	0878344011	0878344041	103308-8	103309-8	5103308-8
Manufacturer	3M	3M	3M	Molex	Molex	Molex	Molex	Molex	TE Connectivity	TE Connectivity	TE Connectivity
Product Status	Obsolete	Active	Active	Active	Active	Active	Active	Active	Active	Active	Active
Connector Type	Header	Header	Header	Header	Header	Header	Header	Header	Header	Header	Header
Contact Type	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin	Male Pin
Number of Positions	40	40	40	40	40	40	40	40	40	40	40
Number of Rows	2	2	2	2	2	2	2	2	2	2	2
Pitch - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Row Spacing - Mating	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)	0.100" (2.54mm)
Shrouding	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall	Shrouded - 4 Wall
Mounting Type	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole	Through Hole
Fastening Type	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull	Push-Pull
Contact Finish - Mating	Gold	Gold	Gold	Gold	Gold	Gold	Gold	Gold	Gold or Gold-Palladium	Gold or Gold-Palladium	Gold or Gold-Palladium
Contact Finish - Post	Tin-Lead	Tin	Tin	Tin	Tin	Tin	Tin	Tin	Tin-Lead	Tin-Lead	Tin
Material Flammability Rating	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0	UL94 V-0
Operating Temperature	-55°C ~ 105°C	-55°C ~ 105°C	-55°C ~ 105°C	Not specified	Not specified	Not specified	Not specified	Not specified	-65°C ~ 105°C	-65°C ~ 105°C	-65°C ~ 105°C
Current Rating	1.75A	1.75A	1.75A	Not specified	Not specified	Not specified	Not specified	Not specified	1A per Contact	1A per Contact	1A per Contact
RoHS Status	RoHS non-compliant	RoHS Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	ROHS3 Compliant	RoHS non-compliant	RoHS non-compliant	ROHS3 Compliant
REACH Status	REACH Affected	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Unaffected	REACH Affected	REACH Affected	REACH Unaffected
Moisture Sensitivity Level	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)	1 (Unlimited)

Engineering Selection Recommendations

3M Active Alternatives (Recommended for Direct Replacement)

D2540-6002-AR and N2540-6002-RB are both active 3M products that maintain design continuity with the obsolete 2540-60K2UG. Both achieve RoHS compliance and REACH unaffected status. D2540-6002-AR is packaged in trays and belongs to the D2500 series, while N2540-6002-RB is bulk-packaged and remains in the 2500 series. Both support the same operating temperature range and current rating as the original part. Selection between these two depends on packaging requirements and inventory management practices.

Molex C-Grid 70246 Series (Alternative Manufacturer)

The Molex 0702464001, 0702464002, and 0702464004 connectors from the C-Grid 70246 series provide functional equivalence with ROHS3 compliance and REACH unaffected status. These parts feature phosphor bronze contact material and PBT insulation. Variations in contact finish thickness (5.00µin to 30.0µin) and packaging (tray or bulk) allow selection based on specific application requirements. Operating temperature and current rating specifications are not provided for these parts.

Molex C-Grid 87834 Series (Alternative Manufacturer)

The Molex 0878344011 and 0878344041 connectors from the C-Grid 87834 series achieve ROHS3 compliance and REACH unaffected status. These parts feature copper alloy contacts and polyamide or nylon insulation materials. Both are packaged in trays and provide active product status. Operating temperature and current rating specifications are not provided for these parts.

TE Connectivity AMP-Latch Series (Extended Temperature Range)

The TE Connectivity 103308-8, 103309-8, and 5103308-8 connectors from the AMP-Latch series support an extended operating temperature range of -65°C to 105°C. The 5103308-8 achieves ROHS3 compliance and REACH unaffected status, making it suitable for applications requiring enhanced regulatory compliance. The 103308-8 and 103309-8 maintain RoHS non-compliant and REACH affected status, similar to the original part. Current rating is specified as 1A per contact for all TE Connectivity options.

Frequently Asked Questions (FAQ)

Q: Can I substitute the 3M 2540-60K2UG with any of the listed alternatives?

A: Yes. All listed parts meet the mandatory core parameters: 40-position, 2-row header with 2.54mm pitch, shrouded 4-wall construction, through-hole mounting, push-pull fastening, and gold-plated mating contacts. Functional compatibility is established through alignment of these electrical and mechanical specifications.

Q: What is the primary reason to transition from the 2540-60K2UG?

A: The 2540-60K2UG is classified as obsolete. Active alternatives ensure continued supply chain availability, improved compliance status, and access to current manufacturing processes. All recommended substitutes are active products with established inventory levels.

Q: How do RoHS and REACH compliance differences affect substitution?

A: The original 2540-60K2UG is RoHS non-compliant and REACH affected. Most active alternatives achieve RoHS3 compliance and REACH unaffected status, which may be required for new designs or applications subject to regulatory restrictions. TE Connectivity 5103308-8 specifically provides both RoHS3 and REACH unaffected status. Selection depends on your application's compliance requirements.

Q: Are there differences in contact material between the original and substitutes?

A: Yes. The original part uses copper alloy contacts. Substitutes employ copper alloy (3M N2540-6002-RB, Molex 0878344011, 0878344041), brass (TE Connectivity 103308-8, 103309-8, 5103308-8), or phosphor bronze (Molex 0702464001, 0702464002, 0702464004). All materials support the same mating pitch and contact configuration.

Q: What packaging options are available?

A: Substitutes are available in tray, bulk, and tube packaging formats. D2540-6002-AR is tray-packaged. N2540-6002-RB is bulk-packaged. Molex parts are available in both tray and bulk formats. TE Connectivity 103308-8 is bulk-packaged, while 103309-8 and 5103308-8 are tube-packaged. Select based on your procurement and handling requirements.

Q: Do all substitutes support the same current rating as the original?

A: The original 2540-60K2UG and 3M substitutes (D2540-6002-AR, N2540-6002-RB) are rated for 1.75A. TE Connectivity parts are rated at 1A per contact. Molex parts do not specify current rating. Verify current requirements for your application before selection.

Q: What is the operating temperature range for each substitute?

A: The original part and 3M substitutes support -55°C to 105°C. TE Connectivity parts support an extended range of -65°C to 105°C. Molex parts do not specify operating temperature. Select based on your thermal environment requirements.

Q: Can I mix different substitute parts in the same assembly?

A: All listed parts are mechanically and electrically compatible due to identical pitch, position count, and connector geometry. However, maintaining consistency within an assembly is recommended for supply chain management and documentation purposes.

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