MIL-DTL-38999 Features and Application Series III Features and Application Universal I/R Tool - A single, expendable plastic tool is used for both insertion and removal of contacts. MIL-DTL-38999 Series III is the newest cylindrical connector designed for highest performance capabilities used in both general purpose and severe environment applications. Scoop-Proof Design - Recessed pins in elongated shells minimize the possibility for contact damage. In a blind mating application, mating shells cannot "scoop" the pins, and cause a shorting or bending of contacts. These connectors feature an improved "one-turn" coupling system, utilizing self-locking acme thread. Acme threads provide coupling durability, while thicker wall sections and greater coupling surface area improve strength and shock resistance. Blunting of the threads on both receptacle and plug coupling nut eliminates cross threading. Closed-Entry Socket Insert - Hard dielectric socket face has lead-in chamfers for positive alignment of pins (even partially bent within pre-established limits) with sockets. Elongated mounting holes permit the Series III Connector to intermount with various existing Mil-spec flange mounted receptacles, giving it a design replacement advantage. Elastomer Wire Sealing Grommet - Sealing over a wide range of wire diameters is assured by a triple wire seal in each cavity at the rear of the connector. Wall mount receptacle, jam nut receptacle and straight self-locking RFI plug are offered in 9 shell sizes and 54 insert arrangements utilizing M39029 contacts in sizes 22D, 20, 16, 12, 10 power and 8 twinax. Superior Contact Stability - Rear release crimp contact system features a stamped beryllium-copper retaining clip captivated by molded-in shoulders of each contact cavity in the insulator. A rear-inserted M81969 plastic tool expands the tines beyond the shoulder, releasing the contact. These connectors are available in wide range of shell materials and finishes. Aluminum shells are offered in electroless nickel and olive drab cadmium. Other finishes such as anodic and zinc cobalt are available upon request to commercial callouts only. In addition, we offer stainless steel shells (both passivated and electro-deposited nickel plated) with firewall inserts, and for highly corrosive environments, nickel-aluminum-bronze shells with standard environment-resisting inserts (commercial callouts only). Metric Accessory Thread - Metric thread results in additional wall thickness giving greater strength and shock resistance. Twinax Contacts - Aero Electric is Qualified to make and supply M39029/90-529 and M39029/91-530 size 8 Twinax contacts used in 38999 III connectors. Please consult factory even when needing to buy just the contacts. MIL-STD-1560 Insert Arrangements - Series III connectors use insert patterns and contacts common to Series I, making for an easy transition from bayonet to triple-lead, acme-thread, self-locking coupling. Metal-to-Metal Bottoming - This feature precludes relative shell-to-shell motion, which may result in ordinary connector wear and moisture entrapment. Lockwiring Eliminated - Self-locking quick coupling plug eliminates the need for lockwiring. Firewall Capability - Stainless steel shells in both K and S firewall classes are offered. www.conesys.com - 44 - sales@aero-electric.com 38999 S III Interfacial Pin Insert Seal - Raised moisture barriers around each pin, which mate into lead-in chamfers of hard face socket insert, provide individual contact sealing. Interfacial seal is never touched by service tools. MIL-DTL-38999 Performance Specifications Series III Performance Specifications Environmental Seal Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in MIL-DTL-38999. Operating Temperature Range Classes F, K, S and BZ*: -65C to +200C (-85F to +392F) Classes W, T, Z, BN* and ZC*: -65C to +175C (-85F to +347F) 38999 S III Material and Finish Data (Class) F - aluminum shell, electroless nickel finish K - stainless steel shell, passivated, firewall S - stainless steel shell, electrodeposited nickel, firewall T *- aluminum shell, nickel flourocarbon polymer finish W- aluminum shell, olive drab cadmium over nickel base Z *- aluminum shell, zinc nickel finish BN* -aluminum shell, black nickel finish BZ* - aluminum nickel bronze shell, std insert ZC*- aluminum shell, zinc cobalt finish Shell-to-Shell Conductivity Maximum potential drop shall not exceed: * Classes F and S = 1.0 millivolt. * Class W = 2.5 millivolts, Class K = 10.0 millivolts Shock and Vibration Requirements Wired, mated connectors shall not be damaged, nor shall there be a current interruption longer than one microsecond when subjected to the following: Shock Pulse of approximate half sine wave of 300 G 15 percent magnitude with duration of 3 1 milliseconds applied in three axes. Corrosion Resistance Military Classes K, W and S, withstand 500-hour salt spray.Class F withstands 48-hour salt spray.Commerical RoHS Classes: BN*, BZ*,ZC*. Consult factory for T and Z class availability. High Impact Shock When mounted as specified in MIL-S-901, grade A, a drop of a 400 lb. Hammer from 1 foot, 3 feet and 5 feet applied to connector in three axes, totaling nine impacts. Durability Minimum of 500 mating cycles. Fluid Resistance Connectors resist specified immersions in MIL-PRF-7808, MIL-PRF-23699, MIL-PRF-5606, M2-V Chevron oil, Coolanol 25, MIL-DTL-83133 (JP-8), MIL-DTL-5624 (JP-4, JP-5), SAE-AMS1424 Type I, and other solvents and cleaning agents. Shielding Effectiveness RFI and EMI attenuation at the specified frequencies meet the requirements of MIL-DTL-38999. * RFI shielding effectiveness of mated connectors with RFI backshells is measured in a triaxial radio frequency leakage fixture. * EMI shielding effectiveness is measured at the interfaceof mated connectors and tested by the mode-stirred technique specified in method 3008 of MIL-STD-1344. Vibration Wired and mated connectors withstand the following vibration levels: * Sine vibration where connector samples with simulated accessory load are subjected to simple harmonic motion from 10 to 2,000 Hz in three mutually perpendicular axes, in 20 minute sweeps, for 12 hours in each axis at velocity of 254 mm/sec from 10-50 Hz, displacement of 1.5 mm from 50-140Hz and acceleration of 60G from 140-2,000Hz. * Random Vibration per MIL-STD-1344, method 2005, test condition V at ambient temperature and test condition VI, Letter "J" at elevated temperature. Voltage Rating * Not on QPL, can be supplied to Aero-Electric part number only. Service Rating M N I II Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage (Sea Level) Sea Level V RMS 1300 1000 1800 2300 50,000 Ft. V RMS 550 400 600 800 70,000 Ft. V RMS 350 260 400 500 100,000 Ft. V RMS 200 200 200 200 AC (RMS) 400 300 600 900 DC 550 450 850 1250 Note: The establishment of electrical safety factors is left entirely to the designer, as he is in the best position to know www.conesys.com exactly what peak voltages, switching currents, transients, etc., can be expected in a particular circuit. - 45 - sales@aero-electric.com MIL-DTL-38999 Part Number Development Series III Military and Aero-Electric Part Number Development Mil. Prefix Aero Prefix D38999/ AE3 20 20 W W C C 35 35 P P N N -340 Shell Type (Specification Sheet Number) 20 = Wall mount receptacle 24 = Jam nut receptacle 26 = Self-locking, RFI grounding plug Class (Material & Finish) F = Aluminum shell, electroless nickel finish W = Aluminum shell, olive drab cadmium over electroless nickel base T = Aluminum shell, nickel flourocarbon polymer finish (consult factory for availability) Z = Aluminum shell, zinc nickel finish (consult factory for availability) K = Stainless steel shell, passivated, with firewall insert 38999 S III S = Stainless steel shell, electrodeposited nickel, with firewall insert BN* = Aluminum shell, black nickel finish, (RoHS), (Aero p/n/ only) BZ* = Aluminum nickel bronze shell with standard insert (Aero p/n only) ZC* = Aluminum shell, zinc cobalt plating, (RoHS), (Aero p/n only) Shell Size A, B, C, D, E, F, G, H or J Insert Arrangement See pages 60 thru 62 Contact Style P = Pin S = Socket A = Pin connector less pins (with intent to use non-std pin contacts) B = Socket connector less sockets (with intent to use non-std socket contacts) Polarization (Keying) N = Normal (Included in part number) A, B, C, D, or E Modification (applies to Aero part numbers only) 01 = Less contacts (is not marked on the part) 340 = Connector kitted with M85049/15-XXX 341 = Connector kitted with M85049/38-XXX straight clamp 342 = Connector kitted with M85049/39-XXX right angle clamp Consult factory for other modifications * Not on QPL, can be supplied to Aero-Electric part number only. Note 2: Proper part number marking has no "0" in front of single digit layout. Example: J D38999/20WB5SN. "N" for normal is included. In addition, J or JAN must be marked immediately in front of MIL part number. Note 1: Each connector is furnished with contacts unless ordered less contacts (L/C) as follows: One spare contact for inserts requiring 2 through 26 of each contact and two spares for inserts with 27 or more contacts, and a minimum of one sealing plug up to 10% of the number contacts. Spare Coax and Twinax contacts are not supplied. One insertion/extraction tool for each contact size is also included. www.conesys.com - 46 - sales@aero-electric.com D38999/20 Wall Mount Receptacle AE320 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof 31.50(1.240) MAX A G MASTER KEYWAY H MAX MAX 7.11(.280) MIN FULL THREAD 2.16(.085) MAX GROMMET EXTENSION D L MAX GROMMET J NUMBER OF TEETH F 38999 S III E MATING THREAD 4 MINOR KEYWAYS LOCKING INDICATOR BAND COLOR: RED C BLUE COLOR BAND (REAR RELEASE) K ACCESSORY THREAD B Page 46 Page 52 Pages 60-62 Page 45 Pages 58, 59 Page 50 A B C (TP) (TP) .012 .30 inch mm inch mm inch A .937 23.80 .719 18.26 B 1.031 26.20 .812 20.62 C 1.126 28.60 .906 D 1.220 31.00 E 1.311 33.30 Shell Size Note 1: "K" Accessory Thread for AE320 is same as AE326 ("D" Accessory Thread) on page 49. Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization Note 2: "F" Mating Thread for AE320 is same as AE326 ("E" Mating Thread) on page 49 except it is Class 2A. Note 3: Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). D E G H J Maximum Maximum No. of Teeth OL .008 .20 .008 .20 mm inch mm inch mm inch mm inch mm .594 15.09 .216 5.49 .128 3.25 .820 20.83 .098 2.50 12 .299 7.59 .719 18.26 .194 4.93 .128 3.25 .820 20.83 .098 2.50 16 .427 10.85 23.01 .812 20.62 .194 4.93 .128 3.25 .820 20.83 .098 2.50 20 .541 13.74 .969 24.61 .906 23.01 .173 4.39 .128 3.25 .820 20.83 .098 2.50 24 .666 16.92 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 .820 20.83 .098 2.50 28 .791 20.09 Maximum inch mm F 1.437 36.50 1.156 29.36 1.062 26.97 .194 4.93 .128 3.25 .820 20.83 .098 2.50 32 .897 22.78 G 1.563 39.70 1.250 31.75 1.156 29.36 .194 4.93 .128 3.25 .790 20.07 .126 3.20 36 1.022 25.96 H 1.689 42.90 1.375 34.93 1.250 31.75 .242 6.15 .154 3.91 .790 20.07 .126 3.20 40 1.147 29.13 J 1.811 46.00 1.500 38.10 1.375 34.93 .242 6.15 .154 3.91 .790 20.07 .126 3.20 44 1.272 32.31 www.conesys.com - 47 - sales@aero-electric.com D38999/24 Jam Nut Receptacle AE324 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof A D 32.50 (1.280) MAX BLUE COLOR BAND (REAR RELEASE) G LOCKING INDICATOR BAND COLOR: RED MASTER KEYWAY 2.16(.085) MAX GROMMET EXTENSION H B MAX GROMMET FLAT F NUMBER OF TEETH C K ACCESSORY THREAD E MATING THREAD HEX NUT PER D38999/28 38999 S III J THREAD 4 MINOR KEYWAYS "O" RING SEAL PANEL THICKNESS 3.20(.126) 1.58(.062) Page 46 Page 52 Pages 60-62 Page 45 Pages 58, 59 Page 50 Note 1: "K" Accessory Thread for AE324 is same as AE326 ("D" Accessory Thread) on page 49. Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization A B Note 2: "E" Mating Thread for AE324 is same as AE326 ("E" Mating Thread) on page 49 except it is Class 2A. Note 3: Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). C Shell Size .016 .40 +.004 -.006 +.10 -.15 inch mm inch mm A 1.063 27.00 .651 16.53 B 1.252 31.80 .751 19.07 C 1.374 34.90 .938 23.82 D 1.500 38.10 1.062 E 1.626 41.30 1.187 D F G inch mm Maximum Jam Nut Thread +.60 -.00 mm inch mm .945/.859 24.00/21.82 .555 14.10 12 .087 2.20 .299 7.59 M17x1-6g 1.063/.984 27.00/24.99 .555 14.10 16 .087 2.20 .427 10.85 M20x1-6g 1.260/1.172 32.00/29.77 .555 14.10 20 .087 2.20 .541 13.74 M25x1-6g 26.97 1.417/1.296 36.00/32.91 .555 14.10 24 .087 2.20 .666 16.92 M28x1-6g 30.15 1.457/1.422 37.00/36.12 .555 14.10 28 .087 2.20 .791 20.09 M32x1-6g inch +.90 -.10 J +.024 -.000 No. of Teeth +.035 -.004 OH mm inch 0.100R F 1.811 46.00 1.312 33.32 1.614/1.546 41.00/39.26 .555 14.10 32 .118 3.00 .897 22.78 M35x1-6g G 1.937 49.20 1.437 36.50 1.811/1.672 46.00/42.47 .555 14.10 36 .118 3.00 1.022 25.96 M38x1-6g H 2.063 52.40 1.562 39.67 1.969/1.796 50.00/45.61 .555 14.10 40 .118 3.00 1.147 29.13 M41x1-6g J 2.189 55.60 1.687 42.85 2.017/1.939 51.23/49.25 .555 14.10 44 .118 3.00 1.272 32.31 M44x1-6g www.conesys.com - 48 - sales@aero-electric.com D38999/26 Self-Locking, RFI Grounding Plug AE326 Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof 31.00(1.220) MAX [A BLUE COLOR BAND LOCATION OPTIONAL (REAR RELEASE) MASTER KEY MAX COUPLING NUT 2.16(.085) MAX GROMMET EXTENSION 7.11(.280) MIN FULL THREAD [B MAX GROMMET RFI STRIP 38999 S III E MATING THREAD 4 MINOR KEYS Page 46 Page 52 Pages 60-62 Page 45 Pages 58, 59 Page 50 T NUMBER OF TEETH Completed Part Number Contacts, Sealing Plugs and Tools Insert Arrangements Performance Specifications Insert Availability and Contact Information Polarization D ACCESSORY THREAD Note : Maximum Grommet Extension for insert layouts incorporating size 8 and 10 contacts = 5.95(.234). OA OB D E T Maximum Maximum Accessory Thread Metric Mating Thread Class 2B No. of Teeth Shell Size inch mm inch A .858 21.80 .299 7.59 M12x1.0-6g 0.100R .6250-0.1P-0.3L 12 B .984 25.00 .427 10.85 M15x1.0-6g 0.100R .7500-0.1P-0.3L 16 C 1.157 29.40 .541 13.74 M18x1.0-6g 0.100R .8750-0.1P-0.3L 20 mm D 1.280 32.50 .666 16.92 M22x1.0-6g 0.100R 1.0000-0.1P-0.3L 24 E 1.406 35.70 .791 20.09 M25x1.0-6g 0.100R 1.1875-0.1P-0.3L 28 F 1.516 38.50 .897 22.78 M28x1.0-6g 0.100R 1.2500-0.1P-0.3L 32 G 1.642 41.70 1.022 25.96 M31x1.0-6g 0.100R 1.3750-0.1P-0.3L 36 H 1.768 44.90 1.147 29.13 M34x1.0-6g 0.100R 1.5000-0.1P-0.3L 40 J 1.890 48.00 1.272 32.31 M37x1.0-6g 0.100R 1.6250-0.1P-0.3L 44 www.conesys.com - 49 - sales@aero-electric.com MIL-DTL-38999 Polarization Series III Keying Positions D NORMAL MASTER KEYWAY A B C 38999 S III Notes: 1. Mating face of receptacle shown (plug is opposite). 2. All minor keyways (keys) are rotated to provide shell polarization while master keyway (key) remains fixed as shown. Shell Size A (9) B (11) C (13) D (15) E (17) F (19) G (21) H (23) J (25) www.conesys.com 3. The angles for a given connector are the same whether it contains pin or socket inserts. 4. Insert arrangement does not rotate relative to the master keyway (key). Key/Keyway Key/Keyway Positions BSC Identification Letter N A B C D E N A B C D E N A B C D E A 105 102 80 35 64 91 95 113 90 53 119 51 80 135 49 66 62 79 - 50 - B 140 132 118 140 155 131 141 156 145 156 146 141 142 170 169 140 145 153 C 215 248 230 205 234 197 208 182 195 220 176 184 196 200 200 200 180 197 D 265 320 312 275 304 240 236 292 252 255 298 242 293 310 244 257 280 272 sales@aero-electric.com MIL-DTL-38999 Series III Flange and Jam Nut Receptacle Panel Cutouts Panel Cutouts JAM NUT MOUNT FLANGE MOUNT 3.20(.126) 1.58(.062) PANEL THICKNESS 4x O C OB MIN 38999 S III D OE A Note: Diameter B cutout dimensions are listed separately for back and front of panel mounting. Shell Size inch A OB OB (TP) For Back Mounting Minimum For Front Mounting Minimum mm inch mm inch OC mm D OE .005 .13 +.000* -.010 +.00* -.25 +.010 -.000 +.25 -.00 inch mm inch mm inch mm A (9) .719 18.26 .656 16.66 .516 13.11 .128 3.25 .657* 16.70* .700 17.78 B (11) .812 20.62 .796 20.22 .625 15.88 .128 3.25 .771 19.59 .825 20.96 C (13) .906 23.01 .922 23.42 .750 19.05 .128 3.25 .955 24.26 1.010 25.65 D (15) .969 24.61 1.047 26.59 .906 23.01 .128 3.25 1.085 27.56 1.135 28.83 E (17) 1.062 26.97 1.219 30.96 1.016 25.81 .128 3.25 1.210 30.73 1.260 32.01 F (19) 1.156 29.36 1.297 32.94 1.141 28.98 .128 3.25 1.335 33.91 1.385 35.18 G (21) 1.250 31.75 1.422 36.12 1.266 32.16 .128 3.25 1.460 37.08 1.510 38.35 H (23) 1.375 34.93 1.547 39.29 1.375 34.93 .154 3.91 1.585 40.26 1.635 41.53 J (25) 1.500 38.10 1.672 42.47 1.484 37.69 .154 3.91 1.710 43.43 1.760 44.70 * Tolerance .10mm (.004") www.conesys.com - 51 - sales@aero-electric.com MIL-DTL-38999 Contacts, Tools and Seal Plugs Series III Contacts, Plastic Insertion/Removal Tools and Seal Plugs Contact Size 22D 20 16 12 12 Coax 12 Coax 10 (Power) 8 Coax 8 Twinax**** Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools Type Power/Signal Power/Signal Power/Signal Power/Signal Coax Coax Power Coax Twinax Military No. M39029/58-360 M39029/58-363 M39029/58-364 M39029/58-365 M39029/28-211 M39029/102-558 M39029/58-528 M39029/60-367 M39029/90-529 Military No. M39029/56-348 M39029/56-351 M39029/56-352 M39029/56-353 M39029/75-416 M39029/103-559 M39029/56-527 M39029/59-366 M39029/91-530 Military No. MS27488-22-1 MS27488-20-1 MS27488-16-1 Plastic Military No. M81969/14-01 M81969/14-10 M81969/14-03 MS27488-12-1 M81969/14-04 M85049/81-10*** MS27488-8-1 MS27488-8-1 M81969/14-05 M81969/14-06 M81969/14-12 Crimping and Metal Insertion/Extraction Tools Positioner Positioner Insertion Tool Extraction Tool For Socket Contacts Military No. M22520/2-07 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 -- M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 Metal Military No. M81969/8-01 Metal Military No. M81969/8-02 M81969/8-05 M81969/8-06 M81969/8-07 M81969/8-08 M81969/8-09 M81969/8-10 M81969/8-11 M81969/8-12 M81969/8-13** M81969/8-14 M22520/5-200 -- -- 16 12 12 Coax Inner 12 Coax Outer 10 ( Power) 8 Coax Inner Military No. M22520/2-01 M22520/1-01 M22520/2-01 M22520/1-01 M22520/1-01 M22520/2-01 M22520/31-01 -- M22520/2-01 8 Coax Outer M22520/5-01 8 Twinax Center 8 Twinax Outer & Intermediate M22520/2-01 For Pin Contacts Military No. M22520/2-09 M22520/1-04 M22520/2-10 M22520/1-04 M22520/1-04 M22520/2-34 M22520/31-02 -- M22520/2-31 M22520/5-05 Die Closure B M22520/2-37 M22520/5-01 M22520/5-200 22D 20 Contact and Wire Data Test Current* Voltage* DC Test Amps 5.0 7.5 13.0 23.0 33.0 Max. Drop Millivolts 73 55 49 42 33 Contact Size 22D 20 16 12 10 Crimp Well Data Well Dia. inch .0345 .0010 .047 .001 .067 .001 .100 .002 .137 .003 MS3348 bushing required with 12 gauge wire. * When tested with silver-plated wire. ** Insertion tool is not required. *** Dummy contact, used in lieu of unwired contact and seal plug. **** Aero Electric is Qualified for Twinax contacts, consult factory for a quote. www.conesys.com Wire Range Minimum Well Dept inch mm .141 3.58 .209 5.31 .209 5.31 .209 5.31 .355 9.02 - 52 - AWG 28-22 24-20 20-16 14-12 12-10 mm2 .08-.33 .20-.52 .52-1.31 2.08-3.31 3.31-5.26 Finished Wire O Range Minimum inch mm .030 .76 .040 1.02 .065 1.65 .097 2.46 .135 3.42 Maximum inch mm .054 1.37 .083 2.11 .109 2.77 .142 3.61 .162 4.12 Note: Size 8 coax contacts are used with M17/095-RG180 cable, while size 8 Twinax contacts are used with M17/176-00002 cable. sales@aero-electric.com 38999 S III Crimp Tool Contact Size/Type MIL-DTL-38999 Contact Installation Instructions Series III Contact Installation Instructions 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. Crimping Contacts 1. Select the appropriate crimp tool and ensure that the proper crimp head positioner is used. 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. 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. 38999 S III 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. 4. Place the contact, mating end first, into the tool. 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. 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. Completion After all the cavities have been filled, slide the hardware back into position on the connector and tighten. 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 after all the contacts are inserted. Extraction of Contacts (Rework) 1. Slide the hardware back over the wire bundle. 2. Select the appropriate tool. Place the wire into the extraction tool of the pin or socket. 3. Slowly slide the extraction tool down wire into the contact cavities until the tool tip bottoms against the contact shoulder, expanding the clip retaining tines. Hold the wire firmly in the tool and pull the wired contact and tool straight out of the rear of the insulator. 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. Size Pin Contact Socket Contact Basic Crimp Tool Pin Positioner Socket Positioner Insertion/Removal Tool 22D M39029/58-360 M39029/56-348 M22520/2-01 M22520/2-09 M22520/07 M81969/14-01 20 M39029/58-363 M39029/56-351 M22520/1-01 M22520/1-04 Red M22520/1-04 red M22520/2-01 M22520/2-10 M22520/2-10 16 M39029/58-364 M39029/56-352 M22520/1-01 M22520/1-04 Blue M22520/1-04 Blue M81969/14-03 12 M39029/58-365 M39029/56-353 M22520/1-01 M22520/1-04 Yellow M22520/1-04 Yellow M81969/14-04 10 M39029/58-528 M39029/56-527 * * * M81969/14-05 For Coax and Twinax contacts refer to instructions that are supplied with contacts. www.conesys.com M81969/14-10 * Contact Daniels Manufacturing for crimp tool/positioner. - 53 - sales@aero-electric.com D38999 Accessories Part Number Development Dummy Stowage Receptacle Part Number Configuration MIL. Prefix Aero Prefix D38999/ AE3 22 22 C C W W Shell Type 22 = receptacle, dummy stowage, threaded Shell Size** A, B, C, D, E, F, G, H or J 38999 S III Material Finish W = Aluminum Shell, Olive Drab Cadmium Finish F = Aluminum, Electroless Nickel Finish K = Stainless Steel, Passivated S = Stainless Steel, Electrodeposited Nickel BN* = Aluminum Shell, Black Nickel Finish (Aero p/n only) * Not on QPL, can be supplied to Aero-Electric part number only. * * Shell size code A is for use with plugs with mating key polarizations "C", "E" or "N". Shell size code AA is for use with plugs with mating key polarizations "A", "B" or "D". Protective Metal Caps Part Number Configuration MIL. Prefix Aero Prefix D38999/ AE3 32 32 W W- 11 11 R R Shell Type 32 = cover, protective, plug 33 = cover, protective, receptacle Material Finish W = Aluminum Shell, Olive Drab Cadmium Finish F = Aluminum, Electroless Nickel Finish K = Stainless Steel, Passivated S = Stainless Steel, Electrodeposited Nickel BN* = Aluminum Shell, Black Nickel Finish (Aero p/n only) Shell Size 9,11,13, 15, 17, 19, 21, 23, 25 Style R = Wire Rope Assembly N = Wire Rope/Ring Assembly * Not on QPL, can be supplied to Aero-Electric part number only. www.conesys.com - 54 - sales@aero-electric.com D38999/22 Dummy Stowage Receptacle AE322 AE322 Threaded Dummy Stowage Receptacle 38999 S III SHELL SIZE SHELL SIZE CODE 9 OB PP R1 R2 S V W MM INCH MM .20 INCH .008 MM INCH MM INCH MM .3 INCH .012 MM .00 -.13 INCH .000 -.005 MM .3 INCH .012 A 12.63 12.47 .497 .491 5.49 .216 18.26 .719 15.09 .594 23.8 .937 20.83 .820 2.5 .098 11 B 15.88 15.73 .625 .619 4.93 .194 20.62 .812 18.26 .719 26.2 1.031 20.83 .820 2.5 .098 13 C 19.63 19.49 .773 .767 4.93 .194 23.01 .906 20.62 .812 28.6 1.126 20.83 .820 2.5 .098 15 D 22.84 22.69 .899 .893 4.39 .173 24.61 .969 23.01 .906 31.0 1.220 20.83 .820 2.5 .098 17 E 25.99 25.84 1.023 1.017 4.93 .194 26.97 1.062 24.61 .969 33.3 1.311 20.83 .820 2.5 .098 19 F 28.63 28.48 1.127 1.121 4.93 .194 29.36 1.156 26.97 1.062 36.5 1.437 20.83 .820 2.5 .098 21 G 31.83 31.68 1.253 1.247 4.93 .194 31.75 1.250 29.36 1.156 39.7 1.563 20.07 .790 3.2 .126 23 H 35.03 34.88 1.379 1.373 6.15 .242 34.93 1.375 31.75 1.250 42.9 1.689 20.07 .790 3.2 .126 25 J 38.18 38.03 1.503 1.497 6.15 .242 38.10 1.500 34.93 1.375 46.0 1.811 20.07 .790 3.2 .126 www.conesys.com - 55 - sales@aero-electric.com D38999/32 Protective Cover, Plug AE332 Protective Cover Plug 38999 S III www.conesys.com SHELL SIZE A THREAD CLASS 2A TRIPLE START 9 11 OB MAX OD MAX OE MAX G INCH MM INCH MM INCH +.512 -.276 MM +13.0 -7.0 23.0 .945 24.0 .512 13.0 5.000 127.00 26.0 1.063 27.0 .709 18.0 5.000 127.00 1.221 31.0 1.181 30.0 .787 20.0 5.000 127.00 1.299 33.0 1.221 31.0 .906 23.0 5.000 127.00 1.1875-0.1P-.03L 1.457 37.0 1.457 37.0 1.024 26.0 5.000 127.00 1.2500-0.1P-.03L 1.575 40.0 1.575 40.0 1.142 29.0 5.000 127.00 21 1.3750-0.1P-.03L 1.732 44.0 1.732 44.0 1.260 32.0 5.000 127.00 23 1.5000-0.1P-.03L 1.811 46.0 1.811 46.0 1.339 34.0 5.000 127.00 25 1.6250-0.1P-.03L 1.969 50.0 1.929 49.0 1.535 39.0 5.000 127.00 INCH MM .6250-0.1P-0.3L .906 .7500-0.1P-.03L 1.024 13 .8750-0.1P-.03L 15 1.0000-0.1P-.03L 17 19 - 56 - sales@aero-electric.com D38999/33 Protective Cover, Receptacle AE333 Protective Cover Receptacle 38999 S III SHELL SIZE A THREAD CLASS 2B TRIPLE START OB MAX INCH OD MIN OC MAX MM INCH MM INCH F MM INCH +.512 -.276 MM +13.0 -7.0 9 .6250-0.1P-0.3L .906 23.0 1.063 27.0 .695 17.64 5.000 127.00 11 .7500-0.1P-0.3L 1.102 28.0 1.260 32.0 .865 21.97 5.000 127.00 133 .8750-0.1P-0.3L 1.221 31.0 1.457 37.0 .989 25.12 5.000 127.00 15 1.0000-0.1P-0.3L 1.260 32.0 1.575 40.0 1.178 29.92 5.000 127.00 17 1.1875-0.1P-0.3L 1.457 37.0 1.732 44.0 1.260 32.00 5.000 127.00 19 1.2500-0.1P-0.3L 1.535 39.0 1.811 46.0 1.428 36.27 5.000 127.00 21 1.3750-0.1P-0.3L 1.654 42.0 1.929 49.0 1.506 38.25 5.000 127.00 23 1.5000-0.1P-0.3L 1.772 45.0 2.126 54.0 1.678 42.62 5.000 127.00 25 1.6250-0.1P-0.3L 1.929 49.0 2.205 56.0 1.750 44.45 5.000 127.00 www.conesys.com - 57 - sales@aero-electric.com MIL-DTL-38999 Series III Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information Insert Arrangement Aero-Electric Service Status Total Quantity of Contacts No. of (by Size) Series III QPL'd Tooled Rating Contacts 22D A35 A98 B2 B4 B5 B35 B98 B99 C4 C8 C35 C98 D5 D15 D18 D19 D35 D97 E6 E8 E26 E35 E99 F11 F28 F30 F32 F35 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes M I I I I M I I I I M I II I I I M I I II I M I II I I I M 6 3 2 4 5 13 6 7 4 8 22 10 5 15 18 19 37 12 6 8 26 55 23 11 28 30 32 66 6 20 16 12 10 8 3 2 4 5 13 6 7 4 38999 S III 8 22 10 14 18 19 5 1 37 8 4 6 8 26 55 21 26 29 32 2 11 2 1 66 See next page for Shell Sizes G thru J layouts. www.conesys.com - 58 - sales@aero-electric.com MIL-DTL-38999 Series III Insert Availability and Contact Information per MIL-STD-1560 Insert Availability and Contact Information (continued) Insert Arrangement Aero-Electric Service Total Status Quantity of Contacts No. of 38999 S III Series III QPL'd Tooled Rating Contacts G11 G16 G35 G39 G41 G48** G75 H21 H32 H35 H53 H55 J4 J8 J11 J19 J20 J24 J29 J35 J43 J46**** J61 J90 Yes Yes Yes Yes Yes N/A Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes I II M I I I Twinax II I M I I I Twinax N I N, Coax, Twinax I I M I I, Coax I I, Twinax 11 16 79 39 41 4 4 21 32 100 53 55 56 8 11 19 30 24 29 128 43 46 61 46 ** G48 layout is not to MIL-STD-1560. It is tooled and intended for comm'l use only. *** Not approved for new design. Pictorial is shown on page 62. (by Size) 22D 20 16 12 10 8 11 16 79 37 41 2 4 (Power) 4 (Twinax) 21 32 100 53 55 48 8 8 (Twinax) 2 9 19 4 (Coax) 12 10 13 12 29 3 (Twinax) 23 40 61 40 20 4 2 (Coax) 4 2 (Twinax) 128 Note 1: J20P uses 4 size 12 coax contacts as follows: 2 ea M39029/28-211 and 2 ea of M39029/102-558; J20S uses 4 size 12 coax contacts as follows: 2 ea M39029/75416 and 2 ea of M39029/103-559. Note 2: Layouts (G75, J8, J20, J46 and J90) that take twinax or coax contacts should not be used for firewall applications (Classes K & S) in Series III. Note 3: H and J contact styles (in lieu of P & S) are meant for Composite (classes J & M) Series III only. Aluminum (classes A, B, F & W) and Firewall (classes K & S) are rated for 500 cycles regardleess what contacts are used. www.conesys.com - 59 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series III Connectors Insert Arrangements Views 5 4 C 1 6 A A98, 3 # 20, I B 1 A 10 E C C E L R J B N H J D A T U S G K C P R F L B N M H E G C K C P 15 A B N P U J D T H E G A H G B C J F C35, 22 # 22D, M D C98, 10 # 20, I K 1 S 5 E C 31 D R V 6 4 C D M 7 K C8, 8 # 20, I C4, 4 # 16, I B M 1 B E C L A K 14 21 12 B35, 13 # 22D, M 22 B99, 7 # 20, I A C 3 13 38999 S III B98, 6 # 20, I A H F B D 2 11 8 B B5, 5 # 20, I G B D A G D B4, 4 # 20, I A F B D E 9 B2, 2 # 16, I A F D A C A35, 6 # 22D, M E D A B 2 3 B 21 A L J B H E M G F F C D E F D15, 1 # 16, 14 # 20, I D5, 5 # 16, II A D F E6, 6 # 12, I www.conesys.com P B T N H E C D E8, 8 # 16, II M L E F W X J G H E26, 26 # 20, I - 60 - 32 D97, 4 # 16, 8 # 20, I A 40 R 47 P 1 V c Y K 25 D U Z 17 4 C b a B F C S 10 B R G D35, 37 # 22D, M D19, 19 # 20, I A A E D18, 18 # 20, I 53 55 3 52 9 16 24 31 39 46 E35, 55 # 22D, M Y B T S C Z U D N V X M E W L K J H F G E99, 2 # 16, 21 # 20, I sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series III Connectors Insert Arrangements Views A T S A J K H d R B G K E 17 25 34 J F28, 2 # 16, 26 # 20, I J 43 51 4 K 38999 S III 63 24 33 42 Y k i T R j h Z m r g n f N p H d e M f K M G39, 2 # 16, 37 # 20, I N L W R L C Z V S U J D T G B D J G48**, 4 # 8 Power, I F H21, 21 # 16, II g S Y 16 25 35 46 56 67 77 f e S R 94 96 4 97 5 G 10 0 7 W H 99 6 E F 15 24 34 45 55 66 76 85 H35, 100 # 22D, M H32, 32 # 20, I P k 95 3 U V B 86 2 C D X C G75, 4 # 8 Twinax, Twinax 1 T d i 8 B R c A C 98 K J E H G A h D H K P b a X K b c L N M B P A G41, 41 # 20, I A M G35, 79 # 22D, M F d e N F E a n p q P J L m r g R 11 E D Z t S 71 79 61 C Y k h G c 31 B s S F b q P F G H 41 A i T E J C D G X j U D a Y 51 G16, 16 # 16, II W V C E F32, 32 # 20, I N R G11, 11 # 12, I B X K P H D E A W V Z B F 50 F35, 66 #22D, M U a 21 C 57 16 J X b M L M S L 66 9 B D g h A H 3 c 1 L 58 G N C W f j F30, 1 # 16, 29 # 20, I A 64 E G H K 1 d F Y J P X Z K G V e R D B U f W F Z F11, 11 # 16, II g a L a L C V M E S U e A T B T b D X M D 10 W e A d c N Y L F C b N C P V c P S R B U 93 h N m z f K p V q BB GG HH FF CC DD J t w d C W X Y x e r s EE g L B U AA y M A T n v c u a b D E F Z G H H53, 53 # 20, I * Inactive for new design. ** Not MIL-STD-1560 layout (not QPL'd.). www.conesys.com - 61 - sales@aero-electric.com MIL-STD-1560 Insert Arrangements (Pin Front View) for MIL-DTL-38999 Series III Connectors Insert Arrangements Views A T AA z R i x N H M DD FF v c d f L b u LL q S G n P H55, 55 # 20, I C V D R E S H 6 7 L 15 25 94 105 8 X 115 1 V 125 4 m 24 35 47 5870 104 81 93 W t V s U v h u g a D q b r c E AA X C W Z q D a p S s f e G d R V E H M w c m P J h M g L K F G e f H J J46, 40 # 20, 4 # 16, 2 # 8 Coax, I / Coax u t s FF d w HH NN KK MM CC n m P N k M L H i j F G h AA BB E g z LL DD D f y EE P C e x JJ PP q R B c v U T A b GG r S d x y k N L J43, 20 # 16, 23 # 20, I z n Z a Y B Y v H J29, 29# 16, I b t G J A X F X Y G u r T F W t s U K N J K J61, 61 # 20, I A u AA X C Y v r B Z q D a p R p V C W K J24, 12 # 12, 12 # 16, I B P 11 4 J35, 128 # 22D, M S k R 121 14 A x S 7 Z w U T T n W 122 Y L V E e Z F H d M V J J20 10 # 20,13 # 16, 4 # 12, 3 # 8 Twinax, N / Coax / Twinax 71 82 36 48 59 D f E U K J J19, 19 # 12, I T W H C U c N a a L G K D B T b S X V S P Z F 2 C Y A R R M E J11 9 # 10, 2 # 20, N B D U W F G 1 3 X D E A P N T 4 Y N M T J B 5 Z F D E C P K L J8 8 # 8 Twinax, Twinax R P U F J E z n b w c m P k N h M g L K F d x y G e f H J J90, 40 # 20, 4 # 16, 2 # 8 Twinax, I / Twinax www.conesys.com - 62 - sales@aero-electric.com 38999 S III K h k A S B N G C L M C G H K m N H J4, 8 # 16, 48 # 20, I A L BB CC p R J M AA J f g KK DD H e K EE r T t w g U F G F z B H E e y JJ B D d HH FF s E a EE V D Z CC s y P Y r HH t X q C x GG A A B c v u W C BB GG j W p A b w X B V n m S k a Z Y U