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38999 S III
– –
MIL-DTL-38999
Features and Application
Series III
Features and Application
MIL-DTL-38999 Series III is the newest cylindrical connector
designed for highest performance capabilities used in both
general purpose and severe environment applications.
ese 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.
Elongated mounting holes permit the Series III Connector to
intermount with various existing Mil-spec ange mounted
receptacles, giving it a design replacement advantage.
Wall mount receptacle, jam nut receptacle and straight
self-locking RFI plug are oered in 9 shell sizes and 54 insert
arrangements utilizing M39029 contacts in sizes 22D, 20, 16,
12, 10 power and 8 twinax.
ese connectors are available in wide range of shell materials
and nishes. Aluminum shells are oered in electroless nickel
and olive drab cadmium. Other nishes such as anodic and
zinc cobalt are available upon request to commercial callouts
only. In addition, we oer stainless steel shells (both passivated
and electro-deposited nickel plated) with rewall inserts, and
for highly corrosive environments, nickel-aluminum-bronze
shells with standard environment-resisting inserts (commer-
cial callouts only).
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 – is 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
rewall classes are oered.
Universal I/R Tool – A single, expendable plastic tool is used
for both insertion and removal of contacts.
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.
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.
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.
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.
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.
Metric Accessory Thread – Metric thread results in
additional wall thickness giving greater strength and shock
resistance.
Twinax Contacts – Aero Electric is Qualied 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.
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38999 S III
– –
MIL-DTL-38999
Performance Specications
Series III
Service
Rating
Suggested Operating Voltage Test Voltage Test Voltage Test Voltage Test Voltage
(Sea Level) Sea Level 50,000 Ft. 70,000 Ft. 100,000 Ft.
AC (RMS) DC V RMS V RMS V RMS V RMS
M 400 550 1300 550 350 200
N 300 450 1000 400 260 200
I 600 850 1800 600 400 200
II 900 1250 2300 800 500 200
Note: e establishment of electrical safety factors is le
entirely to the designer, as he is in the best position to know
exactly what peak voltages, switching currents, transients, etc.,
can be expected in a particular circuit.
Environmental Seal
Wired, mated connectors with specied accessories
attached, shall meet the altitude-immersion test specied in
MIL-DTL-38999.
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 mag-
nitude with duration of 3 ± 1 milliseconds applied in three axes.
High Impact Shock
When mounted as specied 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.
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.
*Not on QPL, can be supplied to Aero-Electric part number only.
Performance Specications
Operating Temperature Range
Classes F, K, S and BZ*: -65°C to +200°C (-85°F to +392°F)
Classes W, T, Z, BN* and ZC*: -65°C to +175°C (-85°F to +347°F)
Material and Finish Data (Class)
F –aluminum shell, electroless nickel nish
K –stainless steel shell, passivated, rewall
S –stainless steel shell, electrodeposited nickel, rewall
T *- aluminum shell, nickel ourocarbon polymer nish
W –aluminum shell, olive drab cadmium over nickel base
Z *- aluminum shell, zinc nickel nish
BN* -aluminum shell, black nickel nish
BZ* –aluminum nickel bronze shell, std insert
ZC*–aluminum shell, zinc cobalt nish
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.
Durability
Minimum of 500 mating cycles.
Fluid Resistance
Connectors resist specied 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 Eectiveness
RFI and EMI attenuation at the specied frequencies meet
the requirements of MIL-DTL-38999.
•
RFI shielding eectiveness of mated connectors with RFI back-
shells is measured in a triaxial radio frequency leakage xture.
• EMI shielding eectiveness is measured at the interfaceof
mated connectors and tested by the mode-stirred tech-
nique specied in method 3008 of MIL-STD-1344.
Voltage Rating
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38999 S III
– –
MIL-DTL-38999
Part Number Development
Series III
Military and Aero-Electric Part Number Development
*Not on QPL, can be supplied to Aero-Electric part number only.
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.
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.
Mil. Prex D38999/ 20 W C 35 P N
Aero Prex AE3 20 W C 35 P N -340
Shell Type (Specication Sheet Number)
20 = Wall mount receptacle
24 = Jam nut receptacle
26 = Self-locking, RFI grounding plug
Class (Material & Finish)
F = Aluminum shell, electroless nickel nish
W = Aluminum shell, olive drab cadmium over electroless nickel base
T = Aluminum shell, nickel ourocarbon polymer nish (consult factory for availability)
Z = Aluminum shell, zinc nickel nish (consult factory for availability)
K = Stainless steel shell, passivated, with rewall insert
S = Stainless steel shell, electrodeposited nickel, with rewall insert
BN* = Aluminum shell, black nickel nish, (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
Modication (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 modications
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38999 S III
– –
D38999/20
Wall Mount Receptacle
AE320
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
BLUE COLOR BAND
(REAR RELEASE)
B
4 MINOR KEYWAYS
E
C
D
LOCKING INDICATOR BAND
COLOR: RED
F
MATING THREAD
MASTER KEYWAY G
MAX
31.50(1.240)
MAX
2.16(.085) MAX
GROMMET EXTENSION
J NUMBER OF TEETH
K ACCESSORY THREAD
7.11(.280)
MIN FULL THREAD
H MAX
A
L
MAX
GROMMET
Page 46 Completed Part Number
Page 52 Contacts, Sealing Plugs and Tools
Pages 60–62 Insert Arrangements
Page 45 Performance Specications
Pages 58, 59 Insert Availability and Contact Information
Page 50 Polarization
Note 1: “K” Accessory read for AE320 is same as AE326
(“D” Accessory read) on page 49.
Note 2: “F” Mating read for AE320 is same as AE326 (“E”
Mating read) 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).
Shell
Size
A B C D E G H J Ø L
No. of
±.012 ±.30 (TP) (TP) ±.008 ±.20 ±.008 ±.20 Maximum Maximum Teeth Maximum
inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
A .937 23.80 .719 18.26 .594 15.09 .216 5.49 .128 3.25 .820 20.83 .098 2.50 12 .299 7.59
B 1.031 26.20 .812 20.62 .719 18.26 .194 4.93 .128 3.25 .820 20.83 .098 2.50 16 .427 10.85
C 1.126 28.60 .906 23.01 .812 20.62 .194 4.93 .128 3.25 .820 20.83 .098 2.50 20 .541 13.74
D 1.220 31.00 .969 24.61 .906 23.01 .173 4.39 .128 3.25 .820 20.83 .098 2.50 24 .666 16.92
E 1.311 33.30 1.062 26.97 .969 24.61 .194 4.93 .128 3.25 .820 20.83 .098 2.50 28 .791 20.09
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
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38999 S III
– –
D38999/24
Jam Nut Receptacle
AE324
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
"O" RING SEAL
HEX NUT
PER D38999/28
MASTER KEYWAY
4 MINOR KEYWAYS
B
FLAT
A
E MATING THREAD
C
J THREAD
LOCKING INDICATOR BAND
COLOR: RED
32.50 (1.280)
MAX
PANEL THICKNESS
3.20(.126)
1.58(.062)
K ACCESSORY THREAD
F NUMBER OF TEETH
H
MAX
GROMMET
2.16(.085) MAX
GROMMET EXTENSION
BLUE COLOR BAND
(REAR RELEASE)
G
D
Page 46 Completed Part Number
Page 52 Contacts, Sealing Plugs and Tools
Pages 60–62 Insert Arrangements
Page 45 Performance Specications
Pages 58, 59 Insert Availability and Contact Information
Page 50 Polarization
Note 1: “K” Accessory read for AE324 is same as AE326
(“D” Accessory read) on page 49.
Note 2: “E” Mating read for AE324 is same as AE326 (“E”
Mating read) 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).
Shell
Size
A B C D F G Ø H J
+.004 +.10 +.024 +.60 No. of +.035 +.90 Jam Nut
±.016 ±.40 -.006 -.15 -.000 -.00 Teeth -.004 -.10 Maximum Thread
inch mm inch mm inch mm inch mm inch mm inch mm 0.100R
A 1.063 27.00 .651 16.53 .945/.859 24.00/21.82 .555 14.10 12 .087 2.20 .299 7.59 M17x1-6g
B 1.252 31.80 .751 19.07 1.063/.984 27.00/24.99 .555 14.10 16 .087 2.20 .427 10.85 M20x1-6g
C 1.374 34.90 .938 23.82 1.260/1.172 32.00/29.77 .555 14.10 20 .087 2.20 .541 13.74 M25x1-6g
D 1.500 38.10 1.062 26.97 1.417/1.296 36.00/32.91 .555 14.10 24 .087 2.20 .666 16.92 M28x1-6g
E 1.626 41.30 1.187 30.15 1.457/1.422 37.00/36.12 .555 14.10 28 .087 2.20 .791 20.09 M32x1-6g
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
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38999 S III
– –
D38999/26
Self-Locking, RFI Grounding Plug
AE326
Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof
MASTER KEY
RFI STRIP
4 MINOR KEYS
E
MATING THREAD
BLUE COLOR BAND
LOCATION OPTIONAL
(REAR RELEASE)
31.00(1.220)
MAX
D ACCESSORY THREAD
T NUMBER OF TEETH
2.16(.085) MAX
GROMMET EXTENSION
7.11(.280)
MIN FULL THREAD
[ A
MAX
COUPLING NUT
[ B
MAX
GROMMET
Note : Maximum Grommet Extension for insert layouts
incorporating size 8 and 10 contacts = 5.95(.234).
Page 46 Completed Part Number
Page 52 Contacts, Sealing Plugs and Tools
Pages 60–62 Insert Arrangements
Page 45 Performance Specications
Pages 58, 59 Insert Availability and Contact Information
Page 50 Polarization
Shell
Size
Ø A Ø B D E T
Accessory Thread Mating Thread No. of
Maximum Maximum Metric Class 2B Teeth
inch mm inch mm
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
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
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38999 S III
– –
MIL-DTL-38999
Polarization
Series III
Keying Positions
C°
B°
D°
A°
MASTER KEYWAY
NORMAL
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 xed
as shown.
3.e 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).
Shell
Size
Key/Keyway Key/Keyway Positions
BSC
Identication Letter A° B° C° D°
A (9)
N 105 140 215 265
A 102 132 248 320
B 80 118 230 312
C 35 140 205 275
D 64 155 234 304
E 91 131 197 240
B (11)
C (13)
D (15)
N 95 141 208 236
A 113 156 182 292
B 90 145 195 252
C 53 156 220 255
D 119 146 176 298
E 51 141 184 242
E (17)
F (19)
G (21)
H (23)
J (25)
N 80 142 196 293
A 135 170 200 310
B 49 169 200 244
C 66 140 200 257
D 62 145 180 280
E 79 153 197 272
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38999 S III
– –
MIL-DTL-38999 Series III
Flange and Jam Nut Receptacle
Panel Cutouts
Panel Cutouts
Note: Diameter B cutout dimensions are listed separately
for back and front of panel mounting.
Shell
Size
AØ B Ø B Ø C DØ E
For Back Mounting For Front Mounting +.000* +.00* +.010 +.25
(TP) Minimum Minimum ±.005 ±.13 -.010 -.25 -.000 -.00
inch mm inch mm inch mm 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
AØE
4x Ø CØ B
MIN
FLANGE MOUNT
3.20(.126)
1.58(.062)
PANEL THICKNESS
D
JAM NUT MOUNT
* Tolerance ± .10mm (±.004”)
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38999 S III
– –
MIL-DTL-38999
Contacts, Tools and Seal Plugs
Series III
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
Crimping and Metal Insertion/Extraction Tools
Contact and Wire Data
†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 Qualied for Twinax contacts, consult factory for a quote.
Note: Size 8 coax contacts are used with M17/095-RG180
cable, while size 8 Twinax contacts are used with
M17/176-00002 cable.
Contact
Size
Application Pin Contacts Socket Contacts Seal Plugs Insertion/Removal Tools
Plastic
Type Military No. Military No. Military No. Military No.
22D Power/Signal M39029/58-360 M39029/56-348 MS27488-22-1 M81969/14-01
20 Power/Signal M39029/58-363 M39029/56-351 MS27488-20-1 M81969/14-10
16 Power/Signal M39029/58-364 M39029/56-352 MS27488-16-1 M81969/14-03
12 Power/Signal M39029/58-365 M39029/56-353
MS27488-12-1 M81969/14-0412 Coax Coax M39029/28-211 M39029/75-416
12 Coax Coax M39029/102-558 M39029/103-559
10 (Power) Power M39029/58-528 M39029/56-527 M85049/81-10*** M81969/14-05
8 Coax Coax M39029/60-367 M39029/59-366 MS27488-8-1 M81969/14- 06
8 Twinax**** Twinax M39029/90-529 M39029/91-530 MS27488-8-1 M81969/14-12
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.
22D M22520/2-01 M22520/2-09 M22520/2-07 M81969/8-01 M81969/8-02
20 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-05 M81969/8-06
M22520/2-01 M22520/2-10 M22520/2-10
16 M22520/1-01 M22520/1-04 M22520/1-04 M81969/8-07 M81969/8-08
12 M22520/1-01 M22520/1-04 M22520/1-04
M81969/8-09 M81969/8-1012 Coax Inner M22520/2-01 M22520/2-34 M22520/2-34
12 Coax Outer M22520/31-01 M22520/31-02 M22520/31-02
10 ( Power) — — — M81969/8-11 M81969/8-12
8 Coax Inner M22520/2-01 M22520/2-31 M22520/2-31
M81969/8-13** M81969/8-14
8 Coax Outer M22520/5-01 M22520/5-05 M22520/5-05
Die Closure B Die Closure B
8 Twinax Center M22520/2-01 M22520/2-37 M22520/2-37
— —
8 Twinax Outer
& Intermediate M22520/5-01 M22520/5-200 M22520/5-200
Contact
Size
Test Current* Voltage* Crimp Well Data Wire Range Finished Wire Ø Range
DC Test Max. Drop Well Dia. Minimum Well Dept Minimum Maximum
Amps Millivolts inch inch mm AWG mm2inch mm inch mm
22D 5.0 73 .0345 ±.0010 .141 3.58 28-22 .08-.33 .030 .76 .054 1.37
20 7.5 55 .047 ±.001 .209 5.31 24-20 .20-.52 .040 1.02 .083 2.11
16 13.0 49 .067 ±.001 .209 5.31 20-16 .52-1.31 .065 1.65 .109 2.77
12 23.0 42 .100 ±.002 .209 5.31 14-12 2.08-3.31 .097 2.46 .142 3.61
10 33.0 33 .137 ±.003 .355 9.02 12-10† 3.31-5.26 .135 3.42 .162 4.12
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38999 S III
– –
MIL-DTL-38999
Contact Installation Instructions
Series III
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 the wire into the ex-
traction 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 rmly in the tool and pull the wired contact and tool
straight out of the rear of the insulator.
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 M81969/14-10
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.
*Contact Daniels Manufacturing for crimp tool/positioner.
54www.conesys.com sales@aero-electric.com
38999 S III
– –
MIL. Prex D38999/ 32 W 11 R
Aero Prex AE3 32 W- 11 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
Part Number Conguration
*Not on QPL, can be supplied to Aero-Electric part number only.
D38999
Accessories
Part Number Development
MIL. Prex D38999/ 22 C W
Aero Prex AE3 22 C W
Shell Type
22 = receptacle, dummy stowage, threaded
Shell Size**
A, B, C, D, E, F, G, H or J
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)
Part Number Conguration
*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”.
Dummy Stowage Receptacle
Protective Metal Caps
55www.conesys.com sales@aero-electric.com
38999 S III
– –
D38999/22
Dummy Stowage Receptacle
AE322
AE322 Threaded Dummy Stowage Receptacle
SHELL
SIZE
SHELL
SIZE
CODE
Ø B 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
9 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
56www.conesys.com sales@aero-electric.com
38999 S III
– –
D38999/32
Protective Cover, Plug
AE332
Protective Cover Plug
SHELL
SIZE
A THREAD
CLASS 2A
TRIPLE START
Ø B
MAX
Ø D
MAX
Ø E
MAX G
INCH MM INCH MM INCH MM
INCH
+.512
-.276
MM
+13.0
-7.0
9 .6250-0.1P-0.3L .906 23.0 .945 24.0 .512 13.0 5.000 127.00
11 .7500-0.1P-.03L 1.024 26.0 1.063 27.0 .709 18.0 5.000 127.00
13 .8750-0.1P-.03L 1.221 31.0 1.181 30.0 .787 20.0 5.000 127.00
15 1.0000-0.1P-.03L 1.299 33.0 1.221 31.0 .906 23.0 5.000 127.00
17 1.1875-0.1P-.03L 1.457 37.0 1.457 37.0 1.024 26.0 5.000 127.00
19 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
57www.conesys.com sales@aero-electric.com
38999 S III
– –
D38999/33
Protective Cover, Receptacle
AE333
SHELL
SIZE
A THREAD
CLASS 2B
TRIPLE START
Ø B
MAX
Ø C
MAX
Ø D
MIN F
INCH MM INCH MM INCH 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
Protective Cover Receptacle
58www.conesys.com sales@aero-electric.com
38999 S III
– –
See next page for Shell Sizes G thru J layouts.
MIL-DTL-38999 Series III
Insert Availability and Contact Information
per MIL-STD-1560
Insert Availability and Contact Information
Insert
Arrangement
Aero-Electric Service Total Quantity of Contacts
Status No. of (by Size)
Series III QPL’d Tooled Rating Contacts 22D 20 16 12 10 8
A35 Yes Yes M 6 6
A98 Yes Yes I 3 3
B2 Yes Yes I 2 2
B4 Yes Yes I 4 4
B5 Yes Yes I 5 5
B35 Yes Yes M 13 13
B98 Yes Yes I 6 6
B99 Yes Yes I 7 7
C4 Yes Yes I 4 4
C8 Yes Yes I 8 8
C35 Yes Yes M 22 22
C98 Yes Yes I 10 10
D5 Yes Yes II 5 5
D15 Yes Yes I 15 14 1
D18 Yes Yes I 18 18
D19 Yes Yes I 19 19
D35 Yes Yes M 37 37
D97 Yes Yes I 12 8 4
E6 Yes Yes I 6 6
E8 Yes Yes II 8 8
E26 Yes Yes I 26 26
E35 Yes Yes M 55 55
E99 Yes Yes I 23 21 2
F11 Yes Yes II 11 11
F28 Yes Yes I 28 26 2
F30 Yes Yes I 30 29 1
F32 Yes Yes I 32 32
F35 Yes Yes M 66 66
59www.conesys.com sales@aero-electric.com
38999 S III
– –
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 Quantity of Contacts
Status No. of (by Size)
Series III QPL’d Tooled Rating Contacts 22D 20 16 12 10 8
G11 Yes Yes I 11 11
G16 Yes Yes II 16 16
G35 Yes Yes M 79 79
G39 Yes Yes I 39 37 2
G41 Yes Yes I 41 41
G48** N/A Yes I 4 4 (Power)
G75 Yes Yes Twinax 4 4 (Twinax)
H21 Yes Yes II 21 21
H32 Yes Yes I 32 32
H35 Yes Yes M 100 100
H53 Yes Yes I 53 53
H55 Yes Yes I 55 55
J4 Yes Yes I 56 48 8
J8 Yes Yes Twinax 8 8 (Twinax)
J11 Yes Yes N 11 2 9
J19 Yes Yes I 19 19
J20 Yes Yes N, Coax, Twinax 30 10 13 4 (Coax) 3 (Twinax)
J24 Yes Yes I 24 12 12
J29 Yes Yes I 29 29
J35 Yes Yes M 128 128
J43 Yes Yes I 43 23 20
J46**** Yes Yes I, Coax 46 40 4 2 (Coax)
J61 Yes Yes I 61 61
J90 Yes Yes I, Twinax 46 40 4 2 (Twinax)
** 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.
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 M39029/75-
416 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 rewall applica-
tions (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.
60www.conesys.com sales@aero-electric.com
38999 S III
– –
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series III Connectors
Insert Arrangements Views
1
2
3
4
56
A35,
6#22D,M
A
B
C
A98,
3#20, I
A
B
B2,
2#16, I
A
B
C
D
B4,
4#20,I
A
B
C
D
E
B5,
5#20,I
1
2
3
4
5
6
7
8
9
10 11
12
13
B35,
13 # 22D,M
A
B
C
D
EF
B98,
6#20, I
A
B
C
D
E
FG
B99,
7#20, I
A
B
C
D
C4,
4#16, I
A
B
C
D
E
F
G
H
C8,
8#20, I
C35,
22 # 22D,M
AB
C
D
E
F
G
H
J
K
C98,
10#20, I
A
B
C
D
E
D5,
5#16, II
A
B
C
D
E
F
G
H
J
K
L
M
RN
D15,
1#16, 14 # 20, I
A
B
C
D
E
F
G
H
J
K
L
MN
P
RS
TU
D18,
18 # 20, I
AB
C
D
E
F
G
H
J
K
L
M
NP
R
ST
UV
D19,
19 # 20, I
D35,
37 # 22D,M
A
B
C
D
E
F
G
H
J
K
L
M
D97,
4#16, 8#20, I
A
B
C
D
E
F
E6,
6#12, I
A
B
C
D
E
F
G
H
E8,
8#16, II
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
ST
U
V
W
X
Y
Z
ab
c
E26,
26 # 20, I
E35,
55 #22D,M
P
1
3
4
9
10
16
17
24
25
31
32
39
40
46
47
52
53
55
1
15
22
21
14
21
1
31
E99,
2#16, 21#20, I
A
B
C
D
E
F
G
HJ
K
L
M
N
P
RST
U
V
W
X
YZ
61www.conesys.com sales@aero-electric.com
38999 S III
– –
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series III Connectors
Insert Arrangements Views
*Inactive for new design.
** Not MIL-STD-1560 layout (not QPL’d.).
F11,
11 # 16, II
F35,
66 #22D,M
G11,
11 # 12, I G16,
16 # 16, II
G75,
4#8Twinax, Twinax
A
B
C
D
E
L
F
G
H
J
K
F28,
2#16,26#20,I
A
B
C
D
E
F
G
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
F30,
1#16, 29 #20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
1
3
4
9
10
16
17
24
25
33
34
42
43
50
51
57
58
63
64
66
F32,
32 # 20, I
A
B
C
D
E
F
G
JH
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
A
B
C
D
E
F
G
H
J
K
L
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
G41,
41 #20, I
G48**,
4#8 Po we r, I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
XY
Z
a
b
c
d
e
f
g
h
i
j
k
m
t
n
p
q
r
s
G39,
2#16, 37 # 20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
X
Y
Z
W
a
b
c
d
e
f
g
h
i
jk
m
n
p
q
rA
BC
D
A
B
C
D
H2 1,
21 # 16, II
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
G35,
79#22D,M
1
11
71
21
31
41
51
61
79
H53,
53#20, I
H35,
100#22D,M
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
k
m
n
p
q
r
s
t
u
v
w
x
y
z
AA
BB
CC
DD
EE
FF
GG
HH
1
2
3
5
6
8
715
16
24
25
34
35
45
46
55
4
56
66
67
76
77
85
86
93
94
95
96
97
98
99
10 0
H32,
32#20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
PR
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
i
62www.conesys.com sales@aero-electric.com
38999 S III
– –
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series III Connectors
Insert Arrangements Views
J8
8#8Twinax,
Twinax
J11
9#10,2#20,
N
J24,
12 # 12, 12#16, I
H55,
55 #20, I
a
b
c
d
e
f
g
H
i
j
k
m
n
p
q
r
s
t
u
v
w
x
y
z
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
AA
BB
CC
DD
EE
FF
GG
HH
J4,
8#16, 48#20, I
e
AB
C
D
E
F
G
H
J
K
L
M
N
X
Y
Za
bc
d
f
g
h
k
m
n
P
R
S
T
U
V
W
p
q
r
s
t
u
v
w
x
y
z
AA
BB
CC
DD
EE
FF
GG
HH
JJ
KK
LL
J19,
19#12, I
AB
C
D
E
F
G
H
J
K
L
M
NP
R
S
T
UV
J43,
20 # 16, 23#20, I
AB
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
YZ
a
b
c
d
ef
g
h
k
m
np
r
s
t
u
v
w
x
q
J29,
29#16, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
ST
U
V
W
X
Y
Z
a
bc
d
e
f
a
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
J46,
40 # 20, 4#16, 2#8Coax,I/Coax
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
k
m
n
p
r
s
tu
v
w
x
y
z
AA
q
J61,
61#20, I
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
YZ
ab
c
d
e
f
g
h
j
k
m
n
P
r
s
t
u
v
w
x
y
z
AA
BB
CC
DD
EE
FF
GG
HH
JJ
KK
LL
MM
NN
PP
i
q
J90,
40 # 20, 4#16,2#8Twinax,
I/Twinax
A
B
C
D
E
F
GH
A
B
C
D
E
F
G
H
L
J
K
J20
10#20,13#16, 4#12, 3#8 Twinax,
N/Coax /Twinax
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
k
m
n
p
r
s
tu
v
w
x
y
z
AA
q
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
1
2
3
4
5
6
7
J35,
128#22D, M
1
4
7
8
14
15
24
25
35
36
47
48
58
59
70
71
81
82 94 105
115
122
125
121
11 4
104
93