MIL-DTL-38999
Features and Application
Series I
Features and Application
38999 S I
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.
MIL-DTL-38999 Series I is a bayonet coupling subminiture
configuration with high contact density, ideal for smaller wire
gauge, general-purpose applications. These environmentresisting connectors are 100% “scoop-proof.” Pins are
recessed in elongated shells to prevent the possibility of
bending contacts when plugs are scooped into the mating
receptacles.
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.
This family of connectors is offered in 5 receptacle-mounting
styles. They include square flange receptacles, for both front
and rear panel (wall) mounting; square flange receptacles, for
both front and rear box mounting; and jam nut receptacles
which incorporate “O” ring seals, designed for rear panel
“D” hole mounting.
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.
Standard plugs provide RFI protection by incorporating a
continuous strip of attached grounding fingers attenuating
interference up to 1 GHz.
Shell Polarization – Alternate key/keyway positions prevent
cross mating of adjacent connectors having identical insert
arrangement.
Fifty-seven insert arrangements per MIL-STD-1560 are
tooled and qualified to MIL-DTL-38999 Series I, utilizing
2 to 128 contacts. Contacts come in sizes 22M, 22D, 20, 16,
12, and 8 (coax and twinax), terminating wire sizes from 28
gauge to 12 gauge including coaxial cable.
These connectors are available in wide range of shell materials
and finishes. Aluminum shells are offered in electroless nickel,
olive drab cadmium and bright cadmium. Other finishes
such as anodic and zinc cobalt are available upon request to
commercial callouts only. In addition, we offer passivated
stainless steel shells with standard environment-resisting
inserts (commercial callouts only), and for highly corrosive
environments, nickel-aluminum-bronze shells with standard
environment-resisting inserts (commercial callouts only).
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.
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MIL-DTL-38999
Performance Specifications
Series I
Performance Specifications
Operating Temperature Range
Finish B: -65°C to +175°C (-85°F to +347°F)
Finish F: -65°C to +200°C (-85°F to +392°F
Finish A: -65°C to +150°C (-85°F to +302°F)
Material and Plating Data (Finish)
B – aluminum shell, olive drab cadmium over nickel base
F – aluminum shell, electroless nickel finish
A – aluminum shell, silver to light iridescent yellow color
(bright) cadmium over electroless nickel
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:
Corrosion Resistance
Finishes A and B withstand 500-hour salt spray.
Finish F withstands 48-hour salt spray.
Standard Shock
Mated connectors withstand a pulse of approximate half
sine wave of 300 G ± 15 percent magnitude with duration of
3 ± 1 milliseconds applied in three axes per MIL-STD-1344,
method 2004.
Durability
Minimum of 500 mating cycles
Environmental Seal
Wired, mated connectors with specified accessories attached, shall meet the altitude-immersion test specified in
MIL-DTL-38999.
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.
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.
Vibration
Mated connectors, with proper accessories, withstand the
following vibration levels:
• Sine Vibration per MIL-STD-202, method 204, test
condition G.
• Random Vibration per MIL-STD-1344, method 2005,
test condition V and test condition VI, Letter “J” at ambient temperature.
Shell-to-Shell Conductivity
• Finish F = 1.0 millivolt maximum potential drop
• Finishes A and B = 2.5 millivolts maximum potential drop
Voltage 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.
Service Rating
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
exactly what peak voltages, switching currents, transients,
etc., can be expected in a particular circuit.
Note: The establishment of electrical safety factors is left
entirely to the designer, as he is in the best position to know
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38999 S I
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 interface
of mated connectors and tested by the mode-stirred
technique specified in method 3008 of MIL-STD-1344.
MIL-DTL-38999
Part Number Development
Series I
Military and Aero-Electric Part Number Development
38999 S I
Mil. Prefix
Aero Prefix
MS
AE
27467
167
T
T
13
13
B
B
35
35
P
P
A
A
-340
Shell Type
27466 = Front, wall mount receptacle = 166 (Aero p/n)
27467 = RFI grounding plug = 167 (Aero p/n)
27468 = Jam nut receptacle = 168 (Aero p/n)
27496 = Front, box mount receptacle = 196 (Aero p/n)
27505 = Rear, box mount receptacle = 105 (Aero p/n)
27656 = Rear, wall mount receptacle = 156 (Aero p/n)
Class
T = With acc. thread (MS27466, MS27467, MS27468 & MS27656)
E = Same as T in line above but is not approved for new design
(E-nut is not included)
= No acc. thread, box mount (MS27496 & MS27505)
Shell Size
9, 11, 13, 15, 17, 19, 21, 23 or 25
Finish (Material & Plating)
A = Aluminum shell, silver to light iridescent yellow color (bright) cadmium over nickel base
B = Aluminum shell, olive drab cadmium over electroless nickel base
F = Aluminum shell, electroless nickel finish
S = Stainless steel shell, passivated (Aero p/n only)
Insert Arrangement
See page 19 thru 21
Contact Style
P = Pin
S = Socket
A = Pin connector less pins (with intent to use non-standard pin contacts)
B = Socket connector less sockets (with intent to use non-standard socket contacts)
Polarization (Keying)
N = Normal (Omitted in part number)
A, B, C, or D (B & C keyways are not available in shell size 9)
Modification (applies to Aero part numbers only)
01 = Less contacts (is not marked on the part)
340 = Connector kitted with M85049/27-XXX E-nut
341 = Connector kitted with M85049/49-2-XXX straight clamp
342 = Connector kitted with M85049/47XXX right angle clamp
Consult factory for other modifications
Note 1: Each connector is furnished with contacts unless
ordered less contacts (L/C) as follows: One spare contact for
inserts requiring 1 through 26 of each contact and two spares
for inserts with more than 26 contacts and a minimum of
one sealing plug up to 10% of the number of contacts. Spare
Coax and Twinax contacts are not supplied. One insertion/
removal tool for each contact size is also included.
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Note 2: Proper part number marking has no “0” in front
of single digit shell size (9) and no “0” in front of single digit
layout. Example of each: J MS27466T9B35S and
J MS27466T11B5S. In both, “N” for normal is omitted. In
addition, J or JAN must now be marked in front of the MS
part number.
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MS27466
Front, Wall Mounting Receptacle
AE166
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
1.323(33.60)
MAX
D
38999 S I
A
MASTER KEYWAY
F
B
.219(5.56)
MIN. FULL THREAD
.060(1.52)
MAX GROMMET EXTENSION
H
E
MAX
GROMMET
J ACCESSORY TEETH
G ACCESSORY THREAD
4X MINOR KEYWAYS
4x C
BLUE COLOR BAND
Page 5
Page 15
Pages 19–21
Page 4
Pages 16-18
Page 13
Completed Part Number
Contacts, Sealing Plugs and Tools
Insert Arrangements
Performance Specifications
Insert Availability and Contact Information
Polarization
A
Shell
Size
B
±.020
±.51
inch
mm
ØC
(TP)
inch
mm
D
ØE
F
G
ØH
J
Maximum
No. of
Teeth
+.010
-.005
+.25
-.13
+.000
-.005
+.00
-.13
+.001
-.005
+.03
-.13
+.015
-.000
+.38
-.00
Accessory
Thread
inch
mm
inch
mm
inch
mm
inch
mm
UNEF-2A
inch
mm
9
.938
23.83
.719
18.26
.128
3.25
.632
16.05
.572
14.53
.085
2.16
7/16-28
.299
7.59
12
11
1.031
26.19
.812
20.62
.128
3.25
.632
16.05
.700
17.78
.085
2.16
9/16-24
.427
10.85
16
13
1.125
28.58
.906
23.01
.128
3.25
.632
16.05
.850
21.59
.085
2.16
11/16-24
.541
13.74
20
15
1.219
30.96
.969
24.61
.128
3.25
.632
16.05
.975
24.77
.085
2.16
13/16-20
.666
16.92
24
17
1.312
33.32
1.062
26.97
.128
3.25
.632
16.05
1.100
27.94
.085
2.16
15/16-20
.791
20.09
28
19
1.438
36.53
1.156
29.36
.128
3.25
.632
16.05
1.207
30.66
.085
2.16
1-1/16-18
.897
22.78
32
21
1.562
39.67
1.250
31.75
.128
3.25
.602
15.29
1.332
33.83
.115
2.92
1-3/16-18
1.022
25.96
36
23
1.688
42.88
1.375
34.93
.147
3.73
.602
15.29
1.457
37.01
.115
2.92
1-5/16-18
1.147
29.13
40
25
1.812
46.02
1.500
38.10
.147
3.73
.602
15.29
1.582
40.18
.115
2.92
1-7/16-18
1.272
32.31
44
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MS27656
Rear, Wall Mounting Receptacle
AE156
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
1.350 (34.29)
MAX
38999 S I
A
MASTER KEYWAY
D
B
F
.219 (5.56)
MIN FULL THREAD
.060 (1.52)
MAX GROMMET EXTENSION
H
E
MAX
GROMMET
J ACCESSORY TEETH
G ACCESSORY THREAD
4X MINOR KEYWAYS
4x C
BLUE COLOR BAND
Page 5
Page 15
Pages 19–21
Page 4
Pages 16-18
Page 13
Completed Part Number
Contacts, Sealing Plugs and Tools
Insert Arrangements
Performance Specifications
Insert Availability and Contact Information
Polarization
A
Shell
Size
B
±.020
±.51
inch
mm
ØC
(TP)
inch
mm
Note: See page 14 for panel thickness.
D
ØE
F
G
ØH
J
Maximum
No. of
Teeth
+.010
-.005
+.25
-.13
+.000
-.005
+.00
-.13
+.001
-.005
+.03
-.13
+.015
-.000
+.38
-.00
Accessory
Thread
inch
mm
inch
mm
inch
mm
inch
mm
UNEF-2A
inch
mm
9
.938
23.83
.719
18.26
.128
3.25
.820
20.83
.572
14.53
.085
2.16
7/16-28
.299
7.59
12
11
1.031
26.19
.812
20.62
.128
3.25
.820
20.83
.700
17.78
.085
2.16
9/16-24
.427
10.85
16
13
1.125
28.58
.906
23.01
.128
3.25
.820
20.83
.850
21.59
.085
2.16
11/16-24
.541
13.74
20
15
1.219
30.96
.969
24.61
.128
3.25
.820
20.83
.975
24.77
.085
2.16
13/16-20
.666
16.92
24
17
1.312
33.32
1.062
26.97
.128
3.25
.820
20.83
1.100
27.94
.085
2.16
15/16-20
.791
20.09
28
19
1.438
36.53
1.156
29.36
.128
3.25
.820
20.83
1.207
30.66
.085
2.16
1-1/16-18
.897
22.78
32
21
1.562
39.67
1.250
31.75
.128
3.25
.790
20.07
1.332
33.83
.115
2.92
1-3/16-18
1.022
25.96
36
23
1.688
42.88
1.375
34.93
.147
3.73
.790
20.07
1.457
37.01
.115
2.92
1-5/16-18
1.147
29.13
40
25
1.812
46.02
1.500
38.10
.147
3.73
.790
20.07
1.582
40.18
.115
2.92
1-7/16-18
1.272
32.31
44
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MS27496
Front, Box Mounting Receptacle
AE196
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
1.104(28.04)
MAX
D
B
38999 S I
A
MASTER KEYWAY
F
.060(1.52)
MAX GROMMET EXTENSION
H
G
MAX
GROMMET MAX
E
.312(7.93)
MAX
4X MINOR KEYWAYS
4x C
BLUE COLOR BAND
Page 5
Page 15
Pages 19–21
Page 4
Pages 16-18
Page 13
Completed Part Number
Contacts, Sealing Plugs and Tools
Insert Arrangements
Performance Specifications
Insert Availability and Contact Information
Polarization
A
B
ØC
D
ØE
F
ØG
+.010
-.005
+.25
-.13
+.000
-.005
+.00
-.13
+.001
-.005
+.03
-.13
+.015
-.000
+.38
-.00
ØH
Shell
Size
±.020
±.51
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
9
.938
23.83
.719
18.26
.128
3.25
.632
16.05
.572
14.53
.085
2.16
.469
11.91
.299
7.59
11
1.031
26.19
.812
20.62
.128
3.25
.632
16.05
.700
17.78
.085
2.16
.594
15.09
.427
10.85
13
1.125
28.58
.906
23.01
.128
3.25
.632
16.05
.850
21.59
.085
2.16
.719
18.26
.541
13.74
15
1.219
30.96
.969
24.61
.128
3.25
.632
16.05
.975
24.77
.085
2.16
.844
21.44
.666
16.92
(TP)
Maximum
Maximum
17
1.312
33.32
1.062
26.97
.128
3.25
.632
16.05
1.100
27.94
.085
2.16
.969
24.61
.791
20.09
19
1.438
36.53
1.156
29.36
.128
3.25
.632
16.05
1.207
30.66
.085
2.16
1.078
27.38
.897
22.78
21
1.562
39.67
1.250
31.75
.128
3.25
.602
15.29
1.332
33.83
.115
2.92
1.203
30.56
1.022
25.96
23
1.688
42.88
1.375
34.93
.147
3.73
.602
15.29
1.457
37.01
.115
2.92
1.328
33.73
1.147
29.13
25
1.812
46.02
1.500
38.10
.147
3.73
.602
15.29
1.582
40.18
.115
2.92
1.453
36.91
1.272
32.31
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MS27505
Rear, Box Mounting Receptacle
AE105
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
1.100(27.94)
MAX
38999 S I
A
MASTER KEYWAY
D
B
F
.060(1.52)
MAX GROMMET EXTENSION
H
E
G
MAX
MAX
GROMMET
4X MINOR KEYWAYS
4x C
BLUE COLOR BAND
Page 5
Page 15
Pages 19–21
Page 4
Pages 16-18
Page 13
Completed Part Number
Contacts, Sealing Plugs and Tools
Insert Arrangements
Performance Specifications
Insert Availability and Contact Information
Polarization
A
Shell
Size
B
±.020
±.51
inch
mm
inch
ØC
Note: See page 14 for panel thickness.
D
ØE
F
ØG
ØH
+.010
-.005
+.25
-.13
+.000
-.005
+.00
-.13
+.001
-.005
+.03
-.13
+.015
-.000
+.38
-.00
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
(TP)
Maximum
Maximum
mm
9
.938
23.83
.719
18.26
.128
3.25
.820
20.83
.572
14.53
.085
2.16
.547
13.89
.299
7.59
11
1.031
26.19
.812
20.62
.128
3.25
.820
20.83
.700
17.78
.085
2.16
.656
16.66
.427
10.85
13
1.125
28.58
.906
23.01
.128
3.25
.820
20.83
.850
21.59
.085
2.16
.828
21.03
.541
13.74
15
1.219
30.96
.969
24.61
.128
3.25
.820
20.83
.975
24.77
.085
2.16
.953
24.21
.666
16.92
17
1.312
33.32
1.062
26.97
.128
3.25
.820
20.83
1.100
27.94
.085
2.16
1.078
27.38
.791
20.09
19
1.438
36.53
1.156
29.36
.128
3.25
.820
20.83
1.207
30.66
.085
2.16
1.203
30.56
.897
22.78
21
1.562
39.67
1.250
31.75
.128
3.25
.790
20.07
1.332
33.83
.115
2.92
1.328
33.73
1.022
25.96
23
1.688
42.88
1.375
34.93
.147
3.73
.790
20.07
1.457
37.01
.115
2.92
1.453
36.91
1.147
29.13
25
1.812
46.02
1.500
38.10
.147
3.73
.790
20.07
1.582
40.18
.115
2.92
1.578
40.08
1.272
32.31
www.conesys.com
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MS27468
Jam Nut Receptacle
AE168
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
E
1.308 (33.22)
MAX
38999 S I
B
.920 (23.37)
.910 (23.11)
.615 (15.62)
.598 (15.19)
MASTER KEYWAY
.060 (1.52) MAX
GROMMET EXTENSION
K
ØC
ØA
FLAT
MAX
GROMMET
G No. OF TEETH
ØD
4X MINOR KEYWAYS
3X BAYONET PINS
EQUALLY SPACED
Page 5
Page 15
Pages 19–21
Page 4
Pages 16-18
Page 13
"O"-RING
J THREAD
BLUE COLOR BAND
HEX NUT
PER MS3186
PANEL THICKNESS
.125(3.18)
.062(1.57)
Completed Part Number
Contacts, Sealing Plugs and Tools
Insert Arrangements
Performance Specifications
Insert Availability and Contact Information
Polarization
ØA
Shell
Size
F ACCESSORY THREAD
BLUE COLOR BAND
B
ØC
+.001
-.005
+.03
-.13
+.011
-.010
+.28
-.25
inch
mm
inch
mm
inch
ØD
E
F
±.016
±.41
±.016
±.41
Accessory
Thread
mm
inch
mm
inch
mm
UNEF- 2A
Maximum
G
J
K
No. of Jam Nut Thread
Flat
Teeth
Class 2A
±.005
±.13
inch
mm
9
.572
14.53
.109
2.77
.299
7.59
1.188
30.18
1.062
26.97
7/16-28
12
11/16-24UNEF
.650
16.51
11
.700
17.78
.109
2.77
.427
10.85
1.375
34.93
1.250
31.75
9/16-24
16
13/16-20UNEF
.750
19.05
13
.850
21.59
.109
2.77
.541
13.74
1.500
38.10
1.375
34.93
11/16-24
20
1-20UNEF
.937
23.80
15
.975
24.77
.109
2.77
.666
16.92
1.625
41.28
1.500
38.10
13/16-20
24
1-1/8-18UNEF
1.061
26.95
17
1.100
27.94
.109
2.77
.791
20.09
1.750
44.45
1.625
41.28
15/16-20
28
1-1/4-18UNEF
1.186
30.12
19
1.207
30.66
.140
3.56
.897
22.78
1.938
49.23
1.812
46.02
1-1/16-18
32
1-3/8-18UNEF
1.311
33.30
21
1.332
33.83
.140
3.56
1.022
25.96
2.062
52.37
1.938
49.23
1-3/16-18
36
1-1/2-18UNEF
1.436
36.47
23
1.457
37.01
.140
3.56
1.147
29.13
2.188
55.58
2.062
52.37
1-5/16-18
40
1-5/8-18UNEF
1.561
39.65
25
1.582
40.18
.140
3.56
1.272
32.31
2.312
58.72
2.188
55.58
1-7/16-18
44
1-3/4-18UNS
1.686
42.82
www.conesys.com
– 10 –
sales@aero-electric.com
MS27467
RFI Grounding Plug
AE167
Bayonet Coupling, Crimp Removable, Rear Release, Scoop-Proof
1.294
(32.87)
MAX
F MAX.
COUPLING NUT
38999 S I
MASTER KEY
E ACCESSORY THREAD
RFI STRIP
.060(1.52) GROMMET
MAX
EXTENSION
A
C
MIN
MAX
GROMMET
D No. OF TEETH
.219(5.56) MIN
FULL THREAD
4 MINOR KEYS
BLUE COLOR BAND
Page 5
Page 15
Pages 19–21
Page 4
Pages 16-18
Page 13
Completed Part Number
Contacts, Sealing Plugs and Tools
Insert Arrangements
Performance Specifications
Insert Availability and Contact Information
Polarization
ØA
ØC
D
E
Minimum
Maximum
No. of
Teeth
Accessory Thread
Class 2A
Shell
Size
inch
mm
inch
mm
ØF
Maximum
inch
mm
9
.417
10.59
.299
7.59
12
7/16-28UNEF
.859
21.82
11
.545
13.84
.427
10.85
16
9/16-24UNEF
.984
24.99
13
.657
16.69
.541
13.74
20
11/16-24UNEF
1.156
29.36
15
.782
19.86
.666
16.92
24
13/16-20UNEF
1.281
32.54
17
.907
23.04
.791
20.09
28
15/16-20UNEF
1.406
35.71
19
1.012
25.70
.897
22.78
32
1-1/16-18UNEF
1.516
38.51
21
1.137
28.88
1.022
25.96
36
1-3/16-18UNEF
1.641
41.68
23
1.262
32.05
1.147
29.13
40
1-5/16-18UNEF
1.766
44.86
25
1.387
35.23
1.272
32.31
44
1-7/16-18UNEF
1.891
48.03
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– 11 –
sales@aero-electric.com
M38999/9
Dummy Stowage Receptacle
AE109
Dummy Stowage Receptacle, Bayonet Coupling
38999 S I
Part Number Configuration
MIL. Prefix
Aero Prefix
M38999
AE10
9/
9-
XX
XX
B
B
Shell Type
9 = receptacle, dummy stowage, bayonet coupling
Shell Size
9 THRU 25 (Note: single digit for shell size 9)
Material Finish
B = Aluminum, Cadmium Olive Drab
A = Aluminum, Bright Cadmium over Nickel base (Aero p/n only)
F = Aluminum shell, Electroless Nickel finish (Aero p/n only)
S = Stainless steel shell, passivated (Aero p/n only)
BN = Aluminum, Black Nickel (Aero p/n only)
BZ = Bronze (Aero p/n only)
SHELL
SIZE
ØA
+.001
-.005
K
+.015
-.000
M
±.010
ØT
+.010
-.005
S
±.020
J
+.010
-.015
9
.572
.085
.727
.128
.938
.567
11
.700
.085
.727
.128
1.031
.567
13
.850
.085
.727
.128
1.125
.567
15
.975
.085
.727
.128
1.219
.567
17
1.100
.085
.727
.128
1.312
.567
19
1.207
.085
.727
.128
1.438
.567
21
1.332
.115
.697
.128
1.562
.567
23
1.457
.115
.697
.147
1.688
.567
25
1.582
.115
.697
.147
1.812
.567
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– 12 –
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MIL-DTL-38999
Polarization
Series I
Keying Positions
38999 S I
NORMAL
C°
N°
MASTER
KEYWAY
A°
B°
D°
5°
DATUM
F
Notes:
1. Mating face of receptacle shown (plug is opposite).
2. The master keyway (key) has various positions relative
to DATUM F; the minor keyways (keys) remain fixed as
shown. In the Normal position, the master keyway (key)
is at 95° from DATUM F.
3. The angles for a given connector are the same whether it
contains pin or socket inserts.
4. The insert arrangement does not rotate relative to master
keyway (key).
Keying Positions
BSC
Shell
Size
N°
A°
B°
C°
D°
9
95
77
–
–
113
11
95
81
67
123
109
13
95
75
63
127
115
15
95
74
61
129
116
17
95
77
65
125
113
19
95
77
65
125
113
21
95
77
65
125
113
23
95
80
69
121
110
25
95
80
69
121
110
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– 13 –
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MIL-DTL-38999 Series I
Flange and Jam Nut Receptacles
Panel Cutouts
Panel Cutouts
D MAX
PANEL THICKNESS
4x
C
38999 S I
JAM NUT MOUNT
FLANGE MOUNT
.125(3.18)
.062(1.57)
PANEL THICKNESS
B
MIN
b
=F
A
Note 1: Flange Mounting Dimensions (Ø B cutout and
D MAX) listed only for back of panel mounting (MS27505
and MS27656).
Note 2: D MAX includes mounting hardware.
Flange and Jam Nut Mounting Dimensions
A
ØB
(TP)
Minimum
Shell
Size
inch
mm
inch
ØC
D
±.005
±.13
mm
inch
mm
inch
E
ØF
+.000*
-.010
+.00*
-.25
+.010
-.000
+.25
-.00
mm
inch
mm
inch
mm
Maximum
9
.719
18.26
.656
16.66
.128
3.25
.234
5.94
.657*
16.70*
.693
17.60
11
.812
20.62
.796
20.22
.128
3.25
.234
5.94
.771
19.59
.825
20.96
13
.906
23.01
.922
23.42
.128
3.25
.234
5.94
.955
24.26
1.010
25.65
15
.969
24.61
1.047
26.59
.128
3.25
.234
5.94
1.085
27.56
1.135
28.83
17
1.062
26.97
1.219
30.96
.128
3.25
.234
5.94
1.210
30.73
1.260
32.01
19
1.156
29.36
1.297
32.94
.128
3.25
.234
5.94
1.335
33.91
1.385
35.18
21
1.250
31.75
1.422
36.12
.128
3.25
.204
5.18
1.460
37.08
1.510
38.35
23
1.375
34.93
1.547
39.29
.154
3.91
.204
5.18
1.585
40.26
1.635
41.53
25
1.500
38.10
1.672
42.47
.154
3.91
.193
4.90
1.710
43.43
1.760
44.70
* Tolerance
± .10mm (±.004”)
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– 14 –
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MIL-DTL-38999
Contacts, Tools and Seal Plugs
Series I
Contacts, Plastic Insertion/Removal Tools and Seal Plugs
38999 S I
Contact Size
22D
22M*
22*
20
16
12
12 Coax
12 Coax
8 Coax
8 Twinax
Application
Pin Contacts
Socket Contacts
Seal Plugs
Insertion/Removal Tools
Type
Power/Signal
Power/Signal
Power/Signal
Power/Signal
Power/Signal
Power/Signal
Coax
Coax
Coax
Twinax
Military No.
M39029/58-360
M39029/58-361
M39029/58-362
M39029/58-363
M39029/58-364
M39029/58-365
M39029/28-211
M39029/102-558
M39029/60-367
M39029/90-529
Military No.
M39029/56-348
M39029/56-349
M39029/56-350
M39029/56-351
M39029/56-352
M39029/56-353
M39029/75-416
M39029/103-559
M39029/59-366
M39029/91-530
Military No.
Plastic
Military No.
Positioner
Positioner
Insertion Tool
Extraction Tool
For Socket Contacts
Military No.
M22520/2-07
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
M81969/8-03
Metal
Military No.
M81969/8-02
M81969/8-04
M81969/8-05
M81969/8-06
M81969/8-07
M81969/8-08
M81969/8-09
M81969/8-10
M81969/8-13**
M81969/8-14
M81969/14-01
MS27488-22-1
MS27488-20-1
MS27488-16-1
—
M81969/14-10
M81969/14-03
MS27488-12-1
M81969/14-04
MS27488-8-1
MS27488-8-1
M81969/14-06
M81969/14-12
Crimping and Metal Insertion/Extraction Tools
Contact Size/
Type
Crimp Tool
16
12
12 Coax Inner
12 Coax Outer
8 Coax Inner
Military No.
M22520/2-01
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
M22520/2-09
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, 22M*
22*
20
—
M22520/5-200
—
Contact and Wire Data
Test Current Voltage
Contact Size
22D
22M*
22*
20
16
12
DC Test
Amps
5.0
3.0
5.0
7.5
13.0
23.0
Max. Drop
Millivolts
73
45
73
55
49
42
Crimp Well Data
AWG
28-22
28-24
26-22
24-20
20-16
14-12
mm2
.08-.33
.08-.20
.13-.33
.20-.52
.52-1.31
2.08-3.31
Finished Wire Ø Range
Minimum
inch
mm
.030
.76
.030
.76
.034
.86
.040
1.02
.065
1.65
.097
2.46
Maximum
inch
mm
.054
1.37
.050
1.27
.060
1.52
.083
2.11
.109
2.77
.142
3.61
Note 2: Size 12 coax contacts purchased in bulk.
* Inactive for new design
** Insertion tool is not required.
Note 3: Size 8 coax contacts are used with M17/095-RG180
cable, while size 8 Twinax contacts are used with
M17/176-00002 cable.
Note 1: Test Current and Maximum Voltage Drop when
tested with silver-plated wire at 25°C.
www.conesys.com
Wire Range
Well Dia.
Minimum Well Dept
inch
inch
mm
.0345 ±.0010
.141
3.58
.028 ±.001
.141
3.58
.0365 ±.0010
.141
3.58
.047 ±.001
.209
5.31
.067 ±.001
.209
5.31
.100 ±.002
.209
5.31
– 15 –
sales@aero-electric.com
MIL-DTL-38999
Contact Installation Instructions
Series I
Contact Installation
Instructions
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.
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
22D
22M
22
M39029/58-360
M39029/58-361
M39029/58-362
M39029/56-348
M39029/56-349
M39029/56-350
20
M39029/58-363
M39029/56-351
20
12
M39029/58-364
M39029/58-365
M39029/56-352
M39029/56-353
M22520/2-01
M22520/2-01
M22520/2-01
M22520/1-01
M22520/2-01
M22520/1-01
M22520/1-01
M22520/2-09
M22520/2-09
M22520/2-09
M22520/1-04 Red
M22520/2-10
M22520/1-04 Blue
M22520/1-04 Yellow
M22520/2-07
M22520/2-07
M22520/2-07
M22520/1-04 Red
M22520/2-10
M22520/1-04 Blue
M22520/1-04 Yellow
Insertion/Removal
Tool
M81969/14-01
M81969/14-01
M81969/14-01
M81969/14-10
M81969/14-03
M81969/14-04
For coax and twinax contacts refer to instructions that are supplied with contacts.
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– 16 –
sales@aero-electric.com
38999 S I
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.
MIL-DTL-38999 Series I
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)
38999 S I
Series I
QPL’d
Tooled
Rating
Contacts
9-6*
9-35
9-98
11-2
11-4
11-5
11-13*
11-35
11-98
11-99
13-4
13-8
13-22*
13-35
13-98
15-5
15-15
15-18
15-19
15-35
15-37*
15-97
17-6
17-8
17-26
17-35
17-55*
17-99
19-11
19-28
19-30
19-32
19-35
19-66*
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
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
M
M
I
I
I
I
M
M
I
I
I
I
M
M
I
II
I
I
I
M
M
I
I
II
I
M
M
I
II
I
I
I
M
M
6
6
3
2
4
5
13
13
6
7
4
8
22
22
10
5
15
18
19
37
37
12
6
8
26
55
55
23
11
28
30
32
66
66
See next page for Shell Sizes 21 thru 25 layouts.
www.conesys.com
22D
22M
22
20
16
12
10
8
6
6
3
2
4
5
13
13
6
7
4
8
22
22
10
14
18
19
5
1
37
37
8
4
6
8
26
55
55
21
26
29
32
2
11
2
1
66
66
* Not approved for new design. Tooled and qualified but their
separate pictorials are not shown on pages 19 thru 21, as they
are the same as corresponding (-35) layouts that take the same
quantity of 22D contacts, but are supplied with 22M contacts
instead.
– 17 –
sales@aero-electric.com
MIL-DTL-38999 Series I
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
QPL’d
Tooled
Rating
Contacts
21-1*
21-11
21-16
21-35
21-39
21-41
21-48**
21-75
23-1*
23-2***
23-21
23-32
23-35
23-53
23-55
25-1*
25-4
25-19
25-24
25-29
25-35
25-43
25-46
25-61
Yes
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
M
I
II
M
I
I
I
Twinax
M
M
II
I
M
I
I
M
I
I
I
I
M
I
I, Coax
I
79
11
16
79
39
41
4
4
100
85
21
32
100
53
55
128
56
19
24
29
128
43
46
61
(by Size)
22D
22M
22
20
16
12
10
8
79
11
16
79
37
41
2
4 (Power)
4 (Twinax)
100
85
21
32
100
53
55
128
48
8
12
29
19
12
128
23
40
61
20
4
2 (Coax)
* Not approved for new design. Tooled and qualified but their separate
pictorials are not shown on pages 19 thru 21, as they are same as
corresponding (-35) layouts that take the same quantity of 22D contacts,
but are supplied with 22M contacts instead.
** 21-48 layout is not to MIL-STD-1560. It is tooled and intended for
commercial use only.
*** Not approved for new design. Pictorial is shown on page 20.
www.conesys.com
– 18 –
sales@aero-electric.com
38999 S I
Series I
MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I Connectors
Insert Arrangements Views
38999 S I
5
C
1
6
4
3
A
B
D
A
A
E
1
A
10
B
2
B
C
D
C
3
8
B
13
12
7
6
4
5
9-35
9-98
11-2
11-4
11-5
11-35
6 # 22D, M
3 # 20, I
2 # 16, I
4 # 20, I
5 # 20, I
13 # 22D, M
A
A
E
F
D
F
B
E
C
G
A
B
D
A
G
H
F
1
15
C
C
E
11-99
13-4
13-8
13-35
4 # 16, I
8 # 20, I
22 # 22D, M
E
J
B
N
H
D
L
B
M
R
C
J
D
P
A
T
U
S
G
K
C
P
R
F
L
B
N
M
H
E
G
C
K
M
A B
N
P
U
J
D
T
H
E
S
G
13-98
10 # 20, I
1
C
31
D
R
V
D
C
D
7 # 20, I
L A
C
F
11-98
K
B
J
K
6 # 20, I
A
G
B
E
A
H
14
21
22
B
D
K
21
A
L
J
B
H
E
C
M
G
F
F
F
D
E
15-5
15-15
15-18
15-19
15-35
15-97
5 # 16, II
1 # 16, 14 # 20, I
18 # 20, I
19 # 20, I
37 # 22D, M
4 # 16, 8 # 20, I
G
F
17-6
6 # 12, I
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B
S
T
E
17-8
8 # 16, II
C
D
M
L
V
c
Y
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17-26
26 # 20, I
– 19 –
E
F
W
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32
A
40
R
47
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25
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1
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17
4
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10
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2
11
9
53
55
3
52
9
16
24
31
39
17-35
55 # 22D, M
46
Y
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C
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M
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J H
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17-99
2 # 16, 21 # 20, I
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MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I Connectors
Insert Arrangements Views
A
T
S
A
J
B
G
C
Y
g
L
G
K
E
J
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F
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19-30
19-32
32 # 20, I
34
J
43
51
L
A
63
24
33
42
j
h
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21-39
2 # 16, 37 # 20, I
29
20
39
48
58
b
c
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5
75
J
N
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M
B
W
R
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K
C
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11
81
28
38
47
57
66
74
U
J
D
K
T
G
23-2*
23-21
85 # 22, M
21 # 16, II
Y
J
E
H
h
g
21-75
4 # 8 Twinax, Twinax
S
c
16
25
35
46
56
67
77
86
1
94
2
C
95
3
T
d
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8
B
R
96
4
97
98
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85
B
A
P
b
a
L
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4
C
C
21-48**
4 # 8 Power, I
P
L
82
1
19
B
D
K
L
N
M
A
H
21-41
41 # 20, I
67
D
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12
p
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21-35
79 # 22D, M
A
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11
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21-16
16 # 16, II
A
W
V
C
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61
41
B
k
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21-11
11 # 12, I
X
71
79
P
D
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A
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31
C
F
50
19-35
66 #22D, M
V
N
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57
16
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66
9
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21
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3
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51
B
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1
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58
64
N
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1 # 16, 29 # 20, I
4
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a
19-28
25
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2 # 16, 26 # 20, I
1
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24
34
45
55
66
76
85
23-32
23-35
32 # 20, I
100 # 22D, M
93
* Inactive for new design.
** Not MIL-STD-1560 layout (not QPL’d.).
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MIL-STD-1560
Insert Arrangements (Pin Front View)
for MIL-DTL-38999 Series I Connectors
Insert Arrangements Views
S
T
R
38999 S I
GG
EE
f
t
w
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K
v
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J
a
b
c
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G
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15
25
36 48 59
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105
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115
122
125
4
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24
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81 93
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121
14
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25-19
19 # 12, I
1
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8
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71 82
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25-35
25-43
20 # 16, 23 # 20, I
AA
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P
N
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25-46
25-61
40 # 20, 4 # 16, 2 # 8 Coax, I / Coax
61 # 20, I
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H
i
j
k
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h
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m
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128 # 22D, M
A
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25-29
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29# 16, I
W
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25-24
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12 # 12, 12 # 16, I
s
n
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25-4
8 # 16, 48 # 20, I
c
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p
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23-55
55 # 20, I
B
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c
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d
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A
P
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DD
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23-53
55 # 20, I
M
CC s
FF
x
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w
v
W
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n
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A
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n
m
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k
A
a
Z
Y
U
J
K
– 21 –
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