D38999/20WH35SB - Aero Conesys

36www.conesys.com sales@aero-electric.com

MIL–DTL– 38999 S III

– –

MIL-DTL-38999

Features and Application

Series III

www.conesys.com sales@aero-electric.com

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.

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.

Elongated mounting holes permit the Series III Connector to

intermount with various existing Mil-spec ﬂange mounted

receptacles, giving it a design replacement advantage.

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.

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 nickel 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 (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 – 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.

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.

37www.conesys.com sales@aero-electric.com

MIL–DTL– 38999 S III

MIL-DTL-38999

Performance Speciﬁcations

Series III

– –

Performance Speciﬁcations

Operating Temperature Range

Classes F, K, S and BZ*: -65°C to +200°C (-85°F to +392°F)

Classes W and ZC*: -65°C to +175°C (-85°F to +347°F)

Material and Finish Data (Class)

F – aluminum shell, electroless nickel ﬁnish

K – stainless steel shell, passivated, ﬁrewall

S – stainless steel shell, electrodeposited nickel, ﬁrewall

W– aluminum shell, olive drab cadmium over nickel base

BZ* – aluminum nickel bronze shell, std insert

Z*– aluminum shell, zinc nickel ﬁnish

Corrosion Resistance

Classes K, W, BZ* and Z* withstand 500-hour salt spray.

Classes F and S withstand 48-hour salt spray.

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 interface

of mated connectors and tested by the mode-stirred

technique speciﬁed in method 3008 of MIL-STD-1344.

Voltage Rating

Environmental Seal

Wired, mated connectors with speciﬁed accessories

attached, shall meet the altitude-immersion test speciﬁed 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 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.

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 205,

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.

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: The establishment of electrical safety factors is left

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.

38www.conesys.com sales@aero-electric.com

MIL–DTL– 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: JD38999/20WB5SN. “N” for

normal is included. In addition, J or JAN must be marked

immediately in front of MIL part number.

Mil. Preﬁx D38999/ 20 W C 35 P N

Aero Preﬁx AE3 20 W C 35 P 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

K= Stainless steel shell, passivated, with ﬁrewall insert

S= Stainless steel shell, electrodeposited nickel, with ﬁrewall insert

BZ* = Aluminum nickel bronze shell with standard insert (Aero p/n only)

Z* = Aluminum shell, zinc nickel plating (Aero p/n only)

Shell Size

A, B, C, D, E, F, G, H or J

Insert Arrangement

See pages 15 thru 19

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 M85049/14-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

39www.conesys.com sales@aero-electric.com

MIL–DTL– 38999 S III

D38999/20

Wall Mounting Receptacle

AE320

Triple Start Threaded Coupling, Crimp Removable, Rear Release, Scoop-Proof

– –

BLUE COLOR BAND

(REAR RELEASE)

4 MINOR KEYWAYS

LOCKING INDICATOR BAND

COLOR: RED

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

[ L

MAX

GROMMET

Page 38 Completed Part Number

Page 44 Contacts, Sealing Plugs and Tools

Pages 17–19 Insert Arrangements

Page 37 Performance Speciﬁcations

Pages 15, 16 Insert Availability and Contact Information

Page 42 Polarization

Note 1: “K” Accessory Thread for AE320 is same as AE326

(“D” Accessory Thread) on page 41.

Note 2: “F” Mating Thread for AE320 is same as AE326

(“E” Mating Thread) on page 41 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  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

40www.conesys.com sales@aero-electric.com

MIL–DTL– 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

FLAT

E MATING THREAD

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)

Page 38 Completed Part Number

Page 44 Contacts, Sealing Plugs and Tools

Pages 17–19 Insert Arrangements

Page 37 Performance Speciﬁcations

Pages 15, 16 Insert Availability and Contact Information

Page 42 Polarization

Note 1: “K” Accessory Thread for AE324 is same as AE326

(“D” Accessory Thread) on page 41.

Note 2: “E” Mating Thread for AE324 is same as AE326

(“E” Mating Thread) on page 41 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 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

41www.conesys.com sales@aero-electric.com

MIL–DTL– 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

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 38 Completed Part Number

Page 44 Contacts, Sealing Plugs and Tools

Pages 17–19 Insert Arrangements

Page 37 Performance Speciﬁcations

Pages 15, 16 Insert Availability and Contact Information

Page 42 Polarization

Shell

Size

A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

42www.conesys.com sales@aero-electric.com

MIL–DTL– 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 ﬁxed

as shown.

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).

Shell

Size

Key/Keyway Key/Keyway Positions

BSC

Identiﬁcation 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

43www.conesys.com sales@aero-electric.com

MIL–DTL– 38999 S III

MIL-DTL-38999 Series III

Flange and Jam Nut Receptacles

Panel Cutouts

– –

Note: Diameter B cutout dimensions are listed separately

for back and front of panel mounting.

[ E

4x [ C[ B

MIN

FLANGE MOUNT

3.20(.126)

1.58(.062)

PANEL THICKNESS

JAM NUT

Shell

Size

ABBC D 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 .670 17.02 .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

44www.conesys.com sales@aero-electric.com

MIL–DTL– 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.

**** Daniels Manufacturing part number.

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) 1716P-1**** N/A N/A 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  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

45www.conesys.com sales@aero-electric.com

MIL–DTL– 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 ﬁrst, 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 after 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 ﬁlm. 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

ﬁrmly.

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

After all the cavities have been ﬁlled, 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

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.

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.