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Amphenol Aerospace
MIL-DTL-38999 Connectors Catalog

MIL-DTL-38999 Connectors Catalog

Product catalog summary

Overview: Amphenol Aerospace, a division of Amphenol Corporation, is a leading manufacturer of interconnect products for military, aerospace, and industrial markets. The company specializes in designing and producing a wide range of connectors and interconnect systems, including circular, rectangular, electronic, fiber optic, and EMI/EMP filter connectors.

Quality Assurance: Amphenol Aerospace holds AS9100 - Revision C and ISO9001:2008 Quality Assurance Certifications, ensuring high standards in their manufacturing processes.

Business Philosophy: The company focuses on serving specific market segments that require high levels of supplier support. Their strategy is built on three key principles: Focus, Innovation, and Responsiveness.

Product Specifications: The document details the MIL-DTL-38999 series connectors, which are designed for military, aerospace, and harsh environments. These connectors are available in Series III, II, I, SJT, and Aquacon, with various insert arrangements and contact sizes.

Insert Availability and Identification: The document includes extensive charts listing the availability and specifications of different insert arrangements for the MIL-DTL-38999 series. These charts specify the contact sizes, service ratings, and total contacts available for each series.

Key Features: - High-density insert patterns using size 23 contacts. - Hermetic inserts with solder termination as standard. - Options for pin or socket contacts, with some arrangements offering ground plane proprietary options.

Special Insert Arrangements: The document also outlines non-standard shell sizes and special insert arrangements, indicating which are not Mil-Spec qualified and providing details on contact sizes and service ratings.

Contact Information: For more information, Amphenol Aerospace can be contacted at their Sidney, NY facility, with customer service available Monday through Friday from 8 AM to 5 PM.

Connector Specifications:
The document outlines various connector types under the MIL-DTL-38999 standard, including Series I (LJT), Series II (JT), and Series III (Tri-Start). Each series has specific insert arrangements and contact configurations.

Insert Arrangements:
The document provides detailed insert arrangements for different connector types, specifying the number of contacts, contact size, and service rating. For example, Insert Arrangement #22-55 and #23-55 are detailed with contact locations and dimensions.

Contact Ratings:
Contact ratings are provided for different series, indicating test currents, maximum millivolt drop for crimp and hermetic contacts, and specific contact sizes. The document also includes crimp and solder well data for various contact sizes.

Contact Part Numbers:
The document lists commercial and military part numbers for contacts used in Series III and Series II connectors, including thermocouple contacts and sealing plugs.

Finish Data:
Information on finish options for aluminum shell components and hermetic connectors is provided, detailing military and commercial standards for various finishes like cadmium plating, anodic coating, and electroless nickel.

Service Ratings:
Suggested operating voltages and test voltages at different altitudes are specified for service ratings M, N, I, and II.

Durmalon Plating:
Durmalon is highlighted as a RoHS-compliant alternative to cadmium, offering properties like lubrication, anti-wetting, corrosion resistance, and high conductivity.

Introduction
Amphenol Aerospace introduces Durmalon, a cadmium-free alternative finish for connectors, addressing EU RoHS/ELV restrictions. This innovation targets commercial, industrial, and military markets moving away from toxic materials like Cadmium and Hexavalent Chromium.

Specifications
Durmalon is compliant with MIL-DTL-38999, Rev L, and EU RoHS Directive 2002/95/EC. It meets or exceeds the 38999 class "T" finish standards, offering a Nickel Fluorocarbon Polymer finish. Durmalon is cadmium, lead, and hexavalent chromium-free, with a temperature rating of 200°C and resistance to 500 hours of dynamic salt spray.

Alternative Platings
Amphenol also offers Black Zinc Nickel as a second RoHS-compliant alternative to cadmium. This non-reflective, conductive finish is approved for 500 hours of salt spray, suitable for harsh environments, and compatible with various connectors.

Applications
Both Durmalon and Black Zinc Nickel are gaining traction in aerospace and military defense sectors, replacing toxic cadmium with environmentally friendly options.

Testing and Performance
Amphenol has conducted extensive testing on these platings, ensuring compliance with rigorous standards. Durmalon and Black Zinc Nickel meet EU RoHS/ELV maximum concentration values and are tested against de-icing fluids.

Connector Features
The MIL-DTL-38999 Series III connectors offer high performance with features like EMI shielding, moisture resistance, corrosion resistance, and vibration/shock tolerance. They are available in various configurations, including high-density, hermetic, and fiber optics options.

Conclusion
Amphenol's Durmalon and Black Zinc Nickel finishes provide reliable, environmentally friendly alternatives to cadmium, meeting the evolving needs of aerospace and defense industries.

Overview: The document provides detailed technical specifications and features of Amphenol Aerospace's high-performance connectors, specifically focusing on the Dualok and HD38999 series. These connectors are designed for high vibration environments and offer significant weight savings and enhanced EMI shielding.

Key Features of Dualok Connectors:

Mates with standard D38999 receptacles and uses standard inserts.
Withstands vibration levels exceeding MIL-DTL-38999 standards.
Offers up to 42% weight savings with stainless steel and 10% with aluminum compared to standard designs.
Provides metal-to-metal bottoming for maximum EMI shielding.

Clutch-Lok Features:

High differential torque and self-tightening under vibration.
Intermateable with existing MIL-DTL-38999 Series III connectors.
Ideal for hard-to-reach areas where mating torque is difficult to apply.

Technical Specifications:

Electrical: Supports various AWG sizes with specific amp ratings and insulation resistance of 5000 megohms min.
Mechanical: Includes details on materials, protection, durability, and vibration resistance.
Environmental: Operating temperature range from -65°C to +175°C, with salt spray resistance varying by material.

HD38999 Series:

Offers 30% more contact density than standard 38999 connectors.
Qualified to MIL-DTL-38999 standards and available in various configurations including filter and hermetic versions.
Supports high-speed data transmission for Gigabit Ethernet applications.

Ordering Information: The document includes detailed instructions on how to order these connectors, specifying shell styles, service classes, and contact types. It also provides a conversion table for military to commercial shell styles.

Overview: This document provides technical specifications and ordering information for Amphenol connectors compliant with the EU RoHS directive 2002/95/EC. It includes details on various connector types, materials, finishes, and configurations.

Connector Types & Styles:

Receptacles: Wall Mounting, Box Mounting, Line, and Jam Nut Receptacles are available in various configurations such as TVPS00RF, TVP00RW, etc.
Plugs: Options include Straight Plug, Flange Mounted Plug, and Straight Plug with Dualok or Clutch-Lok.
Printed Circuit Board (PCB): Wall Mounting and Box Mounting Receptacles with options for double flange and clinch nuts.
Hermetic: Available only in stainless steel for Box Mounting and Jam Nut Receptacles.

Materials & Finishes:

Composite and Stainless Steel: Connectors are available in composite and stainless steel materials.
Finishes: Options include Electroless Nickel, Olive Drab Cadmium, and Passivated finishes, each with specific temperature and durability ratings.

Ordering Information:

Shell Size & Insert Arrangement: Detailed on pages 2-5, specifying shell size and insert arrangement numbers.
Contact Type: Options include Pin, Socket, and Eyelet contacts with various cycle ratings.
Alternate Keying: Key/keyway positions are specified for different connector configurations.
PCB Length: Specific to commercial and HD38999 connectors, with standard tail diameters and stick-out measurements.

Boeing BACC63 Ordering:

Styles: CT Composite Plug and CU Composite Receptacle.
Shell Finish & Contact: Options include Cadmium and Nickel plating, grounded or ungrounded.
Contact Type & Keying: Pin or Socket contacts with normal or alternate keying positions.

Technical Specifications:

Dimensions: Detailed dimensions for various shell sizes and configurations, including panel mounting options.
Performance Ratings: Temperature ratings up to 200°C and durability up to 2,000 hours, with specific dB ratings at 10GHz.

Additional Information: For more details, contact Amphenol Aerospace at 800-678-0141 or visit their website.

Overview: This document provides technical specifications and configurations for various connector types used in aerospace applications, specifically focusing on the Amphenol Aerospace connectors. It includes details on shell sizes, thread specifications, material options, and unique features such as the CLUTCH-LOK system.

Specifications:

Shell Sizes and Threads: The document lists multiple shell sizes (9 to 25) with corresponding thread specifications in both inches and metric measurements. It includes details for both TV and CTV series connectors.
Material Options: Connectors are available in aluminum, composite, and stainless steel, each with specific part numbers for different configurations.
Dimensional Details: Detailed dimensions are provided for various connector components, including maximum and minimum sizes for different parts of the connectors.

Procedures:

Assembly and Mating: The document highlights the importance of proper mating, indicated by red and blue bands, which signify fully mated connectors and rear release contact retention systems, respectively.
Mounting Options: Various mounting options are discussed, including jam nut receptacles and PCB wall mounting receptacles, with specific instructions on dimensions and configurations.

Features and Benefits:

CLUTCH-LOK System: Designed for high vibration environments, this system offers increased uncoupling torque and self-tightening under vibration, making it suitable for aircraft and military applications.
Intermateability: The connectors are fully intermateable with existing MIL-DTL-38999 Series III connectors, providing compatibility and flexibility in various applications.

Recommedations:

Consultation: Users are advised to consult Amphenol Aerospace for specific configurations and availability, especially for partially tooled parts.
Online Configurator: An online configurator is available for building part numbers and exploring different connector options.

Overview: This document provides detailed specifications and ordering information for Amphenol Aerospace's MIL-DTL-38999 Series III connectors, focusing on hermetic connectors with PCB tail and breakaway fail-safe connectors.

Specifications:

Base Number: 10-626 for MIL-DTL-38999 Series III Hermetic with PCB Tail.
Shell Sizes: Range from size 9 to 25, with specific dimensions provided for each size.
Materials: Options include passivated stainless steel, stainless steel with nickel plate, and carbon steel with reflowed tin plate.
Contact Types: Pin and socket contacts are available, with alternate keying positions detailed.

Ordering Procedure:

Select a base number and shell size from the provided chart.
Choose an insert arrangement and contact type.
Select a shell finish and tail length.

Breakaway Fail-Safe Connectors:

Designed for quick-disconnect applications with an axial pull of a lanyard.
Features include instant decoupling, EMI/EMP shielding, and solid metal-to-metal coupling.
Qualified to MIL-DTL-38999/29, /30, and /31 standards.

Key Features:

Red band indicates fully mated connectors.
Various lanyard lengths and custom configurations available.
Consult Amphenol Aerospace for non-glass-sealed versions and custom designs.

Contact Information: For more details, contact Amphenol Aerospace at 800-678-0141 or visit www.amphenol-aerospace.com.

Overview: The document provides detailed specifications and ordering information for Amphenol Aerospace's D38999 Series III connectors, specifically focusing on the fail-safe lanyard release plug-crimp, metal connectors used in military and commercial applications.

Specifications:

The connectors are available in various shell sizes, each with specific dimensions and thread metrics. The document includes tables listing maximum dimensions and accessory diameters for each shell size.
Materials include electroless nickel-plated aluminum and corrosion-resistant olive drab cadmium plate aluminum, offering different levels of EMI shielding and salt spray resistance.

Ordering Procedures:

Military part numbers are structured with a specific format, including DOD number prefix, specification sheet number, service class, lanyard length code, insert arrangement, contact style, alternate keying position, and type number.
Lanyard lengths are specified in both inches and millimeters, with corresponding codes for ordering.

Features and Benefits:

The connectors are designed for quick-disconnect with an axial pull of the lanyard, offering low force separation capabilities.
They are compatible with all mil-spec backshells and accessories and can mate with existing D38999 receptacles.
The commercial version offers more versatility than the mil-spec version, with a wider variety of insert arrangements.

Hybrid Breakaway Connectors:

A new hybrid lanyard breakaway connector is introduced, featuring a composite thermoplastic outer sleeve for greater durability and a lower profile compared to full metal designs.
This connector meets MIL-DTL-38999/31 requirements and is available in shell sizes 25 and 17.

Testing and Compliance:

The connectors undergo various tests, including durability, high impact shock, vibration, ice resistance, fail-safe disengagement, and high-speed pull separation, ensuring compliance with military standards.

Applications:

The connectors are used in military applications, such as the Navy F-18 program, and are designed for use on aircraft carrying rail launch missiles.

Overview: The document provides detailed specifications and ordering information for the Amphenol MIL-DTL-38999 Series I LJT and Series II JT connectors. These connectors are used in military and commercial applications, offering a variety of shell sizes, contact options, and configurations.

Specifications: The connectors come in nine shell sizes with options for crimp, solder, PCB, wire wrap, coaxial, twinaxial, triaxial, thermocouple, fiber optic, and filter contacts. They are available in both commercial and military versions, with hermetic options limiting air leakage to 1 x 10^-7 cm³ per second.

Features: The connectors feature a "Breakaway" lanyard release style for quick disconnect, inventory support commonality with standard MIL-DTL-38999 contacts, and RoHS compliance. They are constructed from impact extruded or machined bar stock aluminum with standard cadmium over nickel plating, with other finishes available.

Contact Options: The JT/LJT Series offers maximum design flexibility with 2 to 128 circuits per connector and contact sizes ranging from 8 to 22M. Contacts are gold-plated, probe-proof, and available in various termination styles.

Optional Features: High-temperature versions (up to 392°F) are available with specific plating and materials. N2O4 resistance is offered for certain connector types when mated and protected.

Ordering Information: The document includes detailed instructions for ordering both military and commercial versions, specifying shell size, insert arrangement, contact style, and keying positions. It also provides a conversion table for military to commercial shell styles.

Applications: These connectors are suitable for high-reliability applications requiring lot control and are available in various configurations, including hermetic and environmental versions.

Connector Specifications and Ordering Guide

1. Keying and Rotation: The connector design allows for a consistent appearance whether it contains pins or sockets. The master key/keyway rotates within the shell, while minor keys remain fixed. The AB angles are viewed from the front face of the connector, with the receptacle shown as a reference. The plug angles are identical but rotate in the opposite direction.

2. Keying Position Selection: Users can select an alternate keying position based on connector type, service class, shell size, insert arrangement, contact type, and special variations.

3. Strain Relief and Finish Options: Strain relief options, designated as "SR," are available for specific service classes (A, C, RE). Various finish options are available, including cadmium plated nickel, olive drab cadmium, electroless nickel, anodic coating, chromate treated, passivated steel, nickel-PTFE, and zinc-nickel plated. Each finish has a corresponding suffix for ordering.

4. Angle of Rotation: The document provides a table of AB angles of rotation for different shell sizes, indicating the normal, A, B, C, and D angles in degrees.

5. Service Class and Applications: The document outlines different service classes (RE, RP, RT, A, C) and their applications, such as environmental crimp applications, potting crimp applications, and general applications with strain relief.

6. Connector Dimensions: Detailed dimensions for various connector types and configurations are provided, including wall mounting receptacles, line receptacles, and jam nut receptacles. Dimensions are given for shell size, diameter, length, and thread specifications.

7. Part Number Builder: The document includes a part number builder for commercial and military connectors, specifying the format for ordering based on connector type, service class, and other parameters.

8. Contact Information: For further information, contact details for Amphenol Aerospace are provided.

Overview: This document provides detailed specifications and part number configurations for various connectors and receptacles used in aerospace applications. It includes both commercial and military-grade components, with specific focus on the 38999 Series II and III, SJT, and other related series.

Specifications: The document outlines dimensions and threading details for different shell sizes, ranging from size 8 to 24. Key parameters include diameter, length, and thread specifications, with UNEF (Unified National Extra Fine) threads being a common standard. The document also specifies modifications for military and commercial versions, such as grounding fingers and iridite finishes.

Part Number Builder: A significant portion of the document is dedicated to the part number builder, which helps in identifying the correct configuration for specific applications. It includes variations for standard, high-temperature, and hermetic versions, with clear distinctions between military and commercial parts.

Military and Commercial Standards: The document references several military standards, such as MS27473, MS27484, MS27500, and MS27336, indicating compliance with rigorous testing and performance criteria. These standards ensure reliability and durability in demanding environments.

Receptacle and Plug Types: Various types of receptacles and plugs are detailed, including straight plugs, 90° plugs, wall mounting, box mounting, and jam nut receptacles. Each type is described with its specific dimensions and applicable military standards.

Recommendations: For specific applications, the document advises consulting Amphenol Aerospace for availability and additional configurations, especially for back panel mounting types and hermetic versions.

Contact Information: For further inquiries, Amphenol Aerospace provides contact details, including a phone number and website, for customer support and additional information.

Overview: This document provides detailed specifications and ordering instructions for various types of connectors, specifically focusing on the JT and JTN series connectors used in commercial and military applications. It includes dimensions, part number configurations, and ordering guidelines.

Specifications:

The document lists dimensions for different shell sizes, including parameters like maximum and minimum dimensions, thread class, and panel thickness.
It provides detailed tables for various connector types, such as 90° Plug - Solder, Jam Mounting Receptacle - Solder, PCB Wall Mounting Receptacle, and others, with specific measurements for each shell size.

Ordering Procedures:

The document outlines a step-by-step process for ordering connectors, including selecting a shell finish, base number, coded shell size, insert arrangement, and contact type/alternate keying positions.
Each step is associated with specific charts and tables that provide the necessary codes and dimensions for accurate ordering.

Standards and Recommendations:

The connectors are military qualified to MIL-DTL-27599 and MIL-DTL-38999 standards, ensuring reliability and compatibility in military applications.
Recommendations for selecting shell finishes and contact types are provided, with references to additional charts for alternate keying positions.

Key Data from Tables:

Tables provide dimensions for shell sizes ranging from 8 to 24, with specific measurements for parameters like maximum length, thread class, and panel thickness.
Each table is tailored to a specific connector type, ensuring that users can find the exact specifications needed for their application.

Critical Information:

All dimensions are for reference only, and users are advised to consult Amphenol Aerospace for additional options and composite styles.
Contact information for Amphenol Aerospace is provided for further inquiries and ordering assistance.

Overview: This document provides technical specifications and ordering instructions for the MIL-DTL-38999 Series III connectors, specifically focusing on hermetic connectors with PCB tails. It includes detailed information on shell sizes, insert arrangements, contact types, finishes, and keying positions.

Specifications:

Base Number: 10-626 for MIL-DTL-38999 Series III hermetic connectors.
Materials: Options include passivated stainless steel, stainless steel with nickel plate, and carbon steel with reflowed tin plate.
Temperature Ratings: Up to 200°C for certain finishes.

Ordering Procedure:

Select a coded shell size from the chart (sizes 9-25).
Choose an insert arrangement from the availability chart and pin-out illustrations.
Determine contact type and keying positions from the specified pages.
Select a shell finish and tail length.

Shell Styles and Types:

Various mounting receptacles and plugs are available, including crimp, solder, and hermetic types.
Specific styles include wall mounting, box mounting, jam nut receptacles, and straight plugs.

Service Classes:

Crimp and solder options are available for different mounting styles.
Hermetic options include wall mount, jam nut, and solder mounting receptacles.

Finishes:

Options include cadmium plated nickel base, olive drab cadmium plate, electroless nickel, anodic coating, and passivated steel.

Keying Positions:

Alternate keying positions are designated by letters (A, B, C, D) with specific AB angles for each shell size.

Additional Information:

Contact Amphenol Aerospace for more details and ordering information.

Overview:
This document provides technical specifications and ordering information for various types of PCB mounting receptacles and connectors, specifically focusing on the MIL-DTL-38999 Series III. It includes details on dimensions, shell sizes, finishes, and contact arrangements.

Specifications:
- The document lists dimensions for different shell sizes ranging from size 9 to 25, with specific measurements for maximum length (L Max), diameter (N, M, SS), and thread types (UNEF, UNJC-3B).
- It specifies the PCB tail stickout dimensions for different contact sizes (16, 20, 22D).
- The document includes information on shell finishes, with options for olive drab cadmium plated and electroless nickel plated shells.

Ordering Procedures:
- The document outlines a step-by-step process for ordering connectors, including selecting a shell finish, base number, coded shell size, insert arrangement, and contact type/keying positions.
- It provides examples of part numbers and how to construct them based on the selected options.

Standards and Recommendations:
- All dimensions are provided for reference only, and it is recommended to consult Amphenol Aerospace for more detailed information and availability of specific options.
- The document suggests consulting additional charts and illustrations for insert arrangements and pin-out configurations.

Key Data from Tables:
- The tables provide detailed measurements for each shell size, including L Max, M, N, P Max, and thread specifications.
- They also list the base numbers and part numbers for different configurations, indicating the available options for each shell size.

Additional Information:
- The document mentions the availability of connectors with clinch nuts and hermetic seals, with specific part numbers for ordering.
- It highlights the availability of weld mounting hermetic receptacles and suggests consulting Amphenol for further details.

Overview: This document provides technical specifications and ordering information for Amphenol Aerospace connectors, specifically focusing on the MIL-DTL-38999 Series and LJT Breakaway Fail Safe connectors. It includes details on shell sizes, insert arrangements, contact types, finishes, and lanyard lengths.

Specifications: The document outlines various connector specifications, including dimensions, materials, and finishes. It specifies shell sizes ranging from 9 to 25, with detailed measurements for each size. The connectors are available in different materials such as stainless steel and carbon steel, with finishes like olive drab cadmium and electroless nickel plating.

Procedures: Instructions on how to order connectors are provided, detailing the selection of base numbers, shell sizes, insert arrangements, contact types, and finishes. The document also explains the process for selecting lanyard lengths and alternate keying positions to prevent cross-mating.

Standards and Recommendations: The connectors comply with MIL-DTL-38999 standards and are designed for high-performance applications requiring quick disconnect features. The document recommends using the LJT Series for quick-disconnect breakaway styles due to its superior performance in harsh environments.

Key Features: The LJT Breakaway Fail Safe connectors offer instant decoupling, damage-free separation, and EMI EMP shielding. They are intermateable with standard LJT receptacles and support a wide range of electrical and mechanical features.

Contact Information: For further details or custom requirements, the document advises contacting Amphenol Aerospace directly.

Overview: The document provides detailed technical specifications and configurations for Amphenol Aerospace's SJT and Aquacon series connectors, focusing on their design features, shell sizes, insert arrangements, and finish variations. It includes information on both hermetic and non-hermetic connectors, as well as specific applications and markets.

1. Finish Variations: The document outlines various finish options for aluminum shell components, including bright cadmium plating, anodic coating, and electroless nickel coating. Hermetic connectors are available with carbon steel or stainless steel shells.

2. Keying and Rotation: Connectors are designed with specific key/keyway rotations to ensure proper mating. The AB angle of rotation is consistent across different shell sizes, with detailed degrees provided for each size.

3. Shell Size and Insert Arrangement: The document lists shell sizes and corresponding insert arrangements, detailing the number of contacts and their configurations. It includes both pin and socket contact types.

4. Connector Types and Styles: Various connector types are described, including wall mounting receptacles, box mounting receptacles, jam nut receptacles, and straight plugs. Each type is available with specific features such as grounding fingers or hermetic sealing.

5. Aquacon Series Features: Designed for oceanic and fluid immersion applications, the Aquacon series offers features like 1500 PSI capability, threaded coupling, and visual mating indicators. It includes both hermetic and non-hermetic options.

6. Contact Ratings and Service Ratings: The document provides test current ratings and maximum millivolt drop for different contact sizes. Service ratings suggest operating voltages for various conditions.

7. Alternate Positioning: Alternate positioning is achieved through rotation of the master key/keyway, allowing connectors with identical insert arrangements to be mounted side by side without cross-mating.

8. Typical Markets: The SJT series is used in military and commercial aviation, military vehicles, and applications compliant with European specifications. The Aquacon series is suitable for oceanic applications, Navy Seal breathers, and space applications requiring water immersion.

Overview: This document provides detailed technical specifications and ordering information for Amphenol Aerospace's Aquacon series connectors, specifically the 38999 type. It includes information on insert arrangements, service ratings, contact sizes, and ordering instructions for various connector types and styles.

Specifications:

Insert Arrangements: The document lists various insert arrangements with corresponding service ratings, number of contacts, and contact sizes. For example, arrangement 20-2 has a service rating of M, 65 contacts, and uses size 22 contacts.
Contact Types: The document specifies different contact types such as non-removable solder termination, removable crimp termination, and hermetic solder termination.
Shell Sizes and Threads: Detailed dimensions and thread specifications are provided for different shell sizes, including UNEF and UNS thread classes.

Procedures:

Ordering Instructions: The document outlines a step-by-step process for ordering connectors, including selecting shell size, insert arrangement, contact type, and special variations.
Installation Instructions: Recommendations for assembly to cable using molding techniques are provided, along with sealing and mounting instructions to ensure hydrostatic integrity.

Standards and Norms:

Service Ratings: The document categorizes connectors into service ratings I, II, and M, indicating their suitability for different applications.
Hydrostatic Pressure Conversion: A conversion table is included to relate salt-water depth to hydrostatic pressure in pounds per square inch.

Recommendations:

Sealing Practices: Emphasizes the importance of fully tightening the coupling nut to ensure a reliable, pressure-rated sealed joint.
Alternate Positioning: Advises using alternate position inserts only when necessary to avoid complications during installation.

Additional Information: The document includes contact information for Amphenol Aerospace for further inquiries and specifies that additional insert arrangements may be available upon request.

Overview: This document provides technical specifications and procedures for the installation and maintenance of Amphenol Aerospace's MIL-DTL-38999 Series connectors and accessories, including Aquacon III and SJT series. It covers contact installation, wire preparation, and accessory options for enhanced connector performance.

Wire and Cable Preparation: The document outlines the recommended wire stripping lengths for different contact types and sizes. It emphasizes the use of hot wire stripping methods to avoid damaging wire strands.

Solder Contact Termination: Instructions are provided for cleaning and pre-tinning conductors, soldering techniques, and recommended soldering equipment wattage for different contact sizes.

Crimp Contact Termination: The document details the selection of crimping tools, proper wire positioning, and the crimping process to ensure a secure connection.

Contact Insertion and Removal: Procedures for inserting and removing contacts using appropriate tools are described, including the use of sealing plugs for unused grommet holes.

Accessories and Tools: A comprehensive list of accessories for MIL-DTL-38999 Series connectors is provided, including backshells, protection caps, dummy receptacles, cable clamps, and strain reliefs. The document specifies different types of backshells, such as environmental and EMI/RFI backshells, and provides part numbers for ordering.

Protection Caps and Dummy Receptacles: Specifications for protection caps and dummy receptacles, including dimensions and material finishes, are detailed for various shell sizes.

Breakaway Connectors: Information on accessories for Breakaway Fail Safe connectors, including low profile backshells, dummy contacts, and wire combs, is provided to enhance connector performance and ease of assembly.

Contact Information: For further details and ordering information, contact Amphenol Aerospace via their website or phone number provided in the document.

Overview: This document provides technical specifications and ordering information for Amphenol Aerospace's MIL-DTL-38999 Series connectors and accessories, including protection caps, strain reliefs, and header assemblies.

Specifications:

Protection Caps: Available for both plug and receptacle configurations across Series I, II, and III. Dimensions and finishes vary by shell size, with options for chromate treatment, anodic coating, cadmium plating, olive drab cadmium, and electroless nickel.
Strain Reliefs: Offered in crimp and solder types, with specific dimensions and thread sizes for each shell size. Finishes include chromate, anodic, cadmium, olive drab cadmium, and electroless nickel.
Header Assemblies: Designed for easy separation of connectors from PC boards, available in circular and square configurations. Materials include FR-4 with gold and nickel plating for electrical contacts.

Ordering Information:

Accessories must be ordered by MS part number for military stamping identification. If ordered by 10-part number, they will be stamped with that number.
To complete order numbers, add shell size and suffix number. Examples are provided for various configurations and finishes.

Key Features:

Protection caps and strain reliefs are designed to protect connectors from environmental damage.
Header assemblies facilitate cost and time savings in manufacturing and allow for easy electrical testing and connector removal.
Mounting applications are versatile, accommodating various connector series without special alterations.

Contact Information: For more details, contact Amphenol Aerospace at 800-678-0141 or visit their website at www.amphenol-aerospace.com.

Overview: This document provides technical specifications, procedures, and guidelines for the assembly and maintenance of connectors, specifically the MIL-DTL-38999 Series III connectors. It includes details on contact sizes, crimping tools, insertion and removal tools, and wire stripping instructions.

Specifications:

Contact sizes and PCB tail diameters are specified for sizes 16, 20, 22, and 23, with corresponding acceptable diameters for PCB tails.
Shell sizes and insert arrangements are detailed, with specific dimensions provided for each shell size.
Contact PCB stickout lengths are specified for different shell sizes and suffixes.

Tools and Equipment:

Crimping tools: Various M22520 series tools are recommended for different contact sizes and types, ensuring reliable crimped wire to contact terminations.
Insertion and removal tools: Specific tools are recommended for inserting and removing contacts, with both plastic and metal options available depending on wire diameter.

Procedures:

Wire Stripping: Instructions are provided for stripping wire to the required length, ensuring no damage to wire strands.
Crimping: Detailed steps for using crimping tools to secure wires inside contacts, including visual inspection requirements.
Contact Insertion: Guidelines for inserting contacts into connectors, emphasizing alignment and pressure application.
Contact Removal: Steps for removing contacts using appropriate tools, with caution against spreading or rotating tool tips.

Recommendations:

Use the correct tools and follow specified procedures to ensure proper assembly and maintenance of connectors.
Refer to sealing plug charts for filling empty cavities after contact insertion.
Use connector pliers and holding tools when reassembling plug or receptacle hardware.

Additional Information: For further details, contact Amphenol Aerospace or refer to the MIL-STD-1560 or 1669 documents for insert coordinates.

Catalog excerpts

MIL-DTL-38999 Connectors FOR MILITARY, AEROSPACE AND HARSH ENVIRONMENTS 40-60 Delaware Avenue, Sidney, NY 13838-1395 • 800-678-0141 www.amphenol-aerospace.com • www.amphenolmao.co

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About Amphenol® Aerospace Your Source for Interconnect Products Amphenol Aerospace 40-60 Delaware Avenue Sidney, NY 13838-1395 Customer Service: Mon - Fri 8AM - 5PM Phone: (800) 678-0141 Fax: (607) 563-5157 Online: www.amphenol-aerospace.com Amphenol Aerospace, Amphenol Commercial Air, and Amphenol Industrial Operations Main Facility in Sidney, NY USA ABOUT AMPHENOL AEROSPACE: Amphenol Aerospace, a Division of Amphenol Corporation, is one of the largest manufacturers of interconnect products in the world for the Military, Commercial Aerospace and Industrial markets. Amphenol designs, manufactures...

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MIL-DTL-38999, Series I LJT, II JT, III TV, HD Insert Availability and Identification Chart 38999 III II I SJT Series Military Crimp Class Class TV* H Y Contact Size Completely tooled. Majority of tooling is completed (contact Amphenol Aerospace for availability). u Not tooled for 02-R. P Available with Pin contacts only S Available with Socket contacts only P/S Available with Pin contacts or Socket contacts H Ground plane proprietary option available. Arrg. 9-5 is exclusively ground plane type. n Not Mil-Qualified. G 21-75 is Mil-Qualified with twinax contacts only. Note: MS connector 21-75...

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Amphenol Aerospace Series Series Series Military 38999 Contact Amphenol Aerospace for more information at 800-678-0141 • www.amphenol-aerospace.com

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MIL-DTL-38999, Series I LJT, II JT, III TV, HD Insert Availability and Identification Chart 38999 Completely tooled. Majority of tooling is completed (contact Amphenol Aerospace for availability). u Not tooled for 02-R. P Available with Pin contacts only S Available with Socket contacts only P/S Available with Pin contacts or Socket contacts H Ground plane proprietary option available. Arrg. 9-5, 26-62 is exclusively ground plane type. n Not Mil-Qualified. G 21-75 is Mil-Qualified with twinax contacts only. * Hermetic inserts - solder termination standard. (Contact Amphenol Aerospace for optional...

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TV SERIES IIISELECT SHELL SIZE - SPECIAL INSERT ARRANGEMENTLJT SERIES ISELECT SHELL SIZE - SPECIAL INSERT ARRANGEMENT (Not Mil-Spec Qualified) Contact Size Shell Size-Insert Arrg. SELECT NON-STANDARD SHELL SIZE - Special Insert Arrangement Contact Size Shell Size-Insert Arrg. (Insert arrangements requiring non-standard shells) X Completely tooled. + Majority of tooling is completed (contact Amphenol Aerospace for availability). ♦ Not tooled for 02-R. P Pin inserts only (contact Amphenol Aerospace for socket availability). * Ground plane proprietary option available. Arrangement...

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MIL-DTL-38999, Series I LJT, II JT, III TV, HDInsert Arrangements Front face of pin inserts illustrated Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Cont Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Cont Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts 8 Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts 14 Contact Size Shell Size & Insert Arrg....

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Amphenol Aerospace Front face of pin inserts illustrated 38999 Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Conti Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts 29 Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT 19-67 Series III TV Service Rating M HD: High Density HD38999 (use size 23 contacts only) Contact Amphenol Aerospace for...

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Front face of pin inserts illustrated Shell Size & Insert Arrg. for: Series II JT 20-1 Series III TV Service Rating M Shell Size & Insert Arrg. for: Series II JT Series I LJT 21-27 Series III TV Service Rating I Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV ^^^^21-48 Service Rating M Contact Size 8 power @) ((§)) © © e • ° t, a HD: High Density HD38999 (use size 23 contacts only) Note: MS connector 21-75 is supplied with four size 8 twinax contacts. Commercial connector 21-75 is supplied with four size 8 coax contacts. MS connector...

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Amphenol Aerospace Front face of pin inserts illustrated 38999 Shell Size & Insert Arrg. for: Series II JT | Series I LJT Series III TV Service Rating Number of Contacts Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT 23-97 Series III TV Service Rating II HD: High Density HD38999 (use size 23 contacts only) Contact Amphenol Aerospace for more information at 800-678-0141 • www.amphenol-aerospace.com

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38999 Series III, II, I MIL-DTL-38999, Series I LJT, II JT, III TVInsert Arrangements Front face of pin inserts illustrated Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size (With Matched Impedance) Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Cont Contact Size CONTACT LEGEND 10 Contact Amphenol Aerospace for more information at 800-678-0141 • www.amphenol-aerospace.com...

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Front face of pin inserts illustrated Amphenol Aerospace Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size Shell Size & Insert Arrg. for: Series II JT Series I LJT Series III TV Service Rating Number of Contacts Contact Size CONTACT LEGEND t Coax contacts for RG180/U or RG195/U cable. HD: High Density HD38999 (use size 23 contacts only) Contact Amphenol Aerospace for more information at 800-678-0141 • www.amphenol-aerospace.com...

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MIL-DTL-38999 Connectors Catalog

MIL-DTL-38999 Connectors Catalog

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