Qualification Test Report. DRCP 86 Pin Inline DTR # /6/2012

Transcription

1 Qualification Test Report DRCP 86 Pin Inline DTR # /6/2012

2 1.0 SPECIFICATION REFERENCES Industrial 1.1 DCPM 2000 Deutsch Calibration Procedures Manual 2.0 TEST CONDITIONS AND EQUIPMENT 3.1 Test Conditions Unless otherwise specified all test and measurements were conducted within the following conditions. Temperature +18C to +35C (+65F to +95F) Relative Humidity 5% to 95% Barometric Pressure 650 to 800 mm Hg 3.2 Test Equipment Instrument calibration was performed in accordance with Deutsch Calibration Procedure Manual DCPM 2000 prior to using the instrument for testing. Calibration records are maintained and are directly traceable to the National Bureau of Standards with no more than three levels of separation. The following data concerning the test equipment was recorded on the data format for each test: a. Descriptive name. b. Laboratory identification. c. Date of last calibration prior to use. 3.0 DOCUMENTATION 4.1 Recorded Data All measurements were recorded to as many significant digits as are meaningful under the accuracy limits of the equipment used. All data was recorded on 8 ½ x 11 data forms. The ambient test conditions (temperature and relative humidity) and the date were recorded on the data form. If a test was conducted on more than one day, the ambient test conditions and dates were recorded for each testing day. The data includes whenever applicable, any diagrams and sketches of the following:

3 a. Electrical hookups that are peculiar to this test program or might prohibit duplication of the test method and results involved if not supplied. b. The orientation of samples to the direct force imparted during any physical shock or vibration testing. c. Any fixtures that would be used for mounting the test samples that were fabricated exclusively for this sequence. 4.0 TEST COMPONENTS 5.1 Test Samples Part Number DRCPF-86A-1 DRCP24-86PA DRCP28-86SA Description Inline Frame Key A Receptacle Key A Plug Key A #20 sleeveless stamped socket Tin #12/14 stamped socket Nickel/Tin #10 /12 stamped socket - Nickel #20 Sealing Plug #12/16 Sealing Plug 5.2 Wire Samples Each test group was wired with the appropriate wire size for the individual tests. Sealing groups were wired with wire samples representing the full connector sealing range. All wire samples were chemically cross-linked polyethylene insulated per SAE J1128. All samples were crimped to each contact with Deutsch DCT DCT crimp tooling. Note: Test wire samples are within sealing range of connector see Envelope DWG Connector Sealing Range SEALING RANGE CAVITY SIZE MINIMUM MAXIMUM #20.063" [1.6mm].124" [3.15mm] #12.118" [3.0mm].210" [5.3mm]

4 Test Samples Specification Sample Insulation OD - Max Measurements J1128 inch mm inch mm 20 TXL TXL SXL SXL SXL SXL SXL TEST GROUPS 6.1 Group Description Test groups were created to test the functionality of the DRCP 86 Pin Inline connector system. The test groups include group 1, 2, 3 and 4 qualification groups. The sample parts were divided into test groups as follows: Group 1 Group 2 Group 3 Group 4 Intended to confirm thermal and sealing performance. Intended to confirm mechanical performance. Intended to confirm vibration and electrical performance. Intended to confirm thermal and chemical resistance.

5 7.0 Test Sequence Each sample group was subjected to the following test methods as outlined below. The tests were conducted in the order shown. Group 1 Sealing Para. 1. Visual Inspection Insulation Resistance Thermal Shock Liquid Dunk Insulation Resistance Visual Inspection Thermal Cycle Thermal Shock Liquid Dunk Insulation Resistance Visual Inspection Temperature Life Thermal Shock Liquid Dunk Insulation Resistance Visual Inspection Pressure Washing Insulation Resistance Visual Inspection Sealing, External Air Pressure Sealing Interior Air Pressure Visual Inspection Group 2 Mechanical Para. 1. Visual Inspection Durability Terminal Retention Axial Terminal Retention Rotation Cross Key Mating Scoop Proof Mating Connector Coupling Strength Maintenance Aging Terminal Retention Axial Terminal Retention Rotation Drop Crimp Tensile Over Torque Visual Inspection Group 3 Vibration Para. 1. Visual Inspection Low Signal Contact Resistance Voltage Drop Thermal Cycle Low Signal Contact Resistance Voltage Drop Vibration Low Signal Contact Resistance Voltage Drop Visual Inspection

6 Group 4 Chemical Para. 1. Visual Inspection Salt Exposure Insulation Resistance Chemical Exposure Diesel Bio-Diesel Kerosene Motor Oil Brake Fluid Coolant Transmission Oil Urea 5. Sealing Interior Air Pressure Sealing Interior Air Pressure Visual Inspection 9.4.7

7 8.0 Sample Description 8.1 Group 1 - Sealing Test samples 1 through 4 wired with crimped 4ft test leads. Test leads to include service connectors for insulation resistance test. Samples 5 and 6 mounted rigidly on the plate fixture with sealing plugs on receptacles and wires on plugs. Group 1 Sample Number Wire Size 1 18 SXL 12 SXL 2 18 SXL 12 SXL 3 18 SXL 12 SXL 4 18 SXL 12 SXL 5 18 SXL Sealing Plugs 12 SXL Sealing Plugs 6 18 SXL Sealing Plugs 12 SXL Sealing Plugs 8.2 Group 2 Mechanical One test sample wired with crimped 2ft test leads. Group 2 Sample Number Wire Size 1 (Key A) 18 SXL 12 SXL 8.3 Group 3 Vibration All test samples wired with crimped 4 ft test leads. Wires to include service connectors and millivolt drop taps. Frame mounted rigidly to vibration fixtures. Wire bundles to be tie-wrapped in the down direction for samples 1 and 2, and in the "across" direction for sample 3. Subtract reference wire reading from the total. Group 3 Sample Number Wire Size 1 18 SXL 12 SXL 2 18 SXL 12 SXL 3 18 SXL 12 SXL

8 8.4 Group 4 Chemical All test samples wired with crimped 2 ft test leads. Test leads to include service connectors for insulation resistance test. Group 4 Sample Fluids Temperature Time Wire Size 1 Diesel Fuel #2 60ºC 24 hours 18 SXL 12 SXL 2 Bio-Diesel Fuel (including Toyu) 60ºC 24 hours 18 SXL 12 SXL 3 Kerosene 60ºC 24 hours 18 SXL 12 SXL 4 Motor Oil 30wt 120ºC 7 Days 18 SXL 12 SXL 5 Brake Fluid (disc type 1) 25ºC 24 hours 18 SXL 12 SXL 6 50/50 Antifreeze / Water mixture 100ºC 24 hours 18 SXL 12 SXL 7 Transmission Oil 90wt 100ºC 7 Days 18 SXL 12 SXL 8 Urea (32.5%) / Water (67.5%) 25ºC 24 hours 18 SXL 12 SXL

9 9.0 TEST METHOD AND RESULTS The validation test and its results are summarized in the following pages. Refer to the Appendix for the detailed laboratory test forms. 9.1 GROUP 1 -- SEALING Visual Inspection Test Method: 1. The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship. 2. Poor molding fabrication, loose materials, damaged or improperly manufactured contacts, galling of metal parts, nicks and burrs of metal parts, torn seals or cracked plastic are considered adequate basis for rejection. Requirements: The connectors shall be correctly constructed, marked and shall show good quality and workmanship. Connector after conditioning shall not show signs of damage or any detectable loss of function. Results: The connectors were thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to part function Insulation Resistance Test Method: Checked insulation resistance between each contact to all other contacts and shell using a 1000 VDC Megohmmeter. Requirements: The resistance shall be 10 megohms minimum. Results:

10 The insulation resistance exceeded 10 megohms for all the tested samples Thermal Shock Liquid Dunk Test Method: The wired mated test samples were placed in an oven at +125±3ºC for two hours and then immediately be placed in water with 5% salt by weight content and 0.1g/L wetting solution to a depth of 1 meter for 30 minutes. The free ends of wires were sealed and remained out of the water. Requirements: Test samples must meet Insulation Resistance per section and Visual Inspection per section Results: Inspected samples per section and Insulation Resistance Test Method: After thermal shock liquid dunk per section 9.1.3, checked insulation resistance between each contact to all other contacts and shell using a 1000 VDC Megohmmeter. Requirements: The resistance shall be 10 megohms minimum. Results: The insulation resistance exceeded 10 megohms for all the tested samples Visual Inspection Test Method: Each sample was visually inspected for anything that could affect the performance or serviceability of the product. Results:

11 There was no evidence of leaking, cracking or detrimental damage to the test samples Thermal Cycle Test Method: Mated test samples were thermal cycled a total of 20 complete cycles between -55±3ºC and +125±3ºC at the rate of 3ºC per minute. Test samples were remained at each temperature extreme for one hour. Requirements: There shall be no evidence of cracking, distortion or other damage detrimental to the normal operation of the connector. Results: No visual or mechanical degradation was observed following the test Thermal Shock Liquid Dunk Test Method: After thermal cycle per section 9.1.6, the wired mated test samples were placed in an oven at +125±3ºC for two hours and then immediately be placed in water with 5% salt by weight content and 0.1g/L wetting solution to a depth of 1 meter for 30 minutes. The free ends of wires were sealed and remained out of the water. Requirements: Test samples must meet Insulation Resistance per section and Visual Inspection per section Results: Examined samples per section and Insulation Resistance Test Method:

12 After thermal shock liquid dunk per section 9.1.7, checked insulation resistance between each contact to all other contacts and shell using a 1000 VDC Megohmmeter. Requirements: The resistance shall be 10 megohms minimum. Results: The insulation resistance exceeded 10 megohms for all the tested samples Visual Inspection Test Method: Each sample was visually inspected for anything that could affect the performance or serviceability of the product. Results: There was no evidence of cracking, distortion or detrimental damage to the test samples Temperature Life Test Method: The wired and mated connectors were subject to 1000 h at 125 C ±3 C. Requirements: No visual or mechanical performance degradation is allowed. Results: There was no evidence of cracking, distortion or detrimental damage to the test samples following the test Thermal Shock Liquid Dunk Test Method:

13 The wired mated test samples were placed in an oven at +125±3ºC for two hours and then immediately be placed in water with 5% salt by weight content and 0.1g/L wetting solution to a depth of 1 meter for 30 minutes. The free ends of wires were sealed and remained out of the water. Requirements: Test samples must meet Insulation Resistance per section and Visual Inspection per section Results: Inspected samples per section and Insulation Resistance Test Method: After thermal shock liquid dunk per section , checked insulation resistance between each contact to all other contacts and shell using a 1000 VDC Megohmmeter. Requirements: The resistance shall be 10 megohms minimum. Results: The insulation resistance exceeded 10 megohms for all the tested samples Visual Inspection Test Method: Each sample was visually inspected for anything that could affect the performance or serviceability of the product. Results: There was no evidence of leaking, cracking or detrimental damage to the test samples Pressure Washing Test Method:

14 The mated test samples were mounted firmly onto a push cart. Test sample 5 and 6 with fixture plates were mounted onto sealed aluminum boxes with receptacles secluded inside. The inline connectors and plugs of sample 5 and 6 were exposed to the room temperature water spray for about 3 to 5 seconds period per connector for a total of 60 minutes. The fan nozzles, with a source pressure of approximately 1750 psi gage, were located 20 to 30 cm away providing 100% coverage of the test sample. Requirements: All test samples must meet Insulation Resistance per section Test samples 5 and 6 must also meet Visual Inspection per section Results: Examined samples per section and Insulation Resistance Test Method: After pressure washing per section , checked insulation resistance between each contact to all other contacts and shell using a 1000 VDC Megohmmeter. Requirements: The resistance shall be 10 megohms minimum. Results: The insulation resistance exceeded 10 megohms for all the test samples Visual Inspection Test Method: Each sample was visually inspected for anything that could affect the performance or serviceability of the product. Test sample 5 and 6 were removed from the aluminum boxes and inspected for leaking inside. Results: There was no evidence of leaking or detrimental damage to the test samples.

15 Sealing, External Air Pressure Test Method: The mated test sample was placed in the sealed pressure chamber with vent tube attached. A 35±5 kpa dry compressed air source was applied to the chamber for 30 minutes minimum. Requirements: No air bubbles are allowed to exit the vent tube after the first fifteen minutes. Results: Intermittent bubbles were observed coming out of the vent tube after the first fifteen minutes Sealing, Interior Air Pressure Test Method: The mated test sample was completely submerged in the water with a pressure tubing introduced into the sealed portion of the test sample. Pressure was slowly applied from zero to 35 kpa at a rate about 2 kpa/sec and maintained at the peak for 30 minutes minimum. Requirements: After 15 minutes, no air bubbles are allowed to leak from the sample. Results: There was no air bubbles observed after the first 15 minutes Visual Inspection Test Method: This was the last step of this group. Each sample was unmated and visually inspected for evidence of leaking, cracking or anything that could affect the performance or serviceability of the product. Results:

16 There was no evidence of leaking, cracking or detrimental damage to the test samples. 9.2 GROUP 2 -- MECHANICAL Visual Inspection Test Method: 1. The connector was visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship. 2. Poor molding fabrication, loose materials, damaged or improperly manufactured contacts, galling of metal parts, nicks and burrs of metal parts, torn seals or cracked plastic are considered adequate basis for rejection. Requirements: The connector shall be correctly constructed, marked and shall show good quality and workmanship. Connector after conditioning shall not show signs of damage or any detectable loss of function. Results: The connector was thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to part function Durability Test Method: The connector was mated and unmated for a total of 50 complete cycles at room temperature. The connector was re-torqued to the recommended torque in*lb [5-7 N*m] after each cycle. Requirements: After 50 cycles, There should be no evidence of damage to the contacts, contact plating, connector housing or seals following the test. No visual or mechanical degradation is permitted. Results:

17 There was no visual or mechanical degradation observed after 50 mating cycles Terminal Retention Axial Test Method: The receptacle pins were axially loaded by the force of 89N (20 lbf) on the 20 size contact and 111 N (25 lbf) on the 12 size contact. The force was applied at a uniform rate of in/min. Terminal position assurance device was utilized and in the locked position during the test. Four pins of 20 size contact and one pin of 12 size contact were tested. Requirements: 1. The contact displacement shall not exceed 0.8mm for both 20 size and 12 size contact. 2. The maximum bearing load for the 20 size contact and 12 size contact before separation shall be greater than 89N (20 lbf) and 111N (25 lbf) respectively. Results: Test sample met the force requirement. Please refer to the lab test form Para in the appendix I for the displacement results Terminal Retention Rotation Test Method: The wired receptacle was rigidly mounted on the table such that the wires could hang downward vertically. A 4.54 kg (10 lbs) weight was affixed to the end of a 610 mm (2 feet) long wire. Each pin in the cavity was rotated by five full turns by spinning the weighted wire. Eight pins of 20 size contact and one pin of 12 size contact were tested. Requirements: There shall be no mechanical degradation or discontinuity following the test. Results: Please refer to the lab test form Para in the appendix I for the results Cross Key Mating

18 Test Method: A mating force of 350 N was applied while attempting to cross-key mate by aligning connector halves into each geometric possible position. All key design possibilities were inspected and tested. Electrical contact was monitored during the test. Requirements: For all connector key design options, connector halves must only mate in one position. Any partial mating of connectors with electrical contact is considered to be a failure. Results: There was no evidence of cracking, distortion or detrimental damage to the key configuration Scoop Proof Mating Test Method: The wired connector was mated through all kinds of intended improper orientation during assembly. Requirements: The connector shall incorporate features preventing its contacts, either male or female, from being touched by the front of the mating connector by improper assembly. Results: All the contacts of the connector were untouched due to the scoop proof features Connector Coupling Strength Test Method: A tensile load of 100 lb [445 N] was applied to the wire bundle of the mated connector for a period of one (1) minute. Requirements:

19 The mated test sample shall withstand 100 lb [445 N] load for a minimum of 30 sec without any damage or disengagement. No visual or mechanical degradation is permitted. Results: There was no evidence of cracking, distortion or detrimental damage to the connector and no uncoupling following the test Maintenance Aging Test Method: Eight pins of 20 size contact and two pins of 12 size contact in receptacle were subjected to a total of ten cycles of inserting and removing its respective contact. Disassembly of the terminal position assurance device required to remove the contacts was included. The connector was mated and unmated in each cycle. Insertion and removal was performed using manufacturer's recommended tools. The pins tested were different from the ones been tested in Terminal Retention Axial and Rotation per section and Requirements: No mechanical degradation or failure is permitted. Results: No failure was observed. Examined connector for mechanical degradation per section and Terminal Retention Axial Test Method: The pin in receptacle was axially loaded by the force of 89N (20 lbf) on 20 size contact and 111 N (25 lbf) on 12 size contact. The force was applied at a uniform rate of in/min. Terminal position assurance device was utilized and in the locked position during the test. Half of the contacts been tested in Maintenance Aging per section were selected. Requirements: 1. The contact displacement shall not exceed 0.8mm for both 20 size and 12 size contact.

20 2. The maximum bearing load for the 20 size contact and 12 size contact before separation shall be greater than 89N (20 lbf) and 111N (25 lbf) respectively. Results: There was no obvious mechanical degradation observed following Maintenance Aging test per section Please refer to the lab test form Para in the appendix I for the results Terminal Retention Rotation Test Method: The wired receptacle was rigidly mounted on the table such that the wires could hang downward vertically. A 4.54 kg (10 lbs) weight was affixed to the end of a 610 mm (2 feet) long wire. Each pin in the cavity was rotated by five full turns by spinning the weighted wire. The other half contacts been tested in Maintenance Aging per section were selected. Requirements: There shall be no mechanical degradation or discontinuity following the test. Results: There was no obvious mechanical degradation observed following Maintenance Aging test per section Please refer to the lab test form Para in the appendix I for the results Drop Test Method: Wired receptacle was attached to free end of a 5 feet long cord. The other end of the cord was fixed to a wall at a height of 2.5 feet above concrete floor. The test sample was held so that the cord was horizontal and then fell to the concrete floor eight times. Test sample was rotated approximately 45 degrees at its fixing each time. Requirements: There shall be no evidence of cracking, distortion or detrimental damage to the connector. Small chips and dents that do not affect connector's performance or serviceability are disregarded.

21 Results: Only small chips and dents were observed on the backshell following the test Crimp Tensile Test Method: The tensile strength of the crimped connection was tested using a tensile tester without the influence of an insulation strain relief crimp. An axial force was applied to the wire and terminal at a speed of 25.4 ± 6mm per minute separating the contact and conductor. 18 SXL and 12 SXL wires were tested. Requirements: The minimum crimp tensile force for the 18 SXL and 12 SXL wires are 111 N and 311 N respectively. Results: All tested terminals met the minimum force values Over Torque Test Method: The connector was torqued to 92 in*lb [10.5 N*m] which is 1.5 times of the maximum allowable torque. Requirements: There should be no evidence of cracking, distortion or detrimental damage to the test samples. Results: No cracking, distortion or detrimental damage to the test sample observed following the test Visual Inspection Test Method:

22 This was the last step of this group. Each sample was visually inspected for evidence of cracking, distortion or anything that could affect the performance or serviceability of the product. Results: The connectors were thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to the part function. 9.3 GROUP 3 -- VIBRATION Visual Inspection Test Method: 1. The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship. 2. Poor molding fabrication, loose materials, damaged or improperly manufactured contacts, galling of metal parts, nicks and burrs of metal parts, torn seals or cracked plastic are considered adequate basis for rejection. Requirements: The connectors shall be correctly constructed, marked and shall show good quality and workmanship. Connector after conditioning shall not show signs of damage or any detectable loss of function. Results: The connectors were thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to part function Low Signal Contact Resistance Test Method: The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading. Requirements:

23 The maximum contact resistance shall be 6 milliohms for 16 AWG wire and 9 milliohms for 18 AWG wire. Results: All the contacts of each connector were tested and passed the requirements Voltage Drop Test Method: The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements. Requirements: The voltage drop shall not exceed 100 millivolts. Results: All the samples tested passed the requirements Thermal Cycle Test Method: Mated test samples were thermal cycled a total of 20 complete cycles between -55±3ºC and +125±3ºC at the rate of 3ºC per minute. Test samples were remained at each temperature extreme for one hour. Requirements: There shall be no evidence of cracking, distortion or other damage detrimental to the normal operation of the connector. Results: No visual or mechanical degradation was observed following the test Low Signal Contact Resistance

24 Test Method: The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading. Requirements: The maximum contact resistance shall be 6 milliohms for 16 AWG wire and 9 milliohms for 18 AWG wire. Results: All the contacts of each connector were tested and passed the requirements Voltage Drop Test Method: The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements. Requirements: The voltage drop shall not exceed 100 millivolts. Results: All the samples tested passed the requirements Vibration Test Method: Three wired and mated connectors were rigidly mounted to three mutually perpendicular axis and randomly vibrated for 20 hours in each axis. Vibration profile was attached in the appendix I Para The wire harness was bent 90 degree and firmly tied to the router with tie-wraps. Backshell was included during vibration. The free end was hooked up to the discontinuity monitor from which 100 milliamps load was applied. Requirements:

25 There shall be no discontinuity greater than 10 ohms in excess of 1 microsecond. Any physical damage or loosening of components are not allowed. Results: All the samples passed the vibration test Low Signal Contact Resistance Test Method: The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading. Requirements: The maximum contact resistance shall be 6 milliohms for 16 AWG wire and 9 milliohms for 18 AWG wire. Results: All the contacts of each connector were tested and passed the requirements Voltage Drop Test Method: The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements. Requirements: The voltage drop shall not exceed 100 millivolts. Results: All the samples tested passed the requirements Visual Inspection Test Method:

26 This was the last step of this group. Each sample was visually inspected for evidence of cracking, distortion, terminal fretting or anything that could affect the performance or serviceability of the product. Results: The connectors were thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to the part function. 9.4 GROUP 4 -- CHEMICAL Visual Inspection Test Method: 1. The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship. 2. Poor molding fabrication, loose materials, damaged or improperly manufactured contacts, galling of metal parts, nicks and burrs of metal parts, torn seals or cracked plastic are considered adequate basis for rejection. Requirements: The connectors shall be correctly constructed, marked and shall show good quality and workmanship. Connector after conditioning shall not show signs of damage or any detectable loss of function. Results: The connectors were thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to part function Salt Exposure Test Method: The fully mated connectors were submerged in a fine mist of 5% by weight of salt solution for 240 hours. The salt spray chamber was maintained at 35 ± 2 C. The free ends of wires were sealed in the service connectors with sealing plugs.

27 Requirements: No evidence of corrosion on the connector or terminals after the connector is removed from the test. Test samples must meet Insulation Resistance per section Results: No detrimental evidence of corrosion observed on the connector or terminals. Test samples were examined per section Insulation Resistance Test Method: After Salt Exposure per section 9.4.2, checked insulation resistance between each contact to all other contacts and shell using a 1000 VDC Megohmmeter. Requirements: The resistance shall be 10 megohms minimum. Results: The insulation resistance exceeded 10 megohms for all the tested samples Chemical Exposure Test Method: Each test sample in the wired and mated condition was submerged in one fluid only as in the following table. All the fluids used in the test were not previously used. Fluids Temperature Time Diesel Fuel #2 60ºC 24 hours Bio-Diesel Fuel (including Toyu) 60ºC 24 hours Kerosene 60ºC 24 hours Motor Oil 30wt 120ºC 7 Days Brake Fluid (disc type 1) 25ºC 24 hours 50/50 Antifreeze / Water mixture 100ºC 24 hours Transmission Oil 90wt 100ºC 7 Days Urea (32.5%) / Water (67.5%) 25ºC 24 hours Requirements:

28 There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. Results: The connector shown compatibility with all the fluids as specified. No degradation to the connector appearance or performance was observed Sealing, External Air Pressure Test Method: The mated test sample was placed in the sealed pressure chamber with vent tube attached. A 35±5 kpa dry compressed air source was applied to the chamber for 30 minutes minimum. Requirements: No air bubbles are allowed to exit the vent tube after the first fifteen minutes. Results: Intermittent bubbles were observed coming out of the vent tube after the first fifteen minutes Sealing, Interior Air Pressure Test Method: The mated test sample was completely submerged in the water with a pressure tubing introduced into the sealed portion of the test sample. Pressure was slowly applied from 0 to 35 kpa at a rate about 2 kpa/sec and maintained at the peak for 30 minutes minimum. Requirements: After 15 minutes, no air bubbles are allowed to leak from the sample. Results: There was no air bubbles observed after the first 15 minutes Visual Inspection

29 Test Method: This was the last step of this group. Each sample was unmated and visually inspected for evidence of corrosion or anything that could affect the performance or serviceability of the product. Results: There was no evidence of corrosion, leaking or detrimental damage to the test samples.

30 10.0 CONCLUSION 10.1 Group 1 -- Sealing Group 1 contained six samples that were tested to confirm thermal and sealing performance. All the samples in group 1 passed all aspects of the tests Group 2 -- Mechanical Group 2 contained one sample that was tested to confirm mechanical performance. The sample in group 2 passed all aspects of the tests Group 3 -- Vibration Group 3 contained three samples that were tested to determine the effects of vibration within the predominant or random vibration frequency ranges and magnitudes that may be encountered during the life of the connector. All the samples in group 3 passed all aspects of the tests Group 4 -- Chemical Group 4 contained eight samples that were tested to determine the ability of an electrical connector to resist degradation when exposed to specific fluids and salt laden atmosphere with which the connector may come into contact during its service life. All the samples in group 4 passed all aspects of the tests.

31 APPENDIX I LAB TEST FORMS TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 3/19/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship.

32 TEST: Spec. N/A DTR# Temp: 76.4 F Insulation Resistance Para Date: 3/19/2012 RH%: 33% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. QUADTECH PRO-I-017 9/22/2011 MΩ Tested By: LORA S. Insulation Resistance Item Resistance Pass / Number (MΩ) Fail Comments / Observations 1 > 10 MΩ PASS 2 > 10 MΩ PASS 3 > 10 MΩ PASS 4 > 10 MΩ PASS 5 > 10 MΩ PASS 6 > 10 MΩ PASS Insulation Resistance The insulation resistance exceeded 10 megohms for all the tested samples. Test Sequences Checked insulation resistance between each contact to all other contacts and shell using 1000 VDC megohmmeter.

33 TEST: Spec. N/A DTR# Temp: 77.2 F Thermal Shock Liquid Dunk Para Date: 03/20/12 RH%: 31% Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. BLUE M Oven EVL-T-028 9/22/2011 N/A Tested By: Lora S. Thermal Shock Liquid Dunk Item Oven Oven Oven Time Water Water Time Pass / Number Time In Time Out Temp C Duration Time In Time Out Duration Fail 1 7:00 AM 9:00 AM 125 C 2HRS. 9:00 AM 9:30 AM 30 MINS PASS 2 7:00 AM 9:00 AM 125 C 2HRS. 9:00 AM 9:30 AM 30 MINS PASS 3 7:00 AM 9:00 AM 125 C 2HRS. 9:00 AM 9:30 AM 30 MINS PASS 4 7:00 AM 9:00 AM 125 C 2HRS. 9:00 AM 9:30 AM 30 MINS PASS 5 7:00 AM 9:00 AM 125 C 2HRS. 9:00 AM 9:30 AM 30 MINS PASS 6 7:00 AM 9:00 AM 125 C 2HRS. 9:00 AM 9:30 AM 30 MINS PASS Observations: There was no evidence of leaking, cracking or detrimental damage to the test samples. Test Sequences Thermal Shock Liquid Dunk The wired mated test samples were placed in an oven at +125±3ºC for two hours and then immediately be placed in water with 5% salt by weight content and 0.1g/L wetting solution to a depth of 1 meter for 30 minutes. The free ends of wires were sealed and remained out of the water.

34 TEST: Spec. N/A DTR# Temp: 77.2 F Insulation Resistance Para Date: 3/20/2012 RH%: 31% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. QUADTECH PRO-I-017 9/22/2011 MΩ Tested By: LORA S. Insulation Resistance Item Resistance Pass / Number (MΩ) Fail Comments / Observations 1 > 10 MΩ PASS 2 > 10 MΩ PASS 3 > 10 MΩ PASS 4 > 10 MΩ PASS 5 > 10 MΩ PASS 6 > 10 MΩ PASS Insulation Resistance The insulation resistance exceeded 10 megohms for all the tested samples. Test Sequences Checked insulation resistance between each contact to all other contacts and shell using 1000 VDC megohmmeter.

35 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 3/20/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection Each sample was visually inspected for anything that could affect the performance or serviceability of the product.

36 TEST: Spec. N/A DTR# GRP#: 1 Thermal Cycle Para Date: 3/20/2012-3/26/2012 Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. BEMCO PRO-T-003 9/22/2011 N/A Tested By: Lora S. Thermal Cycle Item Pass / Number Fail Comments / Observations 1 PASS 2 PASS 3 PASS 4 PASS 5 PASS 6 PASS Thermal Cycle No crack, distortion or mechanical degradation was observed following the test. Test Sequences Mated test samples were thermal cycled a total of 20 complete cycles between -55±3ºC and +125±3ºC at the rate of 3ºC per minute. Test samples were remained at each temperature extreme for one hour.

37 TEST: Spec. N/A DTR# Temp: 74.8 F Thermal Shock Liquid Dunk Para Date: 03/27/12 RH%: 28% Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. BLUE M Oven EVL-T-028 9/22/2011 N/A Tested By: Lora S. Thermal Shock Liquid Dunk Item Oven Oven Oven Time Water Water Time Pass / Number Time In Time Out Temp C Duration Time In Time Out Duration Fail 1 3:00 PM 7:00 AM 125 C 16 HRS. 7:00 AM 7:30 AM 30 MINS PASS 2 3:00 PM 7:00 AM 125 C 16 HRS. 7:00 AM 7:30 AM 30 MINS PASS 3 3:00 PM 7:00 AM 125 C 16 HRS. 7:00 AM 7:30 AM 30 MINS PASS 4 3:00 PM 7:00 AM 125 C 16 HRS. 7:00 AM 7:30 AM 30 MINS PASS 5 3:00 PM 7:00 AM 125 C 16 HRS. 7:00 AM 7:30 AM 30 MINS PASS 6 3:00 PM 7:00 AM 125 C 16 HRS. 7:00 AM 7:30 AM 30 MINS PASS Observations: There was no evidence of leaking, cracking or detrimental damage to the test samples. Test Sequences Thermal Shock Liquid Dunk The wired mated test samples were placed in an oven at +125±3ºC for two hours and then immediately be placed in water with 5% salt by weight content and 0.1g/L wetting solution to a depth of 1 meter for 30 minutes. The free ends of wires were sealed and remained out of the water.

38 TEST: Spec. N/A DTR# Temp: 74.8 F Insulation Resistance Para Date: 3/27/2012 RH%: 28% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. QUADTECH PRO-I-017 9/22/2011 MΩ Tested By: LORA S. Insulation Resistance Item Resistance Pass / Number (MΩ) Fail Comments / Observations 1 > 10 MΩ PASS 2 > 10 MΩ PASS 3 > 10 MΩ PASS 4 > 10 MΩ PASS 5 > 10 MΩ PASS 6 > 10 MΩ PASS Insulation Resistance The insulation resistance exceeded 10 megohms for all the tested samples. Test Sequences Checked insulation resistance between each contact to all other contacts and shell using 1000 VDC megohmmeter.

39 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 3/27/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection Each sample was visually inspected for anything that could affect the performance or serviceability of the product.

40 TEST: Spec. N/A DTR# GRP# Temperature Life Para Date: 3/28/12-5/9/12 1 Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. DESPATCH BON-T-008 9/20/2011 Hours, C Tested By: Lora S. Temperature Life Item Date Time Date Time Time Oven Number In In Out Out Duration Temp. 1 3/28/2012 7:30 AM 5/9/2012 7:30 AM 1000 hrs 125 C 2 3/28/2012 7:30 AM 5/9/2012 7:30 AM 1000 hrs 125 C 3 3/28/2012 7:30 AM 5/9/2012 7:30 AM 1000 hrs 125 C 4 3/28/2012 7:30 AM 5/9/2012 7:30 AM 1000 hrs 125 C 5 3/28/2012 7:30 AM 5/9/2012 7:30 AM 1000 hrs 125 C 6 3/28/2012 7:30 AM 5/9/2012 7:30 AM 1000 hrs 125 C Observations: There was no evidence of cracking, distortion or detrimental damage to the test samples. Test Sequences Temperature Life The wired and mated connectors were subject to 1000 hours at 125 C±3 C. Pass / Fail Pass Pass Pass Pass Pass Pass

41 TEST: Spec. N/A DTR# Temp: 73.8 F Thermal Shock Liquid Dunk Para Date: 05/10/12 RH%: 30% Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. BLUE M Oven EVL-T-028 9/22/2011 N/A Tested By: Lora S. Thermal Shock Liquid Dunk Item Oven Oven Oven Time Water Water Time Pass / Number Time In Time Out Temp C Duration Time In Time Out Duration Fail 1 7:00 AM 9:00 AM 125 C 2 HRS. 9:00 AM 9:30 AM 30 MINS PASS 2 7:00 AM 9:00 AM 125 C 2 HRS. 9:00 AM 9:30 AM 30 MINS PASS 3 7:00 AM 9:00 AM 125 C 2 HRS. 9:00 AM 9:30 AM 30 MINS PASS 4 7:00 AM 9:00 AM 125 C 2 HRS. 9:00 AM 9:30 AM 30 MINS PASS 5 7:00 AM 9:00 AM 125 C 2 HRS. 9:00 AM 9:30 AM 30 MINS PASS 6 7:00 AM 9:00 AM 125 C 2 HRS. 9:00 AM 9:30 AM 30 MINS PASS Observations: There was no evidence of leaking, cracking or detrimental damage to the test samples. Test Sequences Thermal Shock Liquid Dunk The wired mated test samples were placed in an oven at +125±3ºC for two hours and then immediately be placed in water with 5% salt by weight content and 0.1g/L wetting solution to a depth of 1 meter for 30 minutes. The free ends of wires were sealed and remained out of the water.

42 TEST: Spec. N/A DTR# Temp: 73.5 F Insulation Resistance Para Date: 5/10/2012 RH%: 27% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. QUADTECH PRO-I-017 9/22/2011 MΩ Tested By: LORA S. Insulation Resistance Item Resistance Pass / Number (MΩ) Fail Comments / Observations 1 > 10 MΩ PASS 2 > 10 MΩ PASS 3 > 10 MΩ PASS 4 > 10 MΩ PASS 5 > 10 MΩ PASS 6 > 10 MΩ PASS Insulation Resistance The insulation resistance exceeded 10 megohms for all the tested samples. Test Sequences Checked insulation resistance between each contact to all other contacts and shell using 1000 VDC megohmmeter.

43 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 5/10/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection Each sample was visually inspected for anything that could affect the performance or serviceability of the product.

44 TEST: Spec. N/A DTR# Temp: 87 F Pressure Washing Para Date: 6/29/2012 RH%: 36% Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. Pressure Washer N/A N/A N/A Tested By: Lora S. Pressure Washing Item Time Water Spray Spray Spray Pass / Time In Time Out Number Duration Temp Pressure Distance Angle Fail 1 12:40 PM 1:40 PM 60 MINS 77 F 1750 PSI 20 to 30 cm 0 to 360 PASS 2 12:40 PM 1:40 PM 60 MINS 77 F 1750 PSI 20 to 30 cm 0 to 360 PASS 3 12:40 PM 1:40 PM 60 MINS 77 F 1750 PSI 20 to 30 cm 0 to 360 PASS 4 12:40 PM 1:40 PM 60 MINS 77 F 1750 PSI 20 to 30 cm 0 to 360 PASS 5 12:40 PM 1:40 PM 60 MINS 77 F 1750 PSI 20 to 30 cm 0 to 360 PASS 6 12:40 PM 1:40 PM 60 MINS 77 F 1750 PSI 20 to 30 cm 0 to 360 PASS Observations: There was no evidence of leaking, distortion or detrimental damage to the test samples. Test Sequences Pressure Washing The mated test samples were mounted firmly onto a push cart. Test sample 5 and 6 with fixture plates were mounted onto sealed aluminum boxes with receptacles secluded inside. The inline connectors and plugs of sample 5 and 6 were exposed to the room temperature water spray for about 3 to 5 seconds period per connector for a total of 60 minutes. The fan nozzles, with a source pressure of approximately 1750 psi gage, were located 20 to 30 cm away providing 100% coverage of the test sample.

45 TEST: Spec. N/A DTR# Temp: 74.8 F Insulation Resistance Para Date: 6/29/2012 RH%: 27% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. QUADTECH PRO-I-017 9/22/2011 MΩ Tested By: LORA S. Insulation Resistance Item Resistance Pass / Number (MΩ) Fail Comments / Observations 1 > 10 MΩ PASS 2 > 10 MΩ PASS 3 > 10 MΩ PASS 4 > 10 MΩ PASS 5 > 10 MΩ PASS 6 > 10 MΩ PASS Insulation Resistance The insulation resistance exceeded 10 megohms for all the tested samples. Test Sequences Checked insulation resistance between each contact to all other contacts and shell using 1000 VDC megohmmeter.

46 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 6/29/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection Each sample was visually inspected for anything that could affect the performance or serviceability of the product. Test sample 5 and 6 were removed from the aluminum boxes and inspected for leaking inside.

47 TEST: Spec. N/A DTR# Temp: 78.4 F Sealing, External Air Pressure Para Date: 7/2/2012 RH%: 29% Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. DI Pressure Chamber PRO-P-004 9/22/2011 PSI Tested by: Lora S. Sealing, External Air Pressure Item Air Amount Number Pressure of Time Observations 1 5 PSI > 30 MINS 1 bubble every 3 seconds 2 5 PSI > 30 MINS 1 bubble every 7 seconds 3 5 PSI > 30 MINS 1 bubble every 2 seconds 4 5 PSI > 30 MINS 1 bubble every 2 seconds 5 5 PSI > 30 MINS 1 bubble every 42 seconds 6 5 PSI > 30 MINS 1 bubble every 2 seconds Test Sequences Sealing, External Air Pressure The mated test sample was placed in the sealed pressure chamber with a vent tube attached. A 35±5 kpa dry compressed air source was applied to the chamber for 30 minutes minimum.

48 TEST: Spec. N/A DTR# Temp: 78.1 F Sealing, Interior Air Pressure Para Date: 7/3/2012 RH%: 31% Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. DI Pressure Gauge PRO-P-003 9/22/2011 PSI Tested by: Lora S. Sealing, Interior Air Pressure Item Air Amount Pass / Observations Number Pressure of Time Fail 1 5 PSI > 30 MINS No air bubbles after the first 15 minutes PASS 2 5 PSI > 30 MINS No air bubbles after the first 15 minutes PASS 3 5 PSI > 30 MINS No air bubbles after the first 15 minutes PASS 4 5 PSI > 30 MINS No air bubbles after the first 15 minutes PASS 5 5 PSI > 30 MINS No air bubbles after the first 15 minutes PASS 6 5 PSI > 30 MINS No air bubbles after the first 15 minutes PASS Test Sequences Sealing, Interior Air Pressure The mated test sample was completely submerged in the water with a pressure tubing introduced into the sealed portion of the test sample. Pressure was slowly applied from zero to 35 kpa at a rate about 2 kpa/sec and maintained at the peak for 30 minutes minimum.

49 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 7/3/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED Observations: There was no evidence of leaking, cracking or detrimental damage to the test samples. Test Sequence Visual Inspection This was the last step of this group. Each sample was unmated and visually inspected for evidence of leaking, cracking or anything that could affect the performance or serviceability of the product.

50 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 7/2/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection The connector was visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship.

51 TEST: Spec. N/A DTR# Temp: 77.6 F Durability Para Date: 7/2/2012 RH%: 30% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. 5/32" Allen Wrench N/A N/A Number of Cycles Tested By: LORA S. Durability Item Number Pass / Number of Cycles Fail Comments / Observations 1 50 PASS There was no visual or mechanical degradation observed after 50 mating cycles Durability Test Sequences The connector was mated and unmated for a total of 50 complete cycles at room temperature. The connector was retorqued to the recommended torque in*lb [5-7 N*m] after each cycle.

52 TEST: Spec. N/A DTR# Temp: 77.6 F Terminal Retention, Axial Para Date: 7/2/2012 RH%: 30% Instrument Inst.# Calib. Unit of Measure Request By: Clark W. Tinius-Olson H5KS PRO-W-015 4/27/2012 mm, N Tested By: Lora S. Terminal Retention, Axial Item Cavity Contact Wire Displacement (mm) Axial Load (N) Number Number Size AWG Spec. Actual Spec. Actual SXL SXL SXL SXL SXL Test Sequences Terminal Retention Axial The receptacle pins were axially loaded by the force of 89N (20 lbf) on the 20 size contact and 111 N (25 lbf) on the 12 size contact. The force was applied at a uniform rate of in/min. Terminal position assurance device was utilized and in the locked position during the test. Four pins of 20 size contact and one pin of 12 size contact were tested.

53 TEST: Spec. N/A DTR# Temp: 77.6 F Terminal Retention, Rotation Para Date: 7/3/2012 RH%: 30% Instrument Inst.# Calib. Unit of Measure Request By: Clark W. 10 Lbs Weight N/A N/A N/A Tested By: Lora S. Terminal Retention, Rotation Item Cavity Contact Wire Wire Load Rotation (Turns) Number Number Size AWG Length Axial Spec. Actual SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs 5 > 5 Test Sequences Terminal Retention, Rotation The wired receptacle was rigidly mounted on the table such that the wires could hang downward vertically. A 4.54 kg (10 lbs) weight was affixed to the end of a 610 mm (2 feet) long wire. Each pin in the cavity was rotated by five full turns by spinning the weighted wire. Eight pins of 20 size contact and one pin of 12 size contact were tested.

54 TEST: Spec. N/A DTR# Temp: 77.5 F Cross Key Mating Para Date: 7/3/2012 RH%: 31% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. Tinius-Olson H5KS PRO-W-015 4/27/2012 N/A Tested By: LORA S. Cross Key Mating Item Load Pass / Number Axial Fail Comments / Observations 1 80 lbf PASS There was no evidence of cracking, distortion or detrimental damage to the key configuration. Test Sequences Cross Key Mating A mating force of 350 N was applied while attempting to cross-key mate by aligning connector halves into each geometric possible position. All key design possibilities were inspected and tested. Electrical contact was monitored during the test.

55 TEST: Spec. N/A DTR# Temp: 78.5 F Scoop Proof Mating Para Date: 7/3/2012 RH%: 31% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Scoop Proof Mating Item Pass / Number Fail Comments / Observations 1 Pass All the contacts of the connector were untouched due to the scoop proof features. Test Sequences Scoop Proof Mating The wired connector was mated through all kinds of intended improper orientation during assembly.

56 TEST: Spec. N/A DTR# Temp: 79.0 F Connector Coupling Strength Para Date: 7/5/2012 RH%: 32% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. Tinius-Olson H5KS PRO-W-015 4/27/2012 Lbf Tested By: LORA S. Connector Coupling Strength Item Contact Wire Pulling Force Pass / Comments / Observations Number Size AWG Spec. Actual Fail SXL 18 SXL Connector Coupling Strength 100 lbf 113 lbf No disengagement or damage observed Pass Test Sequences A tensile load of 100 lbf [445 N] was applied to the wire bundle of the mated connector for a period of one minute.

57 TEST: Spec. N/A DTR# Temp: 79 F Maintenance Aging Para Date: 7/5/2012 RH%: 32% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. Contact Removal Tool DT/RT1 N/A Number of Cycles Tested By: LORA S. Maintenance Aging Item Cavity No. of Pass / Number Number Cycles Fail Comments / Observations Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass No mechanical degradation or damage was observed to the retainer finger, terminal position assurance or connector. Test Sequences Maintenance Aging Eight pins of 20 size contact and two pins of 12 size contact in receptacle were subjected to a total of ten cycles of inserting and removing its respective contact. Disassembly of the terminal position assurance device required to remove the contacts was included. The connector was mated and unmated in each cycle. Insertion and removal was performed using manufacturer's recommended tools. The pins tested were different from the ones been tested in Terminal Retention Axial and Rotation per section and

58 TEST: Spec. N/A DTR# Temp: 79 F Terminal Retention, Axial Para Date: 7/5/2012 RH%: 32% Instrument Inst.# Calib. Unit of Measure Request By: Clark W. Tinius-Olson H5KS PRO-W-015 4/27/2012 mm, N Tested By: Lora S. Terminal Retention, Axial Item Cavity Contact Wire Displacement (mm) Axial Load (N) Number Number Size AWG Spec. Actual Spec. Actual SXL SXL SXL SXL SXL Test Sequences Terminal Retention Axial The pin in receptacle was axially loaded by the force of 89N (20 lbf) on 20 size contact and 111 N (25 lbf) on 12 size contact. The force was applied at a uniform rate of in/min. Terminal position assurance device was utilized and in the locked position during the test. Half of the contacts been tested in Maintenance Aging per section were selected.

59 TEST: Spec. N/A DTR# Temp: 79 F Terminal Retention, Rotation Para Date: 7/5/2012 RH%: 32% Instrument Inst.# Calib. Unit of Measure Request By: Clark W. 10 Lbs Weight N/A N/A N/A Tested By: Lora S. Terminal Retention, Rotation Item Cavity Contact Wire Wire Load Rotation (Turns) Number Number Size AWG Length Axial Spec. Actual SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs SXL 2 ft 10 lbs 5 >5 Test Sequences Terminal Retention, Rotation The wired receptacle was rigidly mounted on the table such that the wires could hang downward vertically. A 4.54 kg (10 lbs) weight was affixed to the end of a 610 mm (2 feet) long wire. Each pin in the cavity was rotated by five full turns by spinning the weighted wire. The other half contacts been tested in Maintenance Aging per section were selected.

60 TEST: Spec. N/A DTR# Temp: 79 F Drop Para Date: 7/5/2012 RH%: 33% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. Height Adjustable Stand N/A N/A N/A Tested By: LORA S. Drop Item Wire Drop Pass / Number Length Height Fail Comments / Observations Drop 5 ft 2.5 ft Pass There were no signs of damage or any detectable loss of function following the test. Test Sequences Wired receptacle was attached to free end of a 5 feet long cord. The other end of the cord was fixed to a wall at a height of 2.5 feet above concrete floor. The test sample was held so that the cord was horizontal and then fell to the concrete floor eight times. Test sample was rotated approximately 45 degrees at its fixing each time.

61 TEST: Spec. N/A DTR# Temp: 79.2 F Crimp Tensile Para Date: 7/5/2012 RH%: 30% Instrument Inst.# Calib. Unit of Measure Request By: Clark W. Tinius-Olson H5KS PRO-W-015 4/27/2012 Lbf Tested By: Lora S. Crimp Tensile Item Pin / Crimp Contact Wire Load (lbf) Number Socket Height Size AWG Spec. Actual Pass / Fail 1 Pin.049" SXL Pass 2 Pin.049" SXL Pass 3 Pin.049" SXL Pass 4 Pin.049" SXL Pass 5 Pin.049" SXL Pass 6 Pin.049" SXL Pass 7 Pin.049" SXL Pass 8 Pin.049" SXL Pass 9 Pin.080" SXL Pass Test Sequences Crimp Tensile The tensile strength of the crimped connection was tested using a tensile tester without the influence of an insulation strain relief crimp. An axial force was applied to the wire and terminal at a speed of 25.4 ± 6mm per minute separating the contact and conductor. 18 SXL and 12 SXL wires were tested.

62 TEST: Spec. N/A DTR# Temp: 79.2 F Over Torque Para Date: 7/5/2012 RH%: 30% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. Torque Wrench PRO-W-016 9/26/2011 N*m Tested By: LORA S. Over Torque Item Torque Pass / Number (N*m) Fail Comments / Observations PASS No Cracking, distortion or detrimental damage to the test sample observed following the test. Test Sequences Over Torque The connector was torqued to 10.5 N*m [92 in*lb] which is 1.5 times of the maximum allowable torque.

63 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 7/5/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments / Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED Observations: The connector was thoroughly inspected and showed no evidence of cracking, distortion or any defects detrimental to the part function. Test Sequence Visual Inspection This was the last step of this group. Test sample was unmated and visually inspected for evidence of cracking, distortion or anything that could affect the performance or serviceability of the product.

64 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 4/19/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship.

65 TEST: Spec. N/A Temp: 76.3 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

66 TEST: Spec. N/A Temp: 76.3 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

67 TEST: Spec. N/A Temp: 76.3 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

68 TEST: Spec. N/A Temp: 76.3 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

69 TEST: Spec. N/A Temp: 76.3 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

70 TEST: Spec. N/A Temp: 76.3 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

71 TEST: Spec. N/A Temp: 77.2 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 4/19/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

72 TEST: Spec. N/A Temp: 77.2 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 4/19/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

73 TEST: Spec. N/A Temp: 77.2 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 4/19/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

74 TEST: Spec. N/A Temp: 77.2 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 4/19/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

75 TEST: Spec. N/A Temp: 77.2 F DTR# Voltage Drop Para RH%: 30% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Tested By: Lora S. Power Supply PRO-I-009 9/20/2011 amperes (A) Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

76 TEST: Spec. N/A Temp: 77.2 F DTR# Voltage Drop Para RH%: 30% Test Date: 4/19/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Tested By: Lora S. Power Supply PRO-I-009 9/20/2011 amperes (A) Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

77 TEST: Spec. N/A DTR# GRP#: 3 Thermal Cycle Para Date: 4/30/2012-5/2/2012 Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. BEMCO PRO-T-003 9/22/2011 N/A Tested By: Lora S. Thermal Cycle Item Pass / Number Fail Comments / Observations 1 PASS 2 PASS 3 PASS Thermal Cycle No crack, distortion or mechanical degradation was observed following the test. Test Sequences Mated test samples were thermal cycled a total of 20 complete cycles between -55±3ºC and +125±3ºC at the rate of 3ºC per minute. Test samples were remained at each temperature extreme for one hour.

78 TEST: Spec. N/A Temp: 76.4 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 5/4/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

79 TEST: Spec. N/A Temp: 76.4 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 5/4/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

80 TEST: Spec. N/A Temp: 76.4 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 5/4/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

81 TEST: Spec. N/A Temp: 76.4 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 5/4/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

82 TEST: Spec. N/A Temp: 76.4 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 5/4/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

83 TEST: Spec. N/A Temp: 76.4 F DTR# Low Signal Contact Resistance Para RH%: 33% Test Date: 5/4/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

84 TEST: Spec. N/A Temp: 76.8 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/7/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

85 TEST: Spec. N/A Temp: 76.8 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/7/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

86 TEST: Spec. N/A Temp: 76.8 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/7/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

87 TEST: Spec. N/A Temp: 76.8 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/7/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

88 TEST: Spec. N/A Temp: 76.8 F Voltage Drop Para RH%: 30% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/7/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

89 TEST: Spec. N/A Temp: 76.8 F DTR# Voltage Drop Para RH%: 30% Test Date: 5/7/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Tested By: Lora S. Power Supply PRO-I-009 9/20/2011 amperes (A) Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

90 TEST: Spec. N/A Temp: DTR# Vibration Para RH%: Date: 5/15/2012-5/25/2012 Instrument Inst. # Calib. Unit of Measure Requested By: CLARK W. Vibration Table LING 395 N/A g/da Tested By: LORA S. Vibration Amplifier LDS CA 4 N/A N/A Vibration Controller PUMA/ /28/ ma Discontinuity Analyzer PRO-I-O27 08/02/11 mv/g Accelerometer PRO - I - 022, 23, 24 12/16/2011 pc/g Part Number/Description: Vibration Item Axis Time Pass / Number (X,Y,Z) Duration Fail Comments / Observations 1 X 20 hrs PASS No discontinuity greater than 10 ohms in excess of 1 microsecond was 2 Y 20 hrs PASS observed. There was no physical damage or loosening of components 3 Z 20 hrs PASS during the test. 1 Y 20 hrs PASS 2 Z 20 hrs PASS 3 X 20 hrs PASS No discontinuity greater than 10 ohms in excess of 1 microsecond was observed. There was no physical damage or loosening of components during the test. 1 Z 20 hrs PASS 2 X 20 hrs PASS 3 Y 20 hrs PASS No discontinuity greater than 10 ohms in excess of 1 microsecond was observed. There was no physical damage or loosening of components during the test. Test Sequence Vibration Three wired and mated connectors were rigidly mounted to three mutually perpendicular axis and randomly vibrated for 20 hours in each axis. Vibration profile was attached in the appendix I Para The wire harness was bent 90 degree and firmly tied to the router with tie-wraps. Backshell was included during vibration. The free end was hooked up to the discontinuity monitor from which 100 milliamps load was applied. 1.0 Vibration Profile GRMS = g PSD g 2 /Hz Frequency (Hz)

91 TEST: Spec. N/A Temp: 75.7 F DTR# Low Signal Contact Resistance Para RH%: 30% Test Date: 5/29/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

92 TEST: Spec. N/A Temp: 75.7 F DTR# Low Signal Contact Resistance Para RH%: 30% Test Date: 5/29/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

93 TEST: Spec. N/A Temp: 75.7 F DTR# Low Signal Contact Resistance Para RH%: 30% Test Date: 5/29/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

94 TEST: Spec. N/A Temp: 75.7 F DTR# Low Signal Contact Resistance Para RH%: 30% Test Date: 5/29/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

95 TEST: Spec. N/A Temp: 75.7 F DTR# Low Signal Contact Resistance Para RH%: 30% Test Date: 5/29/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail REF Wire N/A N/A N/A REF Wire N/A N/A N/A Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

96 TEST: Spec. N/A Temp: 75.7 F DTR# Low Signal Contact Resistance Para RH%: 30% Test Date: 5/29/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. VALHALLA PRO-I-016 9/20/2011 milliohms (mω) Tested By: Lora S. Low Signal Contact Resistance Item Cavity Contact Spec. Forward Reverse Average Contact Pass/ Number Number Size Limit (mω) (mω) (mω) (mω) (mω) Fail Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Test Sequence Low Signal Contact Resistance The mated connector was tested with applied voltage not to exceed 20 millivolts open circuit and the current limited to 100 milliamps. The contact resistance was obtained by subtracting the reference wire resistance from the test reading.

97 TEST: Spec. N/A Temp: 74.8 F Voltage Drop Para RH%: 33% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/30/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

98 TEST: Spec. N/A Temp: 74.8 F Voltage Drop Para RH%: 33% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/30/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

99 TEST: Spec. N/A Temp: 74.8 F Voltage Drop Para RH%: 33% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/30/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

100 TEST: Spec. N/A Temp: 74.8 F DTR# Voltage Drop Para RH%: 33% Test Date: 5/30/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Tested By: Lora S. Power Supply PRO-I-009 9/20/2011 amperes (A) Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

101 TEST: Spec. N/A Temp: 74.8 F Voltage Drop Para RH%: 33% Instrument Inst.# Calib. Unit of Measure Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Power Supply PRO-I-009 9/20/2011 amperes (A) DTR# Test Date: 5/30/2012 Requested by: Clark W. Tested By: Lora S. Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail REF Wire N/A SXL N/A N/A N/A REF Wire N/A SXL N/A N/A N/A SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

102 TEST: Spec. N/A Temp: 74.8 F DTR# Voltage Drop Para RH%: 33% Test Date: 5/30/2012 Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. Digital Multimeter PRO-I-015 9/20/2011 millivolts (mv) Tested By: Lora S. Power Supply PRO-I-009 9/20/2011 amperes (A) Voltage Drop Item Cavity Contact Wire Spec. Amperes Actual Contact Pass/ Number Number Size AWG Limit (mv) (A) (mv) (mv) Fail SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass SXL Pass Test Sequence Voltage Drop The mated connector was tested using 7.5 amps on 18 AWG wire and 20 amps on 12 AWG wire with the test voltage set to be 4.50 ± 0.25 VDC open circuit. The voltage drop was recorded by deducting the reference wire measurements.

103 TEST: Spec. N/A DTR# GRP# Visual Inspection 3 Para Date: 6/1/2012 Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO FUNCTIONAL DEFECTS TO CONNECTOR 2) NO FUNCTIONAL DEFECTS TO CONNECTOR 3) NO FUNCTIONAL DEFECTS TO CONNECTOR Observations: The connectors were thoroughly inspected and showed no evidence of distortion or any defects detrimental to the part function. Test Sequence Visual Inspection This was the last step of this group. Each sample was unmated and visually inspected for evidence of cracking, distortion, terminal fretting or anything that could affect the performance or serviceability of the product.

104 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 4/12/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED 7) NO VISUAL DEFECTS TO CONNECTOR / PASSED 8) NO VISUAL DEFECTS TO CONNECTOR / PASSED Test Sequence Visual Inspection The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship.

105 TEST: Spec. N/A DTR# Temp: Salt Exposure Para Date: 4/13/2012-4/23/2012 RH%: Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. Salt Spray Chamber N/A N/A N/A Tested By: Lora S. Salt Exposure Item Time Salt Chamber Chamber Pass / Number Time In Date In Date Out Duration Solution Temp PH Fail 1 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 2 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 3 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 4 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 5 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 6 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 7 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS 8 7:00 AM 4/13/2012 4/23/ hrs 5% 35 ± 2 C 6.8 PASS Observations: No detrimental evidence of corrosion observed on the connector or terminals. Test Sequences Salt Exposure The fully mated connectors were submerged in a fine mist of 5% by weight of salt solution for 240 hours. The salt spray chamber was maintained at 35 ± 2 C. The free ends of wires were sealed in the service connectors with sealing plugs.

106 TEST: Spec. N/A DTR# Temp: 76.5 F Insulation Resistance Para Date: 4/23/2012 RH%: 30% Instrument Inst.# Calib. Unit of Measure Requested By: CLARK W. QUADTECH PRO-I-017 9/20/2011 MΩ Tested By: LORA S. Insulation Resistance Item Resistance Pass / Number (MΩ) Fail Comments / Observations 1 > 10 MΩ PASS 2 > 10 MΩ PASS 3 > 10 MΩ PASS 4 > 10 MΩ PASS 5 > 10 MΩ PASS 6 > 10 MΩ PASS 7 > 10 MΩ PASS 8 > 10 MΩ PASS Insulation Resistance The insulation resistance exceeded 10 megohms for all the tested samples. Test Sequences Checked insulation resistance between each contact to all other contacts and shell using 1000 VDC megohmmeter.

107 TEST: Spec. N/A DTR# Temp: N/A Chemical Exposure Para Date: RH%: N/A Instrument Inst.# Calib. Unit of Measure Requested By: Clark W. Oven Despatch PRO-T-005 9/20/2011 N/A Tested By: Lora S. Chemical Exposure Item Time Pass / Time In Date In Date Out Fluid Type Temp. Number Duration Fail 1 1:00 PM 4/25/2012 4/26/ hrs Diesel Fuel #2 60 C PASS 2 2:30 PM 4/26/2012 4/27/ hrs Bio-Diesel Fuel (Including Toyu) 60 C PASS 3 9:30 AM 4/30/2012 5/1/ hrs Kerosene 60 C PASS 4 9:00 AM 5/15/2012 5/22/ Days Motor Oil 30wt 120 C PASS 5 11:00 AM 5/23/2012 5/24/ hrs Brake Fluid (Disc type 1) 25 C PASS 6 11:30 AM 5/1/2012 5/2/ hrs 50/50 Antifreeze / Water mixture 100 C PASS 7 2:00 PM 5/2/2012 5/9/ Days Transmission Oil 90wt 100 C PASS 8 1:00 PM 5/24/2012 5/25/ hrs Urea (32.5%) / Water (67.5%) 25 C PASS Observations: The connector shown compatibility with all the fluids as specified. No degradation to the connector appearance or performance was observed. Test Sequences Chemical Exposure Each test sample in the wired and mated condition was submerged in one fluid only as in the following table. All the fluids used in the test were not previously used.

108 TEST: Spec. N/A DTR# Temp: N/A Sealing, External Air Pressure Para Date: See Below RH%: N/A Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. DI Pressure Chamber PRO-P-004 9/22/2011 PSI Tested by: Lora S. Sealing, External Air Pressure Item Air Amount Test Number Pressure of Time Date Observations 1 5 PSI > 30 MINS 4/26/ bubble every 7 min and 4 sec 2 5 PSI > 30 MINS 4/27/ bubble every 4 min and 20 sec 3 5 PSI > 30 MINS 5/1/ bubble every 5 sec 4 5 PSI > 30 MINS 5/23/ bubble every 13 min and 9 sec 5 5 PSI > 30 MINS 5/25/ bubble every 1 sec 6 5 PSI > 30 MINS 5/2/ bubble every 3 sec 7 5 PSI > 30 MINS 5/3/ bubble every 24 min and 7 sec 8 5 PSI > 30 MINS 5/28/ bubble every 1 sec Test Sequences Sealing, External Air Pressure The mated test sample was placed in the sealed pressure chamber with vent tube attached. A 35±5 kpa dry compressed air source was applied to the chamber for 30 minutes minimum.

109 TEST: Spec. N/A DTR# Temp: N/A Sealing, Interior Air Pressure Para Date: See Below RH%: N/A Instrument Inst.# Calib. Unit of Measure Requested by: Clark W. DI Pressure Gauge PRO-P-003 9/22/2011 PSI Tested by: Lora S. Sealing, Interior Air Pressure Item Air Amount Test Number Pressure of Time Date Observations 1 5 PSI > 30 MINS 4/26/2012 No air bubbles after the first 15 min / Pass 2 5 PSI > 30 MINS 4/27/2012 No air bubbles after the first 15 min / Pass 3 5 PSI > 30 MINS 5/1/2012 No air bubbles after the first 15 min / Pass 4 5 PSI > 30 MINS 5/23/2012 No air bubbles after the first 15 min / Pass 5 5 PSI > 30 MINS 5/25/2012 No air bubbles after the first 15 min / Pass 6 5 PSI > 30 MINS 5/2/2012 No air bubbles after the first 15 min / Pass 7 5 PSI > 30 MINS 5/3/2012 No air bubbles after the first 15 min / Pass 8 5 PSI > 30 MINS 5/28/2012 No air bubbles after the first 15 min / Pass Test Sequences Sealing, Interior Air Pressure The mated test sample was completely submerged in the water with a pressure tubing introduced into the sealed portion of the test sample. Pressure was slowly applied from 0 to 35 kpa at a rate about 2 kpa/sec and maintained at the peak for 30 minutes minimum.

110 TEST: Spec. N/A DTR# GRP# Visual Inspection Para Date: 5/29/ Instrument Inst.# Calib. Date Unit of Measure Requested By: CLARK W. N/A N/A N/A N/A Tested By: LORA S. Comments/Conclusion Sample Number: 1) NO VISUAL DEFECTS TO CONNECTOR / PASSED 2) NO VISUAL DEFECTS TO CONNECTOR / PASSED 3) NO VISUAL DEFECTS TO CONNECTOR / PASSED 4) NO VISUAL DEFECTS TO CONNECTOR / PASSED 5) NO VISUAL DEFECTS TO CONNECTOR / PASSED 6) NO VISUAL DEFECTS TO CONNECTOR / PASSED 7) NO VISUAL DEFECTS TO CONNECTOR / PASSED 8) NO VISUAL DEFECTS TO CONNECTOR / PASSED Observations: There was no evidence of leaking or detrimental evidence of corrosion to the test samples. Test Sequence Visual Inspection This was the last step of this group. Each sample was unmated and visually inspected for evidence of leaking, corrosion or anything that could affect the performance or serviceability of the product.

111 APPENDIX II TEST PHOTOS Visual Inspection

112 Insulation Resistance Thermal Shock Liquid Dunk

113 Pressure Washing Pressure Washer

114 Sealing, External Air Pressure

115 Sealing, Interior Air Pressure Sealing, Interior Air Pressure

116 Vibration Test Vibration Test, Discontinuity Monitor

117 Low Signal Contact Resistance Voltage Drop

118 Salt Exposure Test

119 Diesel Dunk Sample 1 after Diesel Dunk

120 Bio-Diesel Dunk Sample 2 after Bio-Diesel Dunk

121 Kerosene Dunk Sample 3 after Kerosene Dunk

122 Motor Oil Dunk Sample 4 after Motor Oil Dunk

123 Brake Fluid Dunk Sample 5 after Brake Fluid Dunk

124 Coolant Dunk Sample 6 after Coolant Dunk

125 Transmission Oil Dunk Sample 7 after Transmission Oil Dunk

126 Urea Dunk Sample 8 after Urea Dunk