vibration, ice and mud. Sealing integrity is maintained with exposure to brake fluid,
gasoline, diesel fuel, anti-freeze, ultraviolet, ozone, and steam.
Applications
Wet, humid, or dirty environments• Automotive• Trucks and Busesrequiring a low cost, small and reliable• Marine• Off-road Vehiclessealed connector
• Appliances• Industrial Machinery• Low Voltage Lighting Systems
Features
Low Installed Cost
One piece molded bodies and crimpare required. Bodies mate using multiplecontacts provide a low cost solution. Inresilient seals and will remain mated evenaddition, these connectors can be easilyunder severe vibration and shock.
terminated by the user.
Field Serviceable
Water Submersible
The use of removable crimp contacts allowsNot just splash-proof, but truly submersibleSure-Seal® connections to be changed orfor short periods of time. Sure-Seal® will sealmodified in the field if necessary.
to the requirements of IP67 and DIN 400 50.
Polarized Against Mis-mates
Resistant to Automotive/IndustrialConnector halves use both pin and socketEnvironments
contacts. The plug and receptacle must beSure-Seal® will operate in temperatures from -properly oriented for the connectors to40˚F to +221˚F under conditions of highmate. Raised indexing ribs in conjunctionhumidity, severe vibration, ice and mud.with a stepped plane allow blind mating ofSealing integrity is maintained with exposurethe connector halves even in dark orto brake fluid, gasoline, diesel fuel, anti-cramped spaces.
freeze, ultraviolet, ozone, and steam.Three Sure-Seal® Versions
Wide Range of Wire Gauges andSure-Seal® is available in three versions. TheCurrent Carrying Capability
basic Sure-Seal® line is the broadest andUp to 85 amps with wire gauges from sizeideal for most applications. Mini-Sure-Seal®20 up to size 4 AWG wire.
provides a slightly smaller connector in aOne-Piece Connector
limited range of configurations. PowerSure-Seal® has a simple one-piece moldedSure-Seal® is for single circuit, high powerbody. No other parts (other than contacts)
applications.
SCOURENNE SCTEALIONSManufacturer of high qualityenvironmental connectors & accessoriesFor technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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Technical
Specifications
(Complete test dataavailable on page 16.)MATERIALS & FINISHES
BodyContactsPlating
Elastomeric material
(PVC Nitrile standard. Also available in silicone & EPDM)Copper alloy
Tin standard; gold plating optional
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2
ELECTRICAL DATA
Operating VoltageCurrent rating
400 Vac maximum15 Amps (Sure-Seal®)
8 Amps (Mini Sure-Seal®)85 Amps (Power Sure-Seal®)14 - 18 AWG (Sure-Seal®)
18 - 20 AWG (Mini Sure-Seal®) 4 - 10 AWG (Power Sure-Seal®)10 Milliohms maximum100 Megohms (minimum)
Dielectric Withstanding Voltage1,200 Vac at sea level
Wire Range Sizes
Contact ResistanceInsulation Resistance
MECHANICAL
Operating TemperatureSealing
Wire Sealing RangeInsulation Strip LengthsMating LifeSalt SprayHeat
Weather, Ozone, & UltravioletVibrationShockContact TypeNumber of CircuitsContact Insertion
-40˚F to +221˚F (-40˚C to +105˚C)~~IP67, DIN 400 50, 3 foot depth in 5% salt solution 24
~hours min. ~ NEMA 6 p
See column 8 on contact chart, page 7.50 cycles minimum
To MIL-STD-202D Method 101D
+221˚F (+105˚C) for 1000 hours (See test data page 16.)In accordance with ASM D-1149 (100pphm) &
ASTM D-1171 (outdoor exposure)
5 to 55 Hz .06\" DA 1 hour; radial & longitudinal axes50g 11ms, 30 cycles; radial & longitudinal axesCrimp: using hand or semi-automatic tooling1 to 10
From rear with simple hand tool or simultaneousinsertion of multiple contacts with semi-automaticinsertion machine. Removable, 5 cycles minimum.7.5 lbs. (35N) minimum
Stepped plane positive polarization, indexing ribs, andvisual polarization all permanently molded into body.UL (E176866) & CSA (LR109871-1)Black (alternate colors optional)
➥
See column 7 on contact chart, page 6. ➥
➥
Contact RetentionPolarizationAgency ListingsColor
SURE SEALCONNECTIONSManufacturer of high qualityenvironmental connectors & accessoriesFor technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
Sure SealCross SectionSure-Seal®OPTIONAL BOOTWIRE HOLE FILLER (OPTIONAL)
Over Mold Models
How to Select1.Choose series:Sure-Seal®(Sure-Seal®, Mini Sure-Seal®, or Power Sure-Seal®).Connectors &2.Determine number of circuits required per connector:Accessories1 to 10 in Sure-Seal®2 to 4 in MINI Sure-Seal®1 in POWER Sure-Seal®3.Select connector with appropriate number of circuits.4.Select Sure-Seal® body style (straight or flanged plug and receptacle).5.Select connector accessories:(Boots, Mounting Ring, Mounting Plates, Mounting Clip,Wire Hole Filler, Holding Blocks).How to SelectSure-Seal®1.Determine current carrying and wire gauge requirements for application.Contacts &2.Select appropriate contacts from contact selection chart on page 6.Tooling3.Choose appropriate crimp, insertion, and extraction tooling on page 7. ➥ ➥For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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○○○○○○LayoutsNotice that allmulti-pin Sure-Seal®connectors use acombination of pinMachinedand socket contactsPC Pinin each connector.Contact.View from matingface of receptacle● pin ❍ socketConnectors○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○Sure-Seal®▲4
Please Call.Number ofCircuitsAWG WireSizesPlugFlanged PlugReceptacleSURE-SEAL®123First-Make/Last-Break Version45671014-18 AWG14-18 AWG14-18 AWG14-18 AWG14-18 AWG14-18 AWG14-18 AWG14-18 AWG14-18 AWG14-18 AWG120-1832-000120-1807-000120-1808-000120-1808-200120-1809-000120-1841-000120-1842-000120-1873-000120-1865-000120-1867-000120-1869-000-**120-8552-200120-8552-201120-8552-202-**-**-**120-8552-305120-8552-306120-8552-307120-1833-000120-1804-000120-1805-000120-1805-200120-1806-000120-1839-000120-1840-000120-1874-000120-1866-000120-1868-000120-1870-000*MINI SURE-SEAL®23418-20 AWG18-20 AWG18-20 AWG120-8552-100120-8552-101120-8552-102---120-8551-100120-8551-101120-8551-102POWER SURE-SEAL®114-6 AWG8-10 AWG120-1905-000120-1906-000--120-1903-000120-1904-000** Use Mounting Rings(2) Page 10.* See page 12 for special rectangular version ➥(2) Mounting Ring
A Mounting Ring snaps into an
appropriate sized hole in a panel or bracketand allows a non-flanged plug orreceptacle to be panel mounted.
➥(1) Boot
SURE SEALFits over the rear of the connector andseals the jacket of the cable. It also providesadditional strain relief and abrasionresistance. See dimensions on page 10for choosing 3 or 4 circuit boot.
(3) Mounting Plate
Metal mounting plates reinforce themolded flanges when attachingflanged connectors to a panel.
CONNECTIONS ➥
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
AccessoriesSure-Seal®Boot(1)Mounting Ring(2)Mounting Plate(3)Posi-LokMounting Clip(4)Wire Hole Filler(5)Holding Block(6)---026-0452-000225-0093-000317-1408-002317-1398-000351-10-000066-8516-000029-0263-000225-0093-000317-1408-001317-1397-000*317-1399-000*351-11-000066-8516-000029-0262-000225-0093-000317-1408-000317-1397-000*317-1399-000*351-11-000066-8516-000029-0262-000225-0093-000317-1408-000317-8657-000351-1633-000-026-0450-000225-0093-000317-1408-003317-8657-000351-1633-000-026-0450-000225-0093-000317-1408-003317-8657-000351-1633-000-026-0450-000225-0093-000317-1408-003317-8657-002351-1634-000066-8516-002026-0451-000225-0093-000317-1408-004317-8657-002351-1634-000066-8516-002026-0451-000225-0093-000317-1408-004317-8657-002351-1634-000066-8516-002026-0451-000225-0093-000317-1408-004195-8508-013 plug---026-0452-000225-1012-000195-8508-014receptacles195-8508-015 plug---026-0452-000225-1012-000195-8508-016receptacles195-8508-017 plug---026-0452-000225-1012-000195-8508-018receptacles----†------†--*See page 10 for Cable O.D. accommodations. ➥† Please call for availability(4) Mounting Clip
Mounting clips can be used free-hanging as a positive lock to(5) Wire Hole Fillers
(6) Holding Block
provide a secondary means of securing the connector halves.Wire Hole fillers are inserted into unusedA holding block makes insertion of contacts intoMated connector pairs can be snapped into the clip for fixedcavities in place of a contact. Hole fillersthe molded body faster and avoids personalmounting using a screw or cable tie. The wires of one of theare required to retain the watertightinjury or damage to the connector. It is highlyconnectors can be passed through an integral retention ringsealing if less than a full compliment ofrecommended that the appropriate block bewhich captivates one of the connector halves to the clip.contacts are to be used.used when inserting contacts. (See AssemblyInstructions, page 15). ➥
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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○5○○○○○IndexCOLUMN 1COLUMN 2Contacts(1)(1)COLUMN 3 COLUMN 4COLUMN 5 COLUMN 6WireCOLUMN 7○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○Sure-Seal®▲
6
Contact StyleSure-Seal®Insulation SupportA.W.G.Wire SizeLoose Pins5K ReelPins(1)LooseSockets5K ReelSockets(1)Strip LengthInches (MM)Tin Plated (Standard)†Gold Plated*†14-1814-18030-2196-001030-2196-006110238-0195110238-0409031-1267-001031-1267-005110238-0194110238-0408.155 - .185(3.94 - 4.70)Sure-Seal®Non-Insulation SupportTin Plated (Standard)Gold Plated*14-1814-18030-2196-000030-2196-008110238-0040110238-0440031-1267-000031-1267-007110238-0085110238-0442.185 - .220(4.70 - 5.59)Mini Sure-Seal®Insulation Support.118 - .13018-20330-8672-100121348-0100031-8703-100121347-0100(3.00 - 3.30)Power Sure-Seal® (VE)**.460 - .480(11.7 - 12.2)Note:6 AWG & 10 AWGsocket contacts haveunique strip lengths.515 - .535(13.1 - 13.6)46810030-2245-002030-2245-001030-2244-001030-2244-002----031-1295-001031-1294-001031-1299-001031-1298-001----New Machined First-Make Last-Break/Pre-Earth Contacts for 120-1808-200 & 120-1805-200 for Cavity 1 OnlySilver PlatedGold Plated16-2016-20for 120-1808-200 use SSFMLB16-16Sfor 120-1808-200 use SSFMLB16-16SGfor 120-1805-200 use SSFMLB16-16Pfor 120-1805-200 use SSFMLB16-16PG.245 (6.2).245 (6.2)* Silver available 50K minimum, please call.** VE can be used with ITT CANNON VE connectors and Deutsch HD connectors.NOTE:Sure-Seal® and Mini Sure-Seal® contacts are available in machined contact versions. Call for information.
Power Sure-Seal® contacts are machined contacts.
(1) Loose Piece or 5K Reel
Contacts are available loose piece oron continuous reels of 5,000 piecesfor use with semi-automated crimpingsystems.
(2) Wire Hole Fillers
These fillers are inserted into unusedcavities in place of a contact. Wire holefillers are required to retain thewatertight sealing if less than a fullcompliment of contacts are to be used.
(3) Insertion Tool
An insertion tool is required to insert contacts into theconnector. These tools are heavy duty productionhand tools. A holding block should also be usedduring the insertion process. An extraction tool is notrequired. See assembly instructions. A semi-automaticinsertion tool is available. See page 15.
➥
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
RangeCOLUMN 8COLUMN 9COLUMN 10COLUMN 11ToolingCOLUMN 12COLUMN 13Sure-Seal® Wire Insulation DiameterWire HoleFillers(2)InsertionTool (3)Hand CrimpTool(4)ExtractionToolPower/Automatic Tools(5)Mini Applicator(See below andReplacement TipReplacement Locatorpage 14 for.100 - .147317-1153-0171181-92005more details)225-0093-000SSI-T-ToolSSI-CS10(2.54 - 3.73)orDRK 152225-0093-000070306-0000SSI-CS10DRK 152 ➥CBIT-SS-150(see page 15for more detail)Replacement TipReplacement Locator317-1153-0151181-92005 ➥.100 - .147225-0093-000SS-T-ToolSS-CS10DRK 152(2.54 - 3.73)or225-0093-000070235-0001SS-CS10DRK 152Replacement TipReplacement LocatorM3000.055 - .071MSS 2000 TIP1181-005Crimping Press(see page 14(1.40 - 1.80)225-1012-000MSS-T-ToolMSS-CS10DRK 32for more detail) ➥Crimp ToolCrimp Kit.274 - .380-CIT-VE4-6-Kit contains: Crimp die,(6.96 - 9.65)-CIT-VE4-6-400BHDLocator(s), and Go No-Go.159 - .245—Gauge. Provide sample of-CIT-VE8-10-wire when ordering. (Call for(4.04 - 6.22)-CIT-VE8-10-more information.).100 - .147(2.54-3.73)—076303-0000AF8 withTH452DRK 152WA27FTH452▲ IMPORTANT: Use holding blocks on page 5.Power insertion tool available, see page 15.
➥
➥Mini Applicator for insulation support
®(4) Hand Crimp Tools
For Sure-Seal stamped contacts
These are heavy duty tools with a ratchet mechanism that will onlyMini applicator modulesrelease the contact when the crimp is completed. These tools produceare used in industry stan-consistent, high quality crimps. They are the only hand crimping toolsdard crimp presses. Thisrecommended for Sure-Seal® contacts.
allows for fast changeoverfor crimping different con-(5) Semi-Automatic Crimp Tools
tacts and by using thesame crimp press, savesFor high volume applications, several types of semi-automaticvaluable factory floorcrimping tools are available for all Sure-Seal® contacts. See pagesspace versus having to13 and 14.
➥
use multiple presses.See page 15.
➥
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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○○○○○○DimensionsSure Seal Plugs & Receptacles○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○Sure-Seal®▲
8
1 Circuit Plug P/N 120-1832-000 Receptacle P/N 120-1833-0002 – 4 Circuit
PlugReceptacleBody IdentifierSS-1 P/RSS-2 P/RSS-3 P/RSS-4 P/RPlug Number (P)120-1832-000120-1807-000120-1808-000120-1809-000Receptacle No. (R)120-1833-000120-1804-000120-1805-000120-1806-000A Dia. Max..380 (9.65).550 (13.97).600 (15.24).600 (15.24)B Dia. Max..550 (13.97).710 (18.03).760 (19.30).760 (19.30)C. Max..230 (5.84).430 (10.92).500 (12.70).500 (12.70)5 – 10 Circuit
PlugBody IdentifierSS-5 P/RSS-6 P/RSS-7 P/RSS-8 P/RSS-9 P/RSS-10 P/RPlug Number120-1841-000120-1842-000120-1873-000120-1865-000120-1867-000120-1869-000Receptacle No.120-1839-000120-1840-000120-1874-000120-1866-000120-1868-000120-1870-000A Dia. Max.1.010 (25.65)1.010 (25.65)1.010 (25.65)1.135 (28.83)1.135 (28.83)1.135 (28.83)B Dia. Max.1.160 (29.46)1.160 (29.46)1.160 (29.46)1.285 (32.)1.285 (32.)1.285 (32.)ReceptacleC Max..810 (20.57).810 (20.57).810 (20.57).935 (23.75).935 (23.75).935 (23.75) D Max.1.610 (40.)1.610 (40.)1.610 (40.)1.610 (40.)1.610 (40.)1.610 (40.)For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
DimensionsSure Seal Flanged PlugsSure-Seal®2 – 4 Circuit1.571 (39.9).874 (22.2)±.012 (0.3).126 (3.2).571 (14.5)±.008 (0.2)1.181 (30.0)±.008 (0.2).906 (23)±.004 (0.1)ABCE.126 (3.2)D±.006 (0.15)Use with MountingPlate #066-8516-000ABCDBodyPartDia.Dia.Dia.Dia.EIdentifierNumber+.12 (0.3)+.008 (0.2)+.012 (0.3)+.012 (0.3)+.008 (0.2)SSF-2P120-8552-200.547 (13.9).524 (13.3).425 (10.8).307 (7.8).039 (1.0)SSF-3P120-8552-201.598 (15.2).583 (14.8).484 (12.3).315 (8.0).020 (0.5)SSF-4P120-8552-202.598 (15.2).583 (14.8).484 (12.3).354 (9.0).039 (1.0)8 – 10 Circuit1.38(35).393 (9.98).417 (10.59).059.150(1.50)(3.8).130(3.30)1.06(27)1.088 (27.)1.104 (28.04).917 (23.29)1.112 (28.24).933 (23.70)1.136 (28.85)1.088 (27.)1.104 (28.04).126(3.2).862 (21.).158.886 (22.50)(4.01)BodyPlug Number1.46 (37.08)Identifier±.020 (0.5)SSF-8P120-8552-305Use with Mounting PlateSSF-9P120-8552-306#066-8516-002 or #066-8516-003SSF-10P120-8552-307Mini-Sure-Seal Plugs & Receptacles2 – 4 Circuit
PlugReceptacleBodyPlug (P)Receptacle (R)ABCDIdentifierPart NumberPart NumberDia. Max.Dia. Max.Dia. Max.Max.MSS-2 P/R120-8552-100120-8551-100.340 (8.).390 (9.91).540 (13.72).550 (13.97)MSS-3 P/R120-8552-101120-8551-101.360 (9.15).420 (10.67).580 (14.74).550 (13.97)MSS-4 P/R120-8552-102120-8551-102.360 (9.15).450 (11.43).610 (15.50).550 (13.97)For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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○○○○○○DimensionsPower Sure-Seal®PlugBodyPartIdentifierNumberSS-1P-4120-1905-000SS-1P-8120-1906-000AWGSize#4 or #6#8 or #10○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○Sure-Seal®▲
10
PlugReceptacle
BodyPartAWGIdentifierNumberSizeSS-1R-4120-1903-000#4 or #6SS-1R-8120-1904-000#8 or #10ReceptacleAccessoriesBoot
KFits over the rear of the connector andseals the jacket of a multi-conductor cable.Also provides additional strain relief and
abrasion resistance.
BDCall for newovermoldedoptions and120-2G heatshrink bootoptions!
BodyIdentifierSS-2 BootSS-3 Boot+SS-4 Boot+SS-5–7 BootSS-8–10 BootPartNumber317-1398-000317-1397-000317-1399-000317-8657-000317-8657-002B Dia. Max..650 (16.51).610 (15.50).750 (19.05)1.063 (27.00)1.220 (31.00)Cable O.D..208-.228 (5.28-5.79).220-.240 (5.59-6.10).345-.380 (8.76-9.65).283-.331 (7.20-8.40).394-.488 (10.00-12.40)KRef.2.050 (52.07)2.050 (52.07)2.050 (52.07)2.441 (62.00)2.480 (63.00)DDia. Max..380 (9.65).380 (9.65).500 (12.70).492 (12.50).732 (18.60)Mounting Ring
Note: In addition to boot, remember to use 225-0093-000 Wire Hole Fillers to fill any unused contact cavities.
+ May be used to cover industry standard BNC crimp style plugs. Call for more info.
See page 4 for matching plugs and receptacles chart.
➥
A Mounting Ring snaps into anappropriate sized hole in a panel orbracket and allows a non-flanged plugor receptacle to be panel mounted.
PartNumber351-10-000351-11-000351-1633-000351-1634-000ADia. Max..410 (10.41).470 (12.06).755 (19.05).875 (22.23)BDia. Max.1.275 (32.39)1.275 (32.39)2.200 (56.)2.200 (56.)CDia. Max..790 (20.07).790 (20.07)1.445 (36.70)1.445 (36.70)FMax..230 (5.84).230 (5.84).330 (8.38).330 (8.38)HRef..055 (1.40).055 (1.40).065 (1.65).065 (1.65) ➥LMax..690 (17.53).690 (17.53).830 (21.08).830 (21.08)HoleDiameter.781(19.84)1.50(38.12)PanelThickness.060(1.52)See page 4 for matching plugs and receptacles chart.For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
AccessoriesMounting PlateSure-Seal®For 2 – 4 Circuit Plug066-8516-000for use with120-8552-200120-8552-201120-8552-202Use Nutplate part number M85528/2-14A .Mounting DimensionsUse Sealing Screws for mounting, see Accessories page 12.For 8 – 10 Circuit Plug ➥MetricThreadedHole066-8516-002 (Through-Hole)for use with120-8552-305Mounting Dimensions120-8552-306Use Nutplate part number M85528/2-18A .120-8552-307Use Sealing Screws for mounting, see Accessories on page 12. ➥Mounting Clip (Sure-Seal® only)III
I
II
StyleBodyPartColorsABCDEFGIdentifierNumberMax.+/-.01Max.Max.ISS-1C026-0452-000Black2.225 (56.52).740 (18.80)–––.210 (5.33).390 (9.91)IISS-2C029-0263-000Red2.443 (62.04).886 (22.50)1.000 (25.40).420 (10.67).420 (10.67).400 (10.16).650 (16.51)IISS-3-4C029-0262-000Yellow2.443 (62.04).926 (23.52)1.053 (26.74).450 (11.43).480 (12.19).400 (10.16).650 (16.51)IIISS-5-7C026-0450-000Natural3.045 (77.34)1.395 (35.43)–––.610 (15.49).910 (23.11)IIISS-8-10C026-0451-000Black3.045 (77.34)1.520 (38.61)–––.660 (16.76).960 (24.38)For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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Special ProductsRectangular Sure-Seal® Connector○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○Sure-Seal®▲
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.940(23.87)MAX.1.250(31.75)MAX.1.080(27.43)MAX.Part Number120-1873-007.500(1.27)MAX..650(16.51)MAX..940(23.87)MAX.Tie WrapMountingSlot.697(17.71)MAX..510(12.95)MAX..150(3.81)MAX.1.067(27.10)MAX..250(6.35)MIN.Tie WrapMountingSlot.510(12.95)MAX.1.405(35.69)MAX..650(16.51)MAX.Part Number120-1874-007AccessoriesSealing ScrewsSealing screws are designed witha groove underneath the headto incorporate an O-ring. Whentightened, the O-ring is compressedagainst the connector flange toform an air, water, and gas-tightseal. Sealing screws are used inconjunction with the nutplatesbelow.CDLength\"O\" RingCDLength\"O\" RingThread SizeThread Size(S) Slotted Pan Head(R) Phillips Pan Head Part NumberS-440-1/2R-440-1/2Thread4-40NC-2A4-40NC-2ALength1/2\"1/2\"C Max.220\".238\" Clear HoleD MaxMinMax.069\".125\".129\".080\".125\".129\"Nut PlatesNutplates should be used in conjunction with mounting plates.
Nutplates eliminate the need for loose nuts which are often difficultto negotiate in confined areas. As well, they effectively distribute thescrew tension across the back of the panel. The bracket is aluminumalloy with Alodine plating, and the nuts are steel alloy platedcadmium. Nutplates mate with above sealing screws.
Nut Plate P/N For Sure Seal (uses 4-40 screws) P/Ns120-8552-200 M85528/2-14A120-8552-201120-8552-202120-8552-305 M85528/2-18A120-8552-306120-8552-307Alcohol PenIsopropyl alcohol is the only lubricantrecommended by Sure Seal Connectionsto ease insertion of contacts into the SureSeal connector cavity. This pen is small andeasy to manipulate, dispensing as much oras little alcohol as needed directly onto thecontact or into the cavity. Perfect for toolkits, shirt pockets, or anywhere a largercontainer might be inconvenient.
Part Number1610NSpecifications subject to change; see inside back cover.
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comAssembly InstructionsWire and Jacketed Cable PreparationSure-Seal®Max. lengthStrip wires to appropriate length (See contact charton page 6 for strip lengths). If using a boot,strip jacket so no more than listed dimension isexposed when contact is full inserted.
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# CircuitsMax. exposedlengthInches (mm)Note: Try stripping back jacket approximately 1.25 inches (32mm)because strip lengths will vary depending on cable being used.2, 3, 45, 6, 78, 9, 10.87 (22)1.02 (26)1.02 (26)Sure Seal Hand Crimp Tool Operation Instructions
The Sure Seal hand crimp tool has a full cycle ratchet controlled release and straight action crimp jaws. The flap locator makes it easy to load theterminal and the pre-positioner assures that the terminal is loaded for proper crimping. To open the tool, you must apply force to the handles toallow the tool to spring open.1. Open hand
Open flap locator.Close flap locator.Pre-close the
crimper by squeezing2. Insert contact up to stop.3. 4. Press pre-positionerdownward firmly for contacthandles5. handles until handlesMake sure contact isalignment. (crimp areaspring open.
inserted properly.should be facing upward).Hand ToolFor ContactsWire StripPart NumberContact TypePinSocketLengthSSI-CS10Insulation030-2196-001031-1267-001.155-.185Support030-2196-005031-1267-006(4.0-4.7)SS-CS10Non-Insulation030-2196-000031-1267-000.185-.220Support030-2196-008031-1267-007(4.7-5.6)MSS-CS10Mini330-8672-100031-8703-100.118-.130(3.0-3.3)6. (Above, left) Insert stripped* wireTool Maintenance: Maintenance and inspection should be performed regularly. The tool should beinto contact up to insulation stop.wiped clean with special emphasis on crimping cavities. The tool may be cleaned by immersing in auntil they pop open. Remove contact7. (Above, right) Squeeze handles
suitable commercial solvent or cleaner that does not attack paints or plastic material. The tool shouldbe re-lubricated after cleaning using a light film of a medium weight oil on bearing surfaces andfrom locator.
pivot pins. When not in use, keep handles closed to prevent objects from becoming lodged in thecrimping dies. Store in a clean dry area.Power Sure-Seal® Machined Contact Crimp Tool
400BHD
The SS400BHD is a pneumatically power heavy duty crimp tool designed forcontacts that are too large to be crimped by hand tools. The 400BHD comeswith a power unit and bench mounting bracket. The 400BHD is actuatedwith either the standard handle actuating switch or optional Pneumatic FootPedal (PFP). Crimp Die Kits are ordered separately (see page 7). It ishighly recommended that you provide a sample of your wire when ordering ➥
these Crimp Die Kits. Your wire sample will be crimped and tested for propercrimp tensile strength.
Power Requirements: 90-125 PSI 1-2 CFM of dry, oil free, air
Operating Instructions: (Call for operating instructions)
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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Assembly InstructionsSemi/Automatic Crimp Tooling
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Mini Applicator
The Sure-Seal mini-applicator is designed for use in most common crimping pressesand automatic wire processing systems. It utilizes a quick change mounting system,which allows the applicator to be installed or removed in two quick steps. This makesthe change over from one applicator to another for crimping a variety of contactsutilizing the same press fast and easy. We offer this side-feed applicator for our mostpopular stamped and formed terminals (see below).
ApplicatorSSMA-SSISSMA-SSMSSMA-SSI
Terminal
110238-0195 & 110238-0194110238-0040 & 110238-0085121348-0100 & 121347-0100
M3000 Crimping Press
The M3000 crimping press is compatible with most side-feed mini-applicators forautomated terminal crimping and is the most economical \"state-of-the-art\" crimpingpress on the market. The M3000 accomodates our mini-applicator listed above aswell as most \"left-to-right\" and \"rear\" quick change \"mini\" style applicators. Otherfeatures include precision crimp height adjustment, electronically interlocking safetyguard, jog cycle and 110V power supply.
Crimp monitors and counters are also available. Call for more information.
Crimp Inspection
Micro sections: Enlargement of micro section allows for final judgment of crimp
quality. This test is recommended whenever new tools or new types of wire are used.NOTE:For accurate pull test results when crimping insulation support contacts
(030-2196-001 & 031-1267-001), strip wire back .3\" so that the insulationsupport tine does not crimp onto insulation.
12345insulationstrandscontactwire inspection holeshoulderFor machined power contacts
Correct Crimp
1
strands must be visible43
2
Incorrect Crimp
5single strand
412
5
3For stamped contacts
5Correct Crimp
1
2strands must
be visible
3
Incorrect Crimpsingle strand12strands extend too
far into contact.3
Incorrect Crimp
12strands not visible
3
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
Assembly InstructionsManual Insertion of ContactsSure-Seal®1.Affix proper connector holding block to stable surface (i.e. vice or table).
See Connector Selection table, page 5, for proper holding block.be slid up the cable (isopropyl alcohol will help indoing this).
holding block with the back end up (wire side). ➥
2.If a jacket wire sealing boot is to be used, it must3.Dip connector in isopropyl alcohol and place in4.Using proper contact insertion tool, (see Contact
Selection table for proper tool):A.place contact in groove of tool
B.make sure that end of the tool is up against
the shoulder of the contact.
5.Insert contact into proper cavity of the connector body by applying
constant pressure until contact snaps into place. Isopropyl alcohol willhelp in doing this. (Warning: Do not tilt the tool during the insertion).6.Insert all remaining contacts. To insure environmental sealing of the
connector any empty contact cavities must be filled with wire hole fillers(see Contact Selection table, page 5, for proper wire hole filler).
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7.Check mating side of the connector to be sure that all contacts are on
the same plane (fully inserted).
8.If you are using jacket sealing boot, slide the boot down the cable and
onto the connector.
9.Remove connector and wire assembly from holding block.
Pneumatic Automatic Insertion Tool (Leased)
CBIT-SS-150
The CBIT-SS-150 Sure-Seal® insertion machine is pneumatically powered, and micropro-cessor controlled. It is designed to insert pre-crimped wires into the standard Sure-Seal®plug and receptacle housings for moderate to high volume applications. This machineis used for SS2P/R through SS10P/R including the 120-1873-007 and 120-1874-007rectangular style Sure-Seal® connectors.
The benefits of using this insertion machine are:
•Ease of operationShort operator training time
Reduces operator fatigue and insertion errorsQuick change over for different connectors sizes
•Low cycle timeMuch faster than manual insertion•High connector integrityLower chance of damaging the wire sealing ripplesPower Requirements:Electrical = 115 Vac, 60 Hz
Pneumatic = 80 PSI, 10 CFM dry oil free filtered air
Extraction of Contacts
1.Slide up any rear accessories (i.e. jacket cable
sealing boots). Using isopropyl alcohol will helpyou slide these up your cable.
2.Grasp individual wire firmly and gently pull the
contact out of the connector.
* Extraction tool available DRK32 & DRK152, please call.
For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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Test DataSure-Seal® Circular Connectors
Typical: Power Sure-Seal®, Flange Sure-Seal®, and Mini Sure-Seal® are essentially the same except for mechanical and amperagecapacity differences. Sure-Seal® products are designed to meet specification CS-155. Items of most general interest to users anddesigners are listed below. With its current capability and large size, Power Sure-Seal® contacts and currents are covered in CS-169.
TestDescriptionEnvironmentalSealingContactTensileStrength–Crimp○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○Sure-Seal®▲
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ReferenceParagraph3.5.13.6.12RequirementsSure-Seal® connectors when mated shall form an environmental seal against water, moisture, aqueous solutions, oils and certain chemicals as well asdust and dirt. Tests include immersion in 3 feet depth in water solution containing 5% salt.The minimum tensile load required to separate the wire from the contact, either by pulling the wire out of the crimp joint or breaking the wire withinthe crimp joint, shall not be less than the applicable limits as specified. Wire breakage, or contact damage not due to crimping, at less than tensileloads shall not constitute failure.Crimp Tensile Strength, Pounds MinimumWithoutWithWithoutWithWithoutWithInsulation InsulationInsulation InsulationInsulation InsulationWire SizeSupportSupportWire SizeSupportSupportWire SizeSupportSupportAWGContactsContactsAWGContactsContactsAWGContactsContacts4140—1080—1825256100—14353520—200—163535Properly assembled and mated connectors shall be tested in accordance with MIL-STD-202, Method 302, except a potential of 500 ± 15 volt DC shallbe used. The resistance shall be measured between adjacent parts of contacts (or contacts to ground for SS-1) and shall not be less than 100 MΩ. Ifthe specimen has been immersed in fluid in the preceding test, it shall be placed wet on a conducting surface and insulation resistance measuredwithin 5 minutes between each contact and also between each contact and the conducting surface (except for SS-1 to be measured contact toground while immersed).Assembled and mated connectors shall show no evidence of breakdown between adjacent contacts (or contact to ground for SS-1) when tested inaccordance with MIL-STD-202, Method 301, and a test voltage of 1200 ± 15 volts A.C.The contact resistance of mated contacts shall be such that the resistance measured across the contacts and 5/8\" behind the crimp junction shall notexceed 10 mΩ. Test current to be 1 amp, and MIL-STD-202, Method 307.Mated connectors properly mounted shall be subjected to the shock test in accordance with MIL-STD-202, Method 213B, CONDITION B. The shocktest shall be repeated three (3) times in each of X, Y & Z axis. Suitable means shall be employed to monitor the current flow. Current discontinuity of 1microsecond or more, disengagement of the mated connectors, evidence of cracking, breaking or loosening of parts shall be cause for rejection.Properly assembled and mated connectors shall be mounted to the vibration table, with the wire leads strapped to a vibrating member approximately3 inches from each end of the connector body and vibrated with a peak-to-peak amplitude of .25 inch across a frequency range of 5 to 39Hz, and a±20g acceleration across 39 to 55 Hz, swept up in one minute and down in another minute. The vibration shall be swept up and down for a total of36 hours under the following conditions:Six (6) hours at 180°F (82°C) along the longitudinal axisSix (6) hours at 180°F (82°C) along a perpendicular axisSix (6) hours at room temperature along the longitudinal axisSix (6) hours at room temperature along a perpendicular axisSix (6) hours at -40°F (-40°C) along the longitudinal axisSix (6) hours at -40°F (-40°C) along a perpendicular axisThe connectors shall be connected in a series circuit with a minimum of 0.1 ampere flowing through the contacts. Electrical continuity shall becontinually monitored. Breaks in continuity longer than one microsecond shall be cause for rejection.The connectors shall be subjected to 25 cycles of mating and unmating at -10°C and another 25 cycles at 50°C. There shall be no evidence ofdamage to the contacts, the contact plating, the insulators or sealing rings, which would be detrimental to connector function.With the connector plug or receptacle held firmly, an axial dead weight of 7.5 lbs. shall be imposed on each wire for one minute without the contactsbeing dislodged from the connector. Plugs and receptacles to be tested separately.Each wired receptacle and plug shall be subjected to 5 cycles of contact insertion and extraction in the same cavity using the approved tools. Plugand receptacle are to be tested separately. After the 5 cycles of insertion and extraction, each plug and receptacle in turn will be subjected to thecontact retention test of 6 lbs. per paragraph 4.4.7.Using an assembled and mated connector with the receptacle held firmly by the wires, a load shall be applied to the wires of the plug until theconnector is completely separated. The rate of loading shall be one inch per minute. The sample shall fall within the limits specified as follows:Unmating Forces (lbs.)Unmating Forces (lbs.)Connector Sizemax.min.Connector Sizemax.min.SS-1126SS-4209SS-2156SS-5/73010SS-3188SS-8/105510Wired and mated connectors shall be subjected to the applicable fluids for the length of time specified. Following the test the connectors shall beimmersed to a depth of 3 feet in salt water for 24 hours at room temperature. At the completion of the salt water immersion test and while stillimmersed insulation resistance shall be measured. Failure to meet the insulation resistance requirements shall be cause for rejection.Gasoline Splash1 second dip - 3 minute air dry for 80 cycles at room ambient temperature.Diesel Fuel Splash1 second dip - 3 minute air dry for 80 cycles at room ambient temperature.Automotive Lubricating OilImmersed in S.A.E. 30 weight lubricating oil for 1 hour.AntifreezeImmersed at 120°F (49°C) for 48 hours.Brake FluidImmersed at room ambient temperature for 24 hours.Automatic Transmission FluidImmersed at 120°F (49°C) for 48 hours.Gasoline VaporImmersed in a gasoline vapor atmosphere at room temperature for 48 hours.Wired and properly mated connectors shall be subjected to ozone test per AS-1149 except that 100 ppm of ozones shall be used. The duration ofthe test shall be 7 days. Outdoor exposure to be conducted per ASTM D-1171. The connector shall show no cracking or other degradation whichwould result in loss of sealing integrity.Wired mated connectors shall be tested in accordance with MIL-STD-202 Method 108A, Test Condition D at 105°C for 1000 hours. Following the test,they shall be subjected to 3 feet salt water immersion for 24 hours. While immersed, insulation resistance shall be determined. Failure to meet theinsulation resistance requirements shall be cause for rejection.Sure Seal Connections has recently completed testing of the Sure Seal PVC Nitrile material (SM 3400-06) for UV resistance. The material was tested inaccordance with ASTM G-26 (Xenon Arc), 720 hours exposure with no loss in tensile strength and greater than 75% retention of elongation.InsulationResistance4.4.1DielectricWithstandingVoltageContactResistanceShockVibration4.4.24.4.34.4.44.4.5DurabilityContactRetentionMaintenanceAgingConnectorSeparatingForce4.4.6 4.4.74.4.84.4.11SolventResistance4.4.134.4.144.4.154.4.1.4.174.4.184.4.194.4.204.4.23Weatherand OzoneResistanceHighTemperatureLong-TermUV-Caution: “Sure-Seal® connectors are rated for use between temperatures of -40 to + 105 degrees Celsius. However, if a Sure-Seal® connector is exposed for long periods oftime to temperatures exceeding 85 degrees Celsius and is unmated, it may lose its environmental sealing integrity upon remating. Thus, we recommend that both theplug and receptacle be replaced if environmental sealing is required after remating.”
16For technical assistance, price or delivery info. call 1-800-523-0727 or visit www.suresealconnections.comSpecifications subject to change; see inside back cover.
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