1
/
29
Document No.
HDM-0012
Confidential C
I-PEX Inc.
QKE-DFFDE09-03 REV.8
ISH
®
VW CONNECTOR
Instruction Manual
RS0789
January 6, 2021
H. Naoi
S. Tono
E. Kawabe
0
RS0615
August 7, 2019
J. Tateishi
Rev.
ECN
Date
Prepared by
Checked by
Approved by
Page 1: ... Confidential C I PEX Inc QKE DFFDE09 03 REV 8 ISH VW CONNECTOR Instruction Manual 1 RS0789 January 6 2021 H Naoi S Tono E Kawabe 0 RS0615 August 7 2019 H Naoi J Tateishi E Kawabe Rev ECN Date Prepared by Checked by Approved by ...
Page 2: ...ion 5 Secondary lock installation 6 How to release secondary lock 7 How to release terminals 8 Mating of connector 9 Unmating of connector 10 Handling of Product 11 Storage of housings and terminals 12 Jig 13 Other notes 14 Contact Sheet 3 Sheet 3 Sheet 4 Sheet 14 Sheet 15 Sheet 18 Sheet 20 Sheet 24 Sheet 25 Sheet 26 Sheet 28 Sheet 28 Sheet 29 Sheet 29 ...
Page 3: ...fidential C 1 Purpose The Manual explains the handling of ISHVW CONNECTOR 2 Applicable items The Manual is applicable to the items listed below MALE TERMINAL VT002 012 Name Part No Image FEMALE TERMINAL VT001 512 MALE CONNECTOR FEMALE CONNECTOR Fig 1 Product summary ...
Page 4: ...rs as shown in Fig 3 Do not use wires with damaged conductors cut off conductors short conductors and deformed conductors Using faulty wires may cause crimping problems MALE TERMINAL VT002 012 VT001 512 Wire size 0 3mm2 0 5mm2 Insulation outer diameter φ1 60mm MAX FEMALE TERMINAL Terminal Type Terminal Parts No Applicable Wire Cut off conductors defect Deformed conductors defect Condition Image Go...
Page 5: ...he wire Please contact our Sales Department shown in 14 sheet 29 about wire used then we will verify it and notify you the appropriate crimp dimensions 0 5mm2 0 95 0 05 1 80 0 05 1 60 0 1 0 05 1 55 0 05 VT001 512 VT002 012 0 3mm2 φ1 60mm MAX 0 90 0 05 1 40 0 04 Insulation barrel crimp width Terminal Part No Wire size Insulation outer diameter Wire barrel crimp height Wire barrel crimp width Insula...
Page 6: ...described below To measure the wire barrel crimp height pinch the top of the wire barrel winding side and the bottom of the wire barrel with a micrometer see Fig 7 Secure terminals firmly to obtain accurate measurement Do not pinch the bell mouth The wire barrel crimp height can not measure accurately Section Fig 7 Wire barrel Crimp height measurement Section FEMALE TERMINAL MALE TERMINAL Do not p...
Page 7: ... Fig 8 Secure terminals firmly to obtain accurate measurement 1 3 Measuring method for wire barrel crimp width is described below To measure the wire barrel crimp width pinch the side of the wire barrel with a micrometer see Fig 9 Secure terminals firmly to obtain accurate measurement Fig 9 Wire barrel crimp width measurement Fig 8 Insulation barrel Crimp height measurement MALE TERMINAL FEMALE TE...
Page 8: ...nsulation barrel with a micrometer see Fig 10 Secure terminals firmly to obtain accurate measurement Fig 10 Insulation barrel crimp width measurement 2 Bottom burrs Burrs produced during crimping process must not extend beyond the bottom surface see Fig 11 Fig 11 Bottom burrs Section Micrometer Section Micrometer FEMALE TERMINAL MALE TERMINAL No extension Extension Bottom surface of terminal Botto...
Page 9: ... No HDM 0012 9 29 Confidential C Bellmouth excess conductors and cut off tab Bellmouth excess conductors and cut off tab must satisfy the dimensions shown in Fig 12 Fig 12 Bellmouth excess conductors and cut off tab FEMALE TERMINAL MALE TERMINAL ...
Page 10: ...different dimension of excess conductors or bellmouth between the sides dimensions must be measured on larger side and be satisfied In the case shown in Fig 14 measure excess conductors a bellmouth b Rolling Rolling is 3 MAX from the wire barrel baseline see Fig 15 Fig 15 Rolling Fig 13 Unaligned wire barrel ends Fig 14 Example of unaligned wire barrel ends Example Example FEMALE TERMINAL MALE TER...
Page 11: ...end up and bend down Bend up is FEMALE TERMIANL 1 9mmMAX MALE TERMINAL 1 1mmMAX Bend down is not allowed The height is from the wire barrel baseline to the terminal measurement point see fig 17 and 18 Fig 16 Twist terminal Fig 17 Bend up Fig 18 Bend down No bend down No bend down FEMALE TERMINAL MALE TERMINAL FEMALE TERMINAL MALE TERMINAL Male terminal Female terminal ...
Page 12: ...rs are insuffuciently inserted into the wire barrel see Fig 20 Excessive conductors out Excess conductors protrude from the wire barrel and does not satisfy the dimension in Fig 12 of sheet 9 Fig 21 Incomplete conductors crimping Conductors are not crimped inside the wire barrel or within the terminal see Fig 22 Fig 20 Not fully inserted conductors into wire barrel Fig 19 No rear bellmouth Fig 21 ...
Page 13: ...nsulation is crimped inside the wire barrel see Fig 23 Strip length is too long and insulation does not fit completely inside the insulation barrel see Fig 24 6 Torn insulation Insulation is torn by insulation barrel see Fig 25 Fig 23 Strip too short Fig 24 Strip too long Fig 25 Torn insulation Torn insulation caused by insulation crimping ...
Page 14: ...d Forcibly inserting terminals in any other orientation may result in damage or deformation Terminal can not be inserted in the incorrect orientation see Fig 27 Once the terminal is inserted do not apply excessive pulling force to the wire Fig 26 Terminal insertion orientation Hold the wire Upper row Position Polarization key upper side Lower row Position Polarization key underside Female terminal...
Page 15: ...male terminals are inserted correctly and sufficiently and repeat the insertion procedure in 4 Insert all the female terminals properly and push the female retainer until audible click is heard When female terminal s is are insufficiently inserted as shown in Fig 29 the female retainer cannot be installed Insert the female terminal s completely and install the female retainer again Push in Correct...
Page 16: ... Fig 31 Notes The female retainer must be inserted in the orientation instructed Inserting retainer in any other orientation may result in damage or deformation see Fig 30 31 If there is any damage or deformation do not use the damaged item Replace the item with a new one Fig 30 Insufficient retainer installation The retainer may be easily bent and damaged when inserting into the housing forcefull...
Page 17: ...not be completely pushed Check that the male terminals are inserted correctly and sufficiently and repeat the insertion procedure in 4 sheet 14 Insert all the terminals properly and push the male retainer until audible click is heard When male terminals are insufficiently inserted as shown in Fig 34 the male retainer cannot be installed Insert the male terminals completely and install the male ret...
Page 18: ...use damage or reduced performance Check for any deformation or damage on both of the female retainer and the female housing after releasing the female retainer before continuing any operation If there is any damage or deformation do not use it Replace the item with a new one Only use the retainer releasing jig specified Care must be taken not to damage edge of the jig e g from dropping etc Female ...
Page 19: ...n where the releasing apertures comes out from the side surface of the male housing Male retainer preset position Therefore must not pull the retainer out any more It may cause damage or deformation of the female housing Check for any deformation or damage on both of the male retainer and the male housing after releasing the male retainer before continuing any operation If there is any damage or d...
Page 20: ...position and pull the terminal out by holding the wire see Figs 38 and 39 If there is any difficulty in pulling out the terminal do not pull it forcefully Check that the terminal releasing jig is in the correct position or it is pushed fully into the housing and then repeat the procedures to Female terminal releasing jig Part No AP0004 01 005 Female terminal releasing jig aperture Female terminal ...
Page 21: ...minal releasing jig Part No AP0004 05 002 Male retainer is released Place flat surface of the male terminal releasing jig facing male terminal side Male terminal releasing jig Part No AP0004 05 002 Direction of release Molding lance Fulcrum of the male terminal releasing jig Contact Fig 39 How to release the male terminal ...
Page 22: ...CONNECTOR Instruction Manual Document No HDM 0012 22 29 Confidential C DETAIL A DETAIL B DETAIL A DETAIL B Fig 40 Dimensions of terminal releasing jig Female terminal releasing jig Male terminal releasing jig ...
Page 23: ...e is any damage or deformation on the terminal or the housing do not use the damaged item Replace the item with a new one Only use the terminal releasing jig specified Do not insert the releasing jig into the cavities see Fig 43 If the terminal releasing jig is inserted into the cavities by mistake the terminal may be damaged Replace the terminal with a new terminal Care must be taken not to damag...
Page 24: ...nt insufficient mating After that pull the female connector lightly to check that the female connector is locked Notes Only mate the connector in the direction instructed above Do not forcefully mate in any orientation shown in Fig 45 Doing so may cause damage or deformation to connectors If there is any damage or deformation do not use the damaged item Replace the item with a new one Direction of...
Page 25: ...ll the female connector not the wires when disengaging the female connectors If there is any damage or deformation do not use the damaged item Replace the item with a new one Pressing down the end of the lock arm may not release the lock fully See Fig 47 Pull out female connector Direction of pressing the lock arm Push in lightly Press down on the edge of the lock arm Fig 46 Unmating of connector ...
Page 26: ...d point 0 5N MAX on outside of the female terminal See Fig 48 Do not insert a probe pin into female terminal as this may damage the terminal spring Do not use female terminal if the probe pin has been inserted Replace the female terminal Probe pin must beφ0 55 0 70mm Must not be smaller than the gap between female housing and female terminal 0 5mm Once tested check there is no deformation e g coll...
Page 27: ... item Replace the item with a new one 10 2 Arrangement of Wires When arranging the wires to sideways keep the wires in straight at least 15mm from the connector to avoid excessive stress to the housing sidewalls and terminals or the terminal leaning inside the housing as shown in Fig 51 Once straight portion is secured arrange the wires with adequately large R Place the probe pin on the end of the...
Page 28: ...l s or terminal s may be deformed if the boxes have been damaged 12 Jigs Use the jig specialized for releasing the retainer and for releasing terminals Table 2 shows the name of the releasing jig and their part number To purchase any of the jigs please contact the Sales Dept of our company at the following in14 Sheet 29 Female retainer releasing jig Releasing female retainer AP0031 02 001 Female h...
Page 29: ... wires and that no rain water dust and dirt etc are present Handle products with care If there is any damage deformation discoloration etc to wires housings and any other parts do not use the damaged item Replace the item with a new one Do not touch the contact part of the connector with fingers or with any object Do not apply excessive current Doing so may cause fire and melting damage Do not dis...
