IPEX ISH VW User manual

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Document No.HDM-0012
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

ISHVW CONNECTOR Instruction Manual
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Contents
1. Purpose
2. Applicable items
3. Crimping procedure
4. Terminal insertion
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
・・・・・ Sheet 3
・・・・・ Sheet 3
・・・・・ Sheet 4
・・・・・ Sheet 13
・・・・・ Sheet 15
・・・・・ Sheet 19
・・・・・ Sheet 21
・・・・・ Sheet 23
・・・・・ Sheet 24
・・・・・ Sheet 25
・・・・・ Sheet 26
・・・・・ Sheet 28
・・・・・ Sheet 28
・・・・・ Sheet 29
・・・・・ Sheet 29

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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

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3. Crimping procedure
3-1.Applicable wires
3-2. Wire strip length
①Strip the insulation off by 3.0±0.1mm (see Fig.2)
②Check to see that there is no damage to the conductors or insulation, cut off conductors, short conductors
and deformed conductors 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
Good
Damaged conductors
(defect)
Fig.2 Wire strip
Fig.3 Wire strip(Unacceptable examples)
3.0±0.1mm
Conductors
Insulation

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3-3. Terminal part names
3-3-1. Female terminal
3-4.Crimping requirements
Crimp dimension
Crimped terminals must satisfy the crimp dimension specified in Table 1.
※Crimp dimensions may be different depending on conductor construction of the 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
Insulation barrel
crimp height
Fig.4 Female terminal part names
Fig.5 Male terminal part names
Table 1 Crimp dimension

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Measuring method for crimp dimension is described below.
Use the micrometer shown in Fig.6 for measurement of each part.
Fig 6. Micrometer
(1)-1. Measuring method for wire barrel crimp height is 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 pinch the bellmouth.
Micrometer
Do not pinch the bellmouth.
Micrometer

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(1)-2. Measuring method for insulation barrel crimp height is described below.
To measure the insulation barrel crimp height, pinch the top of the insulation barrel (winding side) and the bottom of
the insulation barrel with a micrometer. (see 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 TERMINAL
Section
Micrometer
Section
Micrometer
Section
Micrometer
Section
Micrometer
FEMALE TERMINAL
MALE TERMINAL

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(1)-4. Measuring method for insulation barrel crimp width is described below.
To measure the insulation barrel crimp width, pinch the side of the insulation 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
Bottom burrs
【Good】
【No good】

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③Bellmouth,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

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④Unaligned wire barrel ends
Unaligned wire barrel ends is 0.1mm MAX..(see Fig.13)
※If wire barrel ends are not aligned, resulting in 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].)
⑤Rolling
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
Example①
Example②
FEMALE TERMINAL
MALE TERMINAL

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⑥Terminal twist
Terminal twist is 1.2°MAX.from the baseline, i.e. the box (baseline). (see Fig.16)
⑦Bend 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

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3-5.Defective criteria
Terminals with the following conditions are deemed defective.
①No rear bellmouth
Rear bellmouth is not formed. (see Fig.19)
②Insufficient conductors insertion
Conductors are insuffuciently inserted into the wire barrel. (see Fig.20)
③Excessive conductors out
Excess conductors protrude from the wire barrel and does not satisfy the dimension in Fig.12 of sheet 9. (Fig.21)
④Incomplete 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 Excessive conductors out
Fig.22 Incomplete conductors crimping

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⑤Incomplete insulation crimping
Strip length is too short and insulation 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.

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4.Terminal insertion
①Ensure that the terminal is crimped correctly and there is no damage, deform or dirt present.
②Hold the wire to insert the terminal as shown in Fig.26.
③Insert the terminal into the corresponding corehole of the housing, as deeply as possible, in the orientation as shown in Fig. 26.
④Once the terminal is inserted, ensure that the terminal retention is fastened by pulling the wire lightly towards you.
Notes:
①Terminals must be inserted in the orientation instructed. 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)
②Once 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
Female housing
Male housing
Male terminal
Male terminal
Since the terminal polarization keys interfere the housing, the terminal is unable to insert.
Fig.27 Orientation of incorrect terminal insertion
Female terminal
Female terminal
Hold the wire
Lower row Position：Polarization key (underside)
Upper row Position：Polarization key (upper side)
Male terminal

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5.Retainer installation
5-1.Female connector
①After female terminal insertion is complete, install the female retainer.
You will hear audible click when the female retainer is engaged properly.
②Check that the female retainer is pushed in completely, i.e. aligned with the sidewall of the female housing.
When the female retainer cannot be pushed in completely, do not push forcefully.
Check that the female 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.
③When 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
Correctly engaged
Fig.28 Installation of retainer
SECTION A-A
SECTION B-B
Fig.29 Insufficient female terminal insertion
Female retainer
Female housing
A female terminal is insufficiently inserted.
The female retainer cannot be properly inserted because female terminals interfere.

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④Do not forcefully insert in any other position than those shown in Fig.30.
⑤The female retainer cannot be inserted, when it is inserted in incorrect orientation to the female housing, as shown in Fig.31.
Notes
①The 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)
②If 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 forcefully.
Insertion is blocked by walls.
Fig.31 Incorrect retainer installation

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5-2. Male connector
①Make sure that the male retainer protrudes from the side of male housing surface before inserting the male terminal into the male housing.
If the male retainer are engaged with the male housing, pay attention not to deform the male housing, and release the male retainer by
the method in 6-2 (sheet 19).
②Push the male retainer perpendicularly to the male housing as shown in Fig.33 after male terminal insertion is
complete. You will hear audible click when the male retainer is engaged properly.
③Check that the male retainer is completely pushed, i.e. aligned with the side surface of the male housing.
Do not push the male retainer forcefully when it cannot 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.
③When 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 retainer again.
Notes
①If there is any damage or deformation, do not use the damaged item. Replace the item with a new one.
Fig.32 Checkpoint before engaging male retainer and the male housing.
OK：Male retainer preset position
No good：Retainer engaged position
Male retainer
Push in
Correctly engaged
Fig.33 Installation of Retainer
SECTION A-A
The male terminal is insufficiently inserted.
Male retainer
Male housing
Fig.34 Insufficient male terminal insertion
The male retainer cannot be properly
inserted because male terminals
interfere.
Male housing

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6.How to release the retainer
6-1.Female connector
①Place the female retainer releasing jig into the releasing apertures situated on the side of the housing
(Pos.1side), and push out the retainer (see Fig.35).
Notes
①Do not use the releasing jig for any other part of the female housing other than the releasing apertures.
Doing so may cause damage or reduced performance.
②Check for any deformation or damage on both of the female retainer and the female housing after
releasing the female retainer, before continuing any operation.
③If there is any damage or deformation, do not use it.
Replace the item with a new one.
④Only use the retainer releasing jig specified.
⑤Care must be taken not to damage edge of the jig (e.g. from dropping, etc.)
Female retainer releasing jig
Part No.:AP0031-02-001
Fig.35 How to release the female retainer
Female retainer
Female housing
Female retainer releasing jig aperture
Fig.36 Dimensions of female retainer releasing jig

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6-2.Male connector
①Insert a screwdriver( width :2.5mm MAX./thickness：0.6mmMAX.) into the releasing jig aperture in
the side surface of the male housing, and push out the male retainer. (see Fig.37).
Notes
①Do not use the screwdriver for any other part of the male housing other than the releasing apertures.
Doing so may cause damage or reduced performance.
②Complete releasing at the position 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.
③Check for any deformation or damage on both of the male retainer and the male housing after releasing the male retainer, before continuing
any operation.
④If there is any damage or deformation, do not use it.
Replace the item with a new one.
⑤Only use the specified screwdriver for releasing the male retainer.
⑥Do not use screwdriver with damage or deformation.
Releasing jig aperture
Direction of release
Fig.37 How to release the male retainer

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7.How to release terminals
①Ensure that the retainer has been removed.
②Hold the wire and push the terminal lightly. Insert the terminal releasing jig into the apertures of the housing (see Fig. 38 and 39).
③Push fully the terminal releasing jig into the molding lance,then lever up the molding lance as shown in Fig.38.
Keep the terminal releasing jig in that position and pull the terminal out by holding the wire. (see Figs. 38 and 39).
④If 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 ①to ③.
Female terminal releasing jig
Part No.：AP0004-01-005
Female terminal releasing jig aperture
Female terminal releasing jig
Part No.：AP0004-01-005
Releasing direction
Molding lance
Fulcrum of the female terminal releasing jig
Fig.38 How to release the female terminal
Female retainer is released.
Contact
Place flat surface of the jig outside.