FUJITSU Component Connector
Standard Operating Instruction of Contact
Crimping for FCN-360 Connector

FUJITSU COMPONENT LIMITED‐1‐Introduction
For cable wire termination to connectors, there are various type in connection method.
FUJITSU FCN-360 series connector has “crimping connection” type product to connect wire tothe connector contact.
This method is also called “pressure connection”. Applying mechanical force to two
conductors makes tight metal contact, that secures permanent connection by maintaining
contact due to residual stress or bonding force between metals.
Crimping connection has an advantage to have uniform quality in wire connection.
To keep this superior feature, it is important to operate crimping work under properconditions. Failing to carry out work management might cause unexpected defect.
This operating instruction mainly focuses on check of crimped contact.
Have a read through it before starting crimping work, and use it for the work management
as a standard operating instruction.

2‐2‐

Table of Contents
1. List of Tool, Wire, Crimp height
2. Contact configuration and description
3. Crimped contact configuration and description
4. Wire strip5. Bell mouth, Cut-off tab, Burr
6. Tensile strength and measurement method
7. Crimp height and measurement method
8. Insulation barrel shape and check method
9. Crimped contact shape
10. Cross section of housing with the contact loaded
11. Check points‐3‐1. List of Tool, Wire, Crimp height

Hand crimping
tool part number

FCN-363T-T005/H(for standard wire)

FCN-363T-T011/H(for thick wire)Contact
part number

Crimpheight(mm)Wiresize(AWG#)

FCN-363J-AU

1.25～1.30
1.20～1.25
1.15～1.20

#24
#26
* #28

0.20～0.24
0.13～0.16
0.088～
0.096

#22
#24
#26
* #28

0.30～0.40
0.20～0.24
0.13～0.16
0.088～
0.096

FCN-363J-AU/S

0.85～0.95
0.75～0.85
0.73～0.81
0.66～0.74

Section area(mm2)Striplength(mm)3.0～4.0

3.0～4.0

The hand crimping tools, when delivered, have been already adjusted for use with thespecified contacts and asterisked (*) wires.

‐4‐

Outer
diameter(φ)

1.2

1.0～1.6

2. Contact configuration and description

Contact (mating part)
Serration

Insulation barrel
Wire barrel

Cut-off tab

Insulation barrel
Wire barrel
Cut-off tabSerration：：：：

Wire insulation holding part
Wire crimping part
Remains after the contact cut-off
Concave portion inside the wire barrel‐5‐3. Crimped contact configuration and description
3.1 Crimped contact configuration and description

Wire crimped seamInsulation barrel
Wire barrel

Effective crimp length
Rear side bell mouth

Front side bell mouth

Cut-off tab

3.2 Cross section of crimped contact

Crimp heightBurr‐6‐

4. Wire strip
4.1 Strip length
To determine wire strip length, use the wire barrel length as the base and check results in
crimped contact shape〔Rough Indication〕 Strip length : 3.0～4.0mm〔Crimped contact shape〕(1)(1) Wire should be visible from above(0.6 mm max.)(2) Insulation should protrude from the barrel(2)(Rough indication 1.0 mm max.)

4.2 Stripped condition〔Good item〕 Wire has no flaws, and is aligned cleanly〔Inferior item〕 Do not use wire that has breaking nor scraggly alignment

Inferior item

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5. Bell mouth, Cut-off tab, Burr
Rear side bell mouth

Front side bell mouth

1.60mm max.
(1) Size of bell mouth at both sides should same, or rear side should be bigger(2) Height of bell mouth at front side should be 1.60mm max. otherwise it would interferewith housing and contact retention might get lower(3) Be sure to make rear side bell mouth to avoid wire breaking(4) Even if no front bell mouth, it is good item. In this case, size of rear side bell mouthshould be 0.5mm max.
0.5 mm max.

No front side bell mouth

Cut-off tab (0.4 mm max.)

Crimp heightBurr‐8‐0.2 mm max.

(5) Size of cut-off tab should be referred to above dimension as a rough indication.
(6) Concerning to burr size, one side should not get too big6. Tensile strength and measurement method
6.1 Tensile strength management
Tensile strength has close relation with crimp height. If crimp height is within standard
specification, tensile strength should also conform to the specification.
Tensile strength after crimping gets lower than that of wire itself because crimping workmakes cross section of the wire smaller, also the wire gets off due to a gap between the barrel
and the wire in case crimping is insufficient.
Tensile strength becomes different even with the same crimp height depending upon wireconfiguration, wire constituent and so on even in the same wire gauge (AWG). Following
table shows standard specification (reference) of tensile strength for each wires.
(Reference value)
Tensile strength (Kg max.)
Wire gauge

FCN-363J-AU(for standard wire)

FCN-363J-AU/S(for thick wire)

AWG#22-

3.5

AWG#24

3.18

3.18

AWG#262.04

2.04

AWG#281.36

1.36

6.2 Measurement method
Measure tensile strength when the wire breaks or comes off crimped part, by attaching
following test sample to a tensile tester and pulling it at specified speed (25.4mm/min., or100mm/min.). Use a spring scale when the tensile tester is not available. Number of the test
sample should be 10pcs min.
Test sample(Wire cut length) 150 mm(Retention length) 20 mm(Strip length) 20 mm

Crimp height should conform tospecified dimension

Insulation barrel should not hold the wire‐9‐

7. Crimp height and measurement method
7.1 Crimp height management
Crimp height has close relation with tensile strength. If crimp height is within standard
specification, tensile strength should also conform to the specification.
Crimping work operator and manager should make measurement periodically to make surecrimp height is appropriate. Be sure to check crimp height to keep good operation and to avoid
breakage of instruments

7.2 Measurement method
Measure crimp height at the center of crimped part by using a micrometer as below.

Direction A

Enlargement (direction A)

Enlargement

Measure at the center of crimped part‐10‐

8. Insulation barrel shape and check method
Determine height of insulation barrel by checking followings.

2.0 mm max.

(1) Max. height of insulation barrel crimped is determined by dimension of the area on thehousing, where the contact is loaded to(2) Insulation should not go out of alignment (not move to right in following figure) when
the crimped wire is bent as below②①①Bent at right (90 degree)②Bent to opposite side
③Place back to original (90 degree)③(3) Confirm the insulation barrel does not make any damage on the wire by crimping it withlonger strip length.

(4) Confirm the crimped wire does not break in the insulation barrel when the contact isfixed and the cable wire is pulled.
(5) Too much crimping might break the wire in the insulation barrel.
(6) When the insulation tip is at higher position than the insulation barrel, it might get hard
to load the crimped contact into the housing.

‐11‐

9. Crimped contact shape
Use these standard specifications below just as rough indications for crimping operation
since they are not uniform depending upon type of wires. Basically the crimped contact
should be judged good item if it can be loaded lightly to the housing and does not have any
deformation on it after loading(1) Bend-up, Bend-down
4 degree max.
4 degree max.
(2) Twist

4 degree max.

4 degree max(3) Rolling3 degree max.
3 degree max.

‐12‐

10. Cross section of housing with the contact loaded

11. Check points
Check following points on the crimped contact before starting the crimping operation and also
during this operation periodically.
(1) There is no deformation on the contact (mating part)(2) Crimp height conforms to the standard specification(3) Bell mouse is made properly(4) Wire is visible at both sides of wire barrel(5) Wire protruded dimension is appropriate(6) There is no core wire drop nor protrusion at the wire barrel portion(7) Wire insulation is visible at between the wire barrel and the insulation barrel(8) Wire barrel does not have gig burr(9) Cut-off tab size is appropriate(10) There is no flaws, that might affects function, at the wire barrel and the insulation
barrel(11) Crimped contact can be loaded lightly into the housing(12) Tensile strength conforms to the standard specification‐13‐

FUJITSU Component Connector
Standard Operation Instruction of contact crimping for FCN-360 connector

June 30, 2017
Issued by Fujitsu Component Limited
Fujitsu Component Limited or its affiliates do not warrant that the content of manual is error free. In acontinuing effort to improve our products Fujitsu Component Limited or its affiliates reserve the right tochange specification/datasheets/manuals without prior notice.
Copyright 2017 FUJITSU COMPONENT LIMITED‐14‐