Push testing of the terminal within the connector cavity with a defined force became an industry standard during the early 1970’s. Hale Manufacturing developed push test continuity testing fixtures at that time and continues to produce these fixtures today.

Terminals within connectors on wire harnesses must be retained in the locked position during testing and final product use. Locking devices are designed for this purpose. During some phases of assembly, continuity testing and final product use, terminals are not always retained correctly. With our push test continuity fixtures, terminals can be checked for the locked position. The defined force for push testing must be applied in the same axial plane as the terminal and must not damage either terminal or connector body.

Push test fixtures are used for testing continuity simultaneously while applying a specified force to terminals. Switch probes are used for this purpose.
They may also be designed for push testing only where continuity testing fixtures are already in place or testing is required on a smaller percentage of connectors. The typical industry standard for most terminals allows a 1-2 pound force or 3-5 pound force on each terminal. Hale’s push test fixtures also assure that the connectors themselves are properly and safely retained in the fixture for safe and reliable results.

Operator fatigue is a critical factor when designing push test fixtures and Hale Manufacturing offers a mechanical operator-friendly style. Air cylinder models are available and offer greater test parameters. Test duration may be controlled and the harness may be retained in the fixture if one or more terminal failures are reported.

Push Test Criteria
Hale Manufacturing, Inc.

Criteria for building push test fixtures includes, but is not limited to, the following:

• Determine the force the terminal and connector body can withstand without damage. Terminal and connector manufacturer may supply this information.

• Determine how much push test force the terminal-locking tab, inside the connector, or on the terminal, can withstand without damage.

• Determine duration of test to prevent terminal or connector damage.

• Determine location on the terminal to which force can be applied without damage.

• Determine surface configuration of push test pin to avoid terminal damage.

• Determine plating required on push test pin surface to avoid terminal contamination.

• Determine force the operator can withstand using push test fixture without muscle fatigue.

• Determine orientation of connector in the test fixture for best results.

• Determine the distance between locked and unlocked position of the terminals to be tested.

• Determine method of routine calibration of each push test pin to avoid terminal or connector damage.

• Determine method of monitoring push test fixture to assure end product user that proper test is being performed.