Crimp Type

DDK
Ltd㸬
㸬
CM10-AP××S-×(D6)
Angle Plug Connector
(Weight saving type㺃
㺃Crimp Type)
Cable Assembly Manual(Standard Type)
Date of Issue: February 16, 2009
Material No. TC-604
DDK Ltd.
2ND Production engineering department assembly group
14 Matsuyama-cho, Moka-shi, Tochigi
TEL : 0285-82-4463
ᨵ∧ ᖺ᭶᪥
Revision
Date
㸿
̓
C
16/02/09
㹀
̓
D
22/Jul/’11
ᨵ∧ 1RNo.
Revision
᪂つⓎ⾜
New
Issue
ኚ᭦㏻▱ 1R7
T-2691
Material No.
TC-604
Page
1/11
Contents
Page
1. Outline ...........................................................................................................................................2
2. Specifications.................................................................................................................................2
2-1. Applicable connector..............................................................................................................2
3. Cable Assembly Process................................................................................................................2
3-1. Cutting a cable .......................................................................................................................2
3-2. Stripping a cable sheath .........................................................................................................2
3-3. Inserting parts ........................................................................................................................3
3-4. Stripping a core wire...............................................................................................................3
3-5. Crimping a contact .................................................................................................................4
3-6. Inserting a contact..................................................................................................................5
3-7. Tightening an angle back shell ...............................................................................................6
3-8. Inserting a bushing and a cable clamp....................................................................................8
3-9. Tightening a clamp nut ...........................................................................................................9
Material No.
TC-604
Page
2/11
1. Outline
This Cable Assembly Manual explains how to assemble the wire to the CM 10 angle plug connector.
(Crimp Type)
2. Specifications
2-1. Applicable connector
Connector name
Drawing number
CM10-AP2S-S(D6)
115J-AP12162-1
CM10-AP2S-M(D6)
115J-AP12162-2
CM10-AP2S-L(D6)
115J-AP12162-3
CM10-AP10S-S(D6)
115J-AP12160-1
CM10-AP10S-M(D6)
115J-AP12160-2
CM10-AP10S-L(D6)
115J-AP12160-3
3. Cable Assembly Process
3-1. Cutting a cable
Cut the cable to the following dimensions:
Note! Not to change cable length.
*Cable length after cutting
Cable length
= measurement A for CM10-AP××S (D6)+ Cable length
= A + Cable length
Product name
A length
CM10-AP XX S-S(D6)
CM10-APXX S-M(D6)
40±0.5mm
CM10-AP XX S-L(D6)
3-2.
Stripping a cable sheath
Strip the cable sheath to the length A as shown below.
Note! Take care the cable peel length.
Take care not to damage anything.
* When making CM10-AP10S(D6), strip the cable for No. 10 terminal in a way that makes the A
length 1mm longer than other cables. (To avoid the cable tension when inserting a contact to
the housing in a later process.)
Cable core
A
(A+1mm for No. 10 terminal only)
Product name
Sheath
A length
CM10-AP XX S-S(D6)
CM10-APXX S-M(D6)
CM10-AP XX S-L(D6)
30±0.5mm
Material No.
TC-604
Page
3/11
3-3. Inserting parts
Insert the clamp nut, the cable clamp, the bushing and the angle back shell to the cable stripped.
Note! Pay attention to the direction each part is inserted.
Make sure that every part is inserted.
Angle back shell
Bushing
Cable
Cable clamp
Clamp nut
* To insert the angle back shell, bend the cable.
Angle back shell
Cable
Insert
Bend
3-4. Stripping a core wire
Strip the cable’s core wire to the length 3.0 to 3.5mm.
Note! Do not mistake the length of the core wire to be stripped.
Do not leave cut or scratch to the cable core.
3.0 to 3.5
Core wire
Cable core
Sheath
Material No.
TC-604
Page
4/11
3-5. Crimping a contact
With the crimping tool or crimping machine, crimp each contact on each cable.
Connector name
Applicable contact
Contact
crimping
tool
Crimp
machine
CM10-#22SC(C1)(D8)
357J-50446T
AP-A50539T
CM10-#22SC(C2)(D8)
357J-50447T
AP-A50540T
CM10-#22SC(C3)(D8)
357J-50448T
AP-A50541T
CM10-AP10S-X(D6)
CM10-AP2S-X(D6)
Applicable
cable
Crimp height
(Wire section)
AWG20
AWG22
AWG23-24
AWG26
AWG28
AWG16
AWG18
AWG20
1.05
0.94
0.71
0.67
0.64
1.25
1.15
1.05
Note! Make sure that the core wire does not come out of the contact.
When soldering, make sure that the solder does not stick to the circumference of the solder
cup.
When using a drain wire, attach a heat shrink tube to the drain cable after soldering.
* When making CM10-AP10S(D6), the cable for No. 10 terminal is 1mm longer than other
cables.
(To avoid
the cable tension when inserting a contact to the housing in a later
process.)
* The difference in the total A length of the cables for other than No. 10 terminal must be 1mm
or less.
Contact
Cable
Heat shrink tube
Crimping drain wire
A
Difference of total length :less than 1mm
(except for No.10)
Product name
A length
CM10-AP™™S-S(D6)
CM10-AP™™S-M(D6)
CM10-AP™™S-L(D6)
39 to 42mm
Material No.
TC-604
Page
5/11
3-6. Inserting a contact
Insert the contact into the specified terminal number point in the housing.
(Insert grounding wire or drain wire into terminal No. 10).
* When the contact catches the housing, you will hear a snap.
* Pulling the wire for confirming the correct position.
Note! Before inserting the contact, check that the clamp nut, cable clamp, bushing and angle back
shell is inserted.
Take care not to insert the contact upside down as shown below.
Contact
Cable
Housing
Core wire
Insert
Terminal No. 10 only
(Grounding wire or drain wire)
* Insert the contact so that the terminal
number face the same direction.
However, in case of CM10-AP2S(D6), insert the
contact so that the lance and the terminal
number face the opposite direction.
Lance
Terminal No.
Contact
CM10-AP10S-X(D6)
* Using a pull out tool for pulling up inserted contact.
Tool No.: 357J-50548T
Terminal No.
Refer to the instruction manual in case of using
pull up tool.
* As Lance falls down easily after pulling up,
set up to original position before re-insert.
Lance
Contact
CM10-AP2S-X(D6)
Material No.
TC-604
Page
6/11
3-7. Tightening an angle back shell
(1) To prevent loosening, the adhesive should be applied to the angle back shell by two threads around the
circumference.
‫ ە‬Recommended adhesive: 1401B (Three Bond Co., Ltd.)
(2) Rotate and temporarily tighten the back shell coupling by setting the connector and the angle back shell
to the specified angle.
Adhesive
(To be coated to two
threads
of the
circumference)
Angle back shell
Angle back shell
Back shell coupling
* When tightening temporarily, match the concavity and convexity of the plug shell with those of the
angle back shell.
(You can confirm the correct connection of concavity and convexity waving lightly back shell just
before inserting to BS coupling.)
Back shell coupling
Plug shell concavity and
convexity
Back shell concavity and
convexity
Material No.
TC-604
Page
7/11
(3) Fix the 2 surface width of the angle back shell on the tightening guide.
(4) Set the back shell wrench adjusting to the 2 surface width of the back shell coupling.
(5) With the wrench, tighten the back shell coupling to the angle back shell.
Recommended tightening torque: 5N‚m
Note! When setting the work to the wrench, adjust it to the 2 surface width.
To remove, take the reverse steps.
Fix the back shell
Set
19
Tighten
Angle back shell
tightening wrench
Back shell coupling
Angle back shell
Set
Torque wrench
Fix the back shell
* Reference dimension for
fixing the back shell
15
(Back shell 2
surface width)
* Recommendation:
Tightening guide
(357J-52658T)
Note! To change the angle of the back shell, do it by changing the engaging position of the
concavity and convexity of the plug shell and the back shell.
z Recommended jigs and tools : Back shell wrench (357J-51333T)
Bit (357J-51344T)
Torque wrench (CL6N x 8D), Tonichi Mfg.)
* Recommended tightening guide: (357J-52658T)
Material No.
TC-604
3-8. Inserting a bushing and a cable clamp
Insert the bushing and the cable clamp to the back shell.
Cable
Cable clamp
Insert
Bushing
Note! After the Bushing insert, confirm that cable position should be inside of Bushing.
Page
8/11
Material No.
TC-604
Page
9/11
3-9. Tightening a clamp nut
(1) Temporarily tighten the clamp nut on the angle back shell.
*To prevent loosening, the adhesive should be applied to the angle back shell.
zRecommended adhesive: 1401B (Three Bond Co., Ltd.)
*Recommended
(2) Fix the 2 surface width of the angle back shell on the tightening guide.
adhesive
(to be coated on
(3) Set the tightening wrench adjusting the 2 surface width of the clamp nut.
2 threads of the
circumference)
(4) With the wrench, tighten the clamp nut on the angle back shell.
Recommended tightening torque: 5 N‚m
Tighten
temporarily
Note! To set the work to the wrench, adjust the 2 surface width.
In case of squeezing the clamp nut with excessed torque provided as above, the clamp nut may be broken. Please use the torque wrench.
To remove, take the reverse steps.
Fix the angle back shell
Torque wrench
Angle back shell
Clamp nut
Set
Tightening wrench
Set
Tighten
Fix the angle back shell
19
* Reference dimension for fixing the back shell
15
(Back shell 2
sruface width)
z Recommended jigs and tools : Clamp nut wrench (357J-51334T)
Bit (357J-51345T)
Torque wrench (CL6N×8D, Tonichi Mfg.)
* Recommended tightening guide :(357J-52658T)
* Recommendation:
Tightening guide
(357J-52568T)
Material No.
TC-604
*To connection
(1) Set the U mark of each other’s connectors.
Receptacle connector
Vmark
Plug connector
Umark
(2) Each other’s key (concavity and convexity) are fit in.
Receptacle connector key
㸦Convexity㸧
Push it straight, take care not to tilt.
Plug connector key
(Concavity)
Push it straight
*To remove, rotate the coupling and pull out to straight.
(1)
Rotate the coupling
(2)
Pull out to straight
Coupling
Page
10/11
Material No.
TC-604
Page
11/11
*When using a conduit
(1) Tighten the nipple of conduit connector on the plug connector (CM10).
(2) Set the conduit on the nipple of conduit connector.
(3) Fix the conduit to the plug connector (CM10). If the conduit is used in a moving part, fix the conduit with a
saddle, etc. so that no load is applied to the plug connector (CM10) and to the conduit connector. If the
conduit is fixed with a saddle, etc., make sure that no load is applied to the fixing area. Set the protective
cover (rubber etc.,) on the conduit to avoid cable damage.
(1)
(2)
Plug
connector
Conduit
Connector
(nipple)
(3)
Plug connector
Plug connector
Conduit
connector
Conduit
connector
Conduit
Saddle
Conduit
Cable
Protective cover
(Rubber etc.)
z Recommended conduit & connector : NIPPON FLEX CO.LTD
Conduit
Tipe:VF Tipe:SR Tipe:FBN Tipe:EM
Tipe:VFS Tipe:SRK etc.,
Connector
Tipe:RCM
* NIPPON FLEX CO., LTD home page → http://www.nipolex.co.jp