DDK Ltd． ． CM10-SP××S-×(D6) Plug Connector ･Crimp type) (Weight saving type･ Cable Assembly Manual(Standard Type) Date of Issue: February 16, 2009 Material No. TC-603 Material No. TC-504 Revision Revision Revision DDK Ltd. 2ND Production engineering department assembly group 14 Matsuyama-cho, Moka-shi, Tochigi TEL : 0285-82-4463 C 16/2/09 New Issue Material No. TC-603 Contents Page 1. Outline・・・・・・・・・・・・・・・・・・・・・・・・ 2 2. Specifications・・・・・・・・・・・・・・・・・・・・・ 2 2-1. 3. Applicable connectors Cable Assembly Process 3-1. Cutting a cable・・・・・・・・・・・・・・・・・・・ 3 3-2. Inserting parts・・・・・・・・・・・・・・・・・・・・ 3 3-3. Stripping a cable・・・・・・・・・・・・・・・・・・ 3-4. Crimping a contact・・・・・・・・・・・・・・・・・・ 4 3-5. Inserting a contact・・・・・・・・・・・・・・・・・・ 5 3-6. Tightening an back shell・・・・・・・・・・・・・・・ 6 3-7. Inserting a bushing and a cable clamp・・・・・・・・ 3-8 Tightening a clamp nut・・・・・・・・・・・・・・・・ 9 3 8 Page 1/11 Material No. TC-603 1. Outline This Cable Assembly Manual explains how to assemble the wire to the CM 10 plug connector. (Crimp Type) 2. Specifications 2-1. Applicable connector Connector name Drawing number CM10-SP2S-S(D6) 115J-AP12161-1 CM10-SP2S-M(D6) 115J-AP12161-2 CM10-SP2S-L(D6) 115J-AP12161-3 CM10-SP10S-S(D6) 115J-AP12159-1 CM10-SP10S-M(D6) 115J-AP12159-2 CM10-SP10S-L(D6) 115J-AP12159-3 Page 2/11 Material No. TC-603 Page 3/11 3. Cable Assembly Process 3-1. Cutting a cable Cut the cable to the following dimensions: Note! Not to change Cable length. Cable length ※ Cable length after cutting = 35 (±0.5)mm for CM10-SP××S(D6) + cable length =35 (±0.5)mm + cable length 3-2. Inserting parts Insert the clamp nut, cable clamp, bushing and back shell into the cable. Note! Take care not to insert them upside down. Take care to insert all of the parts Bushing Cable clamp Back shell Cable Clamp nut 3-3. Stripping a cable Strip the cable to a length of 20 (±0.5)mm and also strip the core wire to a length of 3 ~3.5mm. Note! Take care the cable peel length. Take care not to damage anything. ※ For CM10-SP10S(D6) strip 1mm longer than others.(avoiding the cable tension in the process of contact insert to the housing.) 20±0.5 (No.10 +1mm) 3.0～3.5 Core wire Wire cable Sheath Material No. TC-603 3-4. Crimping a contact Page 4/11 With the crimping tool, crimp each contact on each cable. Connector name Applicable contact Contact crimping tool Crimp machine CM10-#22SC(C1)(D8) 357J-50446T AP-A50539T CM10-SP10S-X(D6) CM10-#22SC(C2)(D8) CM10-SP2S-X(D6) CM10-#22SC(C3)(D8) 357J-50447T 357J-50448T AP-A50540T AP-A50541T Applicable cable Crimp height (Wire section) AWG20 1.05 AWG22 0.94 AWG23-24 0.71 AWG26 0.67 AWG28 0.64 AWG16 1.25 AWG18 1.15 AWG20 1.05 Note! Refer to the instruction manual in case of using contact crimp tool or crimp machine. Take care not to stick out the wire from the contact. When using a drain wire, attach a heat shrink tube on it after crimping. ※ Make the cable 1mm longer in case of using No.10 for CM10-SP10S(D6)(for avoiding the cable tension in the next procedure). ※ Less than 1mm of the difference of length between two contacts except for No.10. Contact Cable Heat shrink tube 29～32mm Difference of total length :less than 1mm (except for No.10) Crimping drain wire Material No. TC-603 3-5. 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 Wire Insert Terminal No. 10 only (Grounding wire or drain wire) Terminal No. ※ Insert the contact so that the lance and the terminal number face the same direction. Lance However, in case of CM10-SP2S-×(D6), insert the contact so that the lance and the terminal number face the opposite direction. Contact ※ Using a pull out tool for pulling up inserted contact. Tool No.: 357J-50548T Refer to the instruction manual in case of using pull up tool. CM10-SP10S-x(D6) Terminal No. ※ As Lance falls down easily after pulling up, set up to original position before re-insert. Lance Contact CM10-SP2S-x(D6) Page 5/11 Material No. TC-603 3-6. Tightening back shell Page 6/11 (a) To prevent loosening, the adhesive should be applied to the back shell by two threads around the circumference. ● Recommended adhesive: 1401B (three bond Co., Ltd.) (b) Temporarily tighten the back shell coupling on the straight back shell. Straight back shell Adhesive (2threads) Temporary tightening Back shell coupling Straight back shell Back shell coupling ※ Put together plug shell and straight back shell with the correct position. (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 Back shell concavity and convexity convexity Material No. TC-603 Page 7/11 (c) Fix the straight back shell width on the tightening guide. (d) Set the back shell wrench on the back shell coupling. (e) With the wrench, tighten the back shell coupling on the straight back shell. Recommended tightening torque: 5 N・m Note! Accurately fit the wrench on the back shell coupling. To remove, take the reverse steps. Back shell Back shell coupling Set 19 Tightening guide Tightening guide BS Wrench ※ Referential dimensions for back shell tightening guide 17 (Back shell width) 20 Back shell wrench Tighten Thickness:10 ※ Recommendation: Tightening guide （357J-50494T） ● Recommended jigs and tools : Back shell wrench (357J-51333T) Bit (357J-51344T) Torque wrench (CL6N×8D, Tonichi Mfg.) ※ Recommended tightening guide: (357J-50494T) Material No. TC-603 Page 8/11 3-7. Inserting a bushing and a cable clamp Insert the bushing and the cable clamp into the back shell. Back shell Bushing Cable clamp Insert Cable t Note! After the Bushing insert, confirm that cable position should be inside of Bushing. Material No. TC-603 Page 9/11 3-8. Tightening a clamp nut (a) Temporarily tighten the clamp nut on the back shell. ※ T o prevent loosening, the adhesive should be applied to the back shell. ● Recommended adhesive: 1401B (three bond Co., Ltd.) (b) Fix the straight back shell width on the tightening guide. (c) Set the clamp nut wrench on the clamp nut. (d) With the wrench, tighten the clamp nut on the angle back shell. Recommended tightening torque: 5 N・m Note! Accurately fit the wrench on the clamp nut. 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. ※Recommendation Adhesive (2 threads around the circumference) Temporary tightening Tightening guide Clamp nut Tightening guide Set Back shell 19 ※Referential dimensions for back shell tightening guide 20 17 (Back shell width) Clamp nut wrench Thickness: 10 Tighten Torque wrench ●Recommended jigs and tools: Clamp nut wrench (357J-51334T) Bit (357J-51345T) Torque wrench (CL6N×8D, Tonichi Mfg.) ※ Recommended tightening jig :(357J-50494T) Recommendation: Tightening guide （357J-50494T） Material No. TC-603 ※ To connection ① Set the △ mark of each other’s connectors. Receptacle connector Plug connector ▽ mark △ mark ② Each other’s key (concavity and convexity)are fit in. Push it straight, take care not to tilt. Receptacle connector key （ Convexity） 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-603 Page 11/11 ※When using a conduit (a) Tighten the nipple of conduit connector on the plug connector. (b) Set the conduit on the nipple of conduit connector. (c) When using by moving part, fix the conduit on the saddle etc., Take care not to damage for plug connector and conduit connector. Set the protective cover (rubber etc.,) on the conduit to avoid cable damage. ① ② ③ Plug connector Plug connector Plug connector Conduit connector Conduit connector Conduit connector Conduit Conduit Saddle Cable Protective cover (Rubber etc.) ●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