CM10-AP××S-×-D Angle Plug Connector (Soldering type) Cable Assembly Manual Date of Issue: March 26, 2008 Material No. TC-610 DDK Ltd. 2ND Production engineering department assembly group 14 Matsuyama-cho, Moka-shi, Tochigi TEL : 0285-82-4463 改版 年 月 日 Revision Date ＡA ’08.3.26 3/26/08 ＢB ’08.5.13 5/13/08 C 2/25/09 改版 No.No. Revision 新規発行 New Issue 変更通知notice No.T-2205 Change T-2205 Change notice T-2489 Material No. TC-610 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. Soldering 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-610 Page 2/11 1. Outline This Cable Assembly Manual explains how to assemble the wire to the CM 10 angle plug connector. (Solder type) 2. Specifications 2-1. Applicable connector Connector name Drawing number CM10-AP2S-S-D 115J-AP10849-1 CM10-AP2S-M-D 115J-AP10849-2 CM10-AP2S-L-D 115J-AP10849-3 CM10-AP10S-S-D 115J-AP10848-1 CM10-AP10S-M-D 115J-AP10848-2 CM10-AP10S-L-D 115J-AP10848-3 3. Cable Assembly Process 3-1. Cutting a cable Cut the cable to the following dimensions: Note! Not to change cable length. Cable length *Cable length after cutting =measurement A for CM10-AP××S-X-D + Cable length = A + Cable length Product name CM10-AP XX S-S-D CM10-APXX S-M-D CM10-AP XX S-L-D A length 40±0.5mm 55±0.5mm 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-x-D, 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) Sheath Product name CM10-AP XX S-S-D CM10-APXX S-M-D CM10-AP XX S-L-D A length 29.5~30.5mm 44.5~45.5mm Material No. TC-610 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 4.5 to 5.0mm. Note! Do not mistake the length of the core wire to be stripped. Do not leave cut or scratch to the cable core. 4.5 to 5.0 Core wire Cable core Sheath Material No. TC-610 Page 4/11 3-5. Soldering a contact Apply preliminary soldering to each contact and to the cable’s core wire, then solder the core wire to the contacts. Contact name Applicable contact Applicable cable CM10-AP10S-X-D CM10-AP2S-X-D CM10-#22SC(S1)(D8) CM10-#22SC(S2)(D8) AWG20 or below AWG16 or below 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-X-D, 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. Soldering Ｂ Enlargement of B area Ａ Difference in total length: 1 mm or less (for other than No. 10 terminal) Core wire Contact Product name Cable A length CM10-AP××S-S-D CM10-AP××S-M-D 39 to 42mm CM10-AP××S-L-D 54 to 57mm Drain wire Heat shrink tube If a drain wire is soldered Material No. TC-610 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 Housing Cable 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-X-D, insert the contact so that the lance and the terminal Lance number face the opposite direction. Terminal No. Contact CM10-AP10S-X-D * Using a pull out tool for pulling up inserted contact. Jig/Tool Used : Contact removing jig (357J-50548T) Refer to the instruction manual in case of using pull up tool. Terminal No. Lance * As Lance falls down easily after pulling up, set up to original position before re-insert. Contact CM10-AP2S-X-D Material No. TC-610 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. *To prevent loosening, the adhesive should be applied to the angle back shell. (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-610 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: 5Nm 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. jig/tools Used : Back shell wrench (357J-51333T) Bit (357J-51344T) Torque wrench (CL6N x 8D), Tonichi Mfg.) * Recommended tightening guide: (357J-52658T) * Recommended adhesive: 1401B (Three Bond Co., Ltd.) Material No. TC-610 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-610 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. (2) Fix the 2 surface width of the angle back shell on the tightening guide. (3) Set the tightening wrench adjusting the 2 surface width of the clamp nut. *Recommended adhesive (4) With the wrench, tighten the clamp nut on the angle back shell. (to be coated on 2 threads of the Recommended tightening torque: 5 Nm circumference) Tighten temporarily Note! To set the work to the wrench, adjust the 2 surface width. To remove, take the reverse steps. Fix the angle back shell Torque wrench Angle back shell Set Clamp nut Tightening wrench Set Tighten Fix the angle back shell 19 * Reference dimension for fixing the back shell (Back shell 2 15 sruface width) jig/tools Used : Clamp nut wrench (357J-51334T) Bit (357J-51345T) Torque wrench (CL6N×8D, Tonichi Mfg.) * Recommended tightening guide :(357J-52658T) * Recommendation: * Recommended adhesive: 1401B (Three Bond Co., Ltd.) Tightening guide (357J-52658T) Material No. TC-610 *To connection (1) Set the mark of each other’s connectors. Receptacle connector mark Plug connector 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-610 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 (3) Plug connector Plug connector Conduit Connector (nipple) 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