DDK Ltd． ． CM10-SP××S-×-D Plug Connector (Soldering type) Cable Assembly Manual Date of Issue: March 26, 2008 Material No. TC-609 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 No.T-2205 Change notice T-2204 Change notice T-2488 Material No. TC-609 Page 1/11 Contents Page 1. Outline ...........................................................................................................................................2 2. Specifications.................................................................................................................................2 2-1. Applicable connector..............................................................................................................2 3. Cable Assembly Process................................................................................................................3 3-1. Cutting a cable .......................................................................................................................3 3-2. Inserting parts ........................................................................................................................3 3-3. Stripping a cable.....................................................................................................................3 3-4. Soldering a contact.................................................................................................................4 3-5. Inserting a contact..................................................................................................................5 3-6. Tightening a back shell...........................................................................................................6 3-7. Inserting a bushing and a cable clamp....................................................................................8 3-8. Tightening a clamp nut ...........................................................................................................9 Material No. TC-609 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-SP2S-S-D 115J-AP10991-1 CM10-SP2S-M-D CM10-SP2S-L-D 115J-AP10991-2 115J-AP10991-3 CM10-SP10S-S-D 115J-AP10990-1 CM10-SP10S-M-D 115J-AP10990-2 CM10-SP10S-L-D 115J-AP10990-3 Page 2/11 Material No. TC-609 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 cut length= 35± ± 0.5mm for CM10-SPxxS-X-D + Cable length = 35± ± 0.5mm + Cable length 3-2. Inserting parts Insert the clamp nut, the cable clamp, the bushing and the back shell to the cable. Note! Pay attention to the direction each part is inserted. Make sure that every part is inserted. Bushing Cable clamp Cable Back shell Clamp nut 3-3. Stripping a cable Strip the cable’s sheath to the A length, cut the wire set at its root and strip the core wire to the B length. Note! Make sure to strip the cable to the correct length. Do not leave cutting or scratch to the cable core. * When making CM10-SP10S-x-D, strip the cable for No. 10 terminal in a way that the A length becomes 1mm longer than that of other cables. (This is to prevent excessive tension of the cable when inserting the contact to the housing in the next process.) Ａmm (A+1mm for No. 10 terminal only) Sheath Ｂmm Core wire Cable core Product name A CM10-SP10S-×-D 18.5 ~19.5 CM10-SP2S-×-D 17.5~18.5 B 4.5~5.0 Material No. TC-609 Page 4/11 3-4. 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-SP10S-X-D CM10-#22SC(S1)(D8) AWG20 or below CM10-SP2S-X-D CM10-#22SC(S2)(D8) 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-SP10S-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 A Enlargement of A area 29 to 32mm Difference in total length: 1 mm or less (for other than No. 10 terminal) Core wire Contact Drain wire Heat shrink tube If a drain wire is soldered Cable Material No. TC-609 Page 5/11 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 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-SP2S-X-D, insert the contact so that the lance and the terminal number face the opposite direction. Lance Terminal No. CM10-SP10S-X-D Contact * 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-SP2S-X-D Material No. TC-609 Page 6/11 3-6. Tightening a back shell (1) To prevent the straight back shell from loosening, coat 2 threads of the circumference of the straight back shell with adhesive. *To prevent loosening, the adhesive should be applied to the angle back shell. (2) Rotate the back shell coupling of the connector and temporarily tighten the straight back shell. Straight back shell Adhesive (to be coated to 2 threads of the circumference) Temporarily tighten Back shell coupling Straight 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-609 Page 7/11 (3) Fix the 2 surface width of the angle back shell on the tightening guide. (4) Set the tightening wrench adjusting to 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. Back shell Back shell coupling Set Fix the back shell 19 Fix the back shell Tightening wrench * Reference dimension for fixing the back shell 17 (Back shell 2 surface width) 20 Torque wrench Tighten Board thickness: 10 * Recommendation: Tightening guide (357J-50494T) Jig/Tool Used : BS coupling tightening tool (wrench) (357J-51333T) Bit (357J-51344T) Torque wrench (CL6N x 8D), Tonichi Mfg.) * Recommended tightening guide: (357J-50494T) *Recommended adhesive: 1401B (Three Bond Co., Ltd.) Material No. TC-609 3-7.Inserting a bushing and a cable clamp Insert the bushing and the cable clamp in the back shell. Back shell Bushing Insert Cable clamp Cable Note! After the Bushing insert, confirm that cable position should be inside of Bushing. Page 8/11 Material No. TC-609 Page 9/11 3-8. Tightening a clamp nut (1) Temporarily tighten the clamp nut on the angle back shell. * To prevent the loosening, it is recommended to coat the straight back shell with adhesive. (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. (4) With the wrench, tighten the clamp nut on the angle back shell. Recommended tightening torque: 5 N m Note! When setting the work to the wrench, adjust the 2 surface width. To remove, take the reverse steps. *Recommended adhesive (to be coated on 2 threads of the circumference) Tighten temporarily Fix the back shell Clamp nut Fix the back shell Back shell Set 19 *Reference dimension for fixing the back shell 17 (Back shell 2 sruface width) 20 Tightening wrench Board thickness: 10 Torque wrench Tighten * Recommendation: Tightening guide (357J-50494T) Jig/Tool Used : Clamp nut tightening tool (wrench) (357J-51334T) Bit (357J-51345T) Torque wrench (CL6N×8D, Tonichi Mfg.) * Recommended tightening guide :(357J-50494T) * Recommended adhesive: 1401B (Three Bond Co., Ltd.) Material No. TC-609 *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. Receptacle connector key （Convexity） 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-609 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. (2) (1) Plug connector (3) Plug connector Plug connector Conduit connector Conduit Connector (nipple) Conduit connector Conduit Conduit Cable Saddle 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