CM10-AP×× ××S ×× Angle Plug Connector (Solder Type) Cable Assembly Manual (Standard Type) Date of Issue: May 19, 2004 Material No. TC-509 DDK Ltd. 2ND Production engineering department assembly group 14 Matsuyama-cho, Moka-shi, Tochigi TEL : 0285-82-4463 Revision A B C D E F G H Date 5/19/04 5/24/04 6/11/04 6/24/04 9/19/05 10/07/05 10/25/05 1/16/07 Version No. Initial No.T-0946 No.T-0963 No.T-0985 No.T-1430 No.T-1465 No.T-1484 No.T-1726 Material No. TC-509 Table of Contents Page 1. Outline 2 2. Specifications 2 2-1. Applicable connector Cable Assembly Process 3. 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 7 3-9 Tightening a clamp nut 8 Page 1/10 Material No. TC-509 1. Outline Page 2/10 This Cable Assembly Manual explains how to assemble the wire to CM 10 angle plug connector. (Solder type) 2. Specifications 2-1. Applicable connector Connector name Drawing number CM10-AP2S 115J-AP10036 CM10-AP10S 115J-AP8959 3. Cable Assembly Process 3-1. Cutting a cable Cut the cable to the following dimensions: Cable length ※Cable length after cutting = measurement A for CM10-AP×× ××S ×× + cable length = A +cable length Product name CM10-AP××S-S-×× CM10-AP××S-M-×× CM10-AP××S-L-×× A 40 mm 55 mm 3-2. Stripping a cable sheath Strip the cable sheath to the following dimensions: Core wire Sheath Product name CM10-AP××S-S-×× CM10-AP××S-M-×× CM10-AP××S-L-×× A 30mm 45mm Material No. TC-509 3-3. Inserting parts Page 3/10 Insert the clamp nut; cable clamp, bushing and angle back shell in to the cable. Caution! Take care not to insert them upside down. Angle back shell Bushing Cable Cable clamp Clamp nut ※Bend and insert the cable into the angle back shell. Angle back shell Cable Insert Bend 3-4. Stripping a core wire Strip the core wire to a length 6 mm. 6 Core wire Cable Material No. TC-509 3-5. Soldering a contact Temporarily solder each contact and core wire, and then solder the core wire on the contact. When using a drain wire, attach a heat shrink tube on it after soldering. Caution! Take care not to stick out the core wire from the contact. Take care to prevent solder from adhering to the edge of solder cup. Connector name Applicable contact Applicable cable CM10-AP10S CM10-#22SC-S1 AWG20 or less CM10-AP2S CM10-#22SC-S2 AWG16 or less Solder A Contact Core wire Detail A Cable Drain wire Heat shrink tube Soldering drain wire Page 4/10 Material No. TC-509 3-6. Inserting the contact Insert the contact into the specified terminal in the housing. (Insert grounding wire or drain wire into terminal No. 10.) ※When the contact catches the housing, you will hear a snap. Caution! 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 Insert Terminal No. 10 only (Grounding wire or drain wire) ※Insert the contact so that the lance and the terminal number face the same direction. However, in case of CM10-AP2S, insert the contact so that the lance and the terminal number face the opposite direction. Terminal number Lance CM10-AP10S Contact Terminal number Lance Contact CM10-AP2S Page 5/10 Material No. TC-509 Page 6/10 3-7. Tightening angle back shell (a) Temporarily tighten the back shell coupling on the angle back shell. ※To prevent loosening, Adhesive should be applied to the angle back shell. (b) Set the angle back shell on the tightening guide. (c) Set the back shell wrench on the back shell coupling. (d) With the wrench, tighten the back shell coupling on the angle back shell. Recommended tightening torque: 5 N m ※ Recommendation Adhesive (2 threads around Caution! Accurately fit the wrench on the back shell coupling. the circumference) To remove, take the reverse steps. Tightening guide Angle back shell Back shell coupling Temporary tightening Tightening guide Set Set Back shell wrench ※ Referential dimensions for back shell tightening guide 17 Back shell width 22 19 Thickness: 10 or more Torque wrench ※ Recommendation: Tightening guide 357J-50508T Tighten Caution! : To change the back shell angle, adjust the toothing position of the plug shell and back shell. ●Recommended jigs and tools : Back shell wrench (357J-51333T) Bit (357J-51344T) Torque wrench (CL6N×8D, Tonichi Mfg.) ※Recommended tightening guide: (357J-50508T) ※Recommended adhesive: Screw lock 1401B (Three bond Co, Ltd) Material No. TC-509 3-8. Inserting a bushing and a cable clamp Insert the bushing and the cable clamp into the angle back shell. Cable Cable clamp Insert Bushing Page 7/10 Material No. TC-509 3-9. Tightening a clamp nut Page 8/10 (a) Temporarily tighten the clamp nut on the angle back shell. ※To prevent loosening, the adhesive should be applied to the angle back shell. (b) Set the angle back shell 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 ※ Recommendation Caution! Accurately fit the wrench on the clamp nut. To remove, take the reverse steps. Adhesive (2 threads around the circumference) Temporary tightening Tightening guide Set Tighten 19 Clamp nut wrench Clamp nut Angle Torque wrench Set Back shell ※Referential dimensions for back shell tightening guide 17 Back shell width 22 Tightening guide Thickness: 10 ●Recommended jigs and tools: Clamp nut wrench (357J-51334T) Bit (357J-51345T) Torque wrench (CL6N×8D, Tonichi Mfg.) ※Recommended tightening guide : (357J-50508T) ※Recommended adhesive : Screw lock 1401B (Three Bond Co. Ltd) or more ※Recommendation: Tightening guide 357J-50508T Material No. TC-509 ※ To connection ① Set the △ mark of each other’s connectors. Receptacle connector ▽ mark ② Plug connector △ mark Each other’s key (concavity and convexity)are fit in. Push it straight, take care not to tilt. Receptacle connector key Plug connector key Convexity (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 9/10 Material No. TC-509 ※When using a conduit Page 10/10 (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 for takes care not to cable damage. ① Plug connector ② Conduit connector ③ Plug connector Plug connector Conduit connector Conduit connector Conduit Saddle Cable Conduit Protective cover (rubber etc.,) ●Recommended conduit & connector ※NIPPON FLEX CO.,LTD home page NIPPON FLEX CO.,LTD Conduit Tipe:VF Tipe:SR Tipe:FBN Tipe:VFS Tipe:SRK etc., Connector Tipe:RCM → http://www.nipolex.co.jp Tipe:EM