CM10-SP×× ××S ×× Plug Connector (Crimp type) Cable Assembly Manual (Standard type) Date of Issue: May 19, 2004 Material No. TC-504 DDK Ltd. 2ND Production engineering department assembly group 14 Matsuyama-cho, Moka-shi, Tochigi TEL : 0285-82-4463 Revision H I Date 10/25/05 1/16/07 Version No. No.T-1479 No.T-1723 Material No. TC-504 Contents Page 1. Outline 2 2. Specifications 2 2-1. Applicable connectors Cable Assembly Process 3. 3-1. Cutting a cable 2 3-2. Inserting parts 2 3-3. Stripping a cable 3 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 7 3-8 Tightening a clamp nut 8 Page 1/10 Material No. TC-504 1. Outline This Cable Assembly Manual explains how to assemble the wire to CM 10 plug connector. (Crimp Type) 2. Specifications 2-1. Applicable connector Connector name Drawing number CM10-SP2S-S 115J-AP10046-1 CM10-SP2S-M 115J-AP10046-2 CM10-SP2S-L 115J-AP10046-3 CM10-SP10S-S 115J-AP8979-1 CM10-SP10S-M 115J-AP8979-2 CM10-SP10S-L 115J-AP8979-3 Page 2/10 Material No. TC-504 Page 3/10 3. Cable Assembly Process 3-1. Cutting a cable Cut the cable to the following dimensions: Cable length ※Cable length after cutting = 35mm for CM10-SP×× ××S ×× + cable length =35mm + cable length 3-2. Inserting parts Insert the clamp nut, cable clamp, bushing and back shell into the cable. Caution! Take care not to insert them upside down. Bushing Cable clamp Back shell Clamp nut 3-3. Stripping a cable Strip the cable to a length 20 mm. Strip the core wire to a length 3 mm. 20 3 Core wire Cable Sheath Material No. TC-504 3-4. Crimping a contact With the crimping tool, crimp each contact on each cable. Applicable contact Crimp machine Contact crimping tool for CM10-AP××S CM10-#22SC-C1 357J-50446T AP-A50539T CM10-#22SC-C2 357J-50447T AP-A50540T CM10-#22SC-C3 357J-50448T AP-A50540T Applicable cable AWG20 AWG22 AWG23-24 AWG26 AWG28 AWG16 AWG18 AWG20 Caution! 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. Contact Cable Heat shrink tube Crimping drain wire Page 4/10 Crimp height (Wire section) 1.05 0.94 0.71 0.67 0.64 1.25 1.15 1.05 Material No. TC-504 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 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 Housing Cable Terminal No. 10 only (Grounding wire or drain wire) Insert ※Insert the contact so that the lance and the terminal number face the same direction. However, in case of CM10-SP2S- × , insert the contact so that the lance and the terminal number face the opposite direction. Terminal number Lance CM10-SP10S-× Contact Terminal No. Lance Contact CM10-SP2S-× Page 5/10 Material No. TC-504 3-6. Tightening back shell Page 6/10 (a) Temporarily tighten the back shell coupling on the back shell. ※To prevent loosening, the adhesive should be applied to the back shell. (b) Set the back shell wrench on the back shell coupling. (c) With the wrench, tighten the back shell coupling on the back shell. Recommended tightening torque: 5 N m Caution! Accurately fit the wrench on the back shell coupling. To remove, take the reverse steps. Recommendation Adhesive (2 threads around the circumference) Temporary tightening Back shell Back shell coupling Tightening guide Set Tightening guide Back shell wrench ※Referential dimensions for back shell tightening guide (Back shell width) Back shell wrench Thickness: 10 or more Tighten ※ 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) Recommended adhesive: Screw lock 1401B (Three Bond Co, Ltd) Material No. TC-504 3-7. Inserting a bushing and a cable clamp Insert the bushing and the cable clamp into the back shell. Back shell Bushing Insert Cable clamp Cable Page 7/10 Material No. TC-504 Page 8/10 3-8. Tightening a clamp nut (a) ※ (b) (c) Temporarily tighten the clamp nut on the back shell. To prevent loosening, the adhesive should be applied to the back shell. Set the clamp nut wrench on the clamp nut. With the wrench, tighten the clamp nut on the angle back shell. Recommended tightening torque: 5 N m Caution! Accurately fit the wrench on the clamp nut. To remove, take the reverse steps. ※Recommendation Adhesive (2 threads around the circumference) Temporary tightening Tightening guide Clamp nut Tightening guide Set Back shell ※Referential dimensions for back shell tightening guide (Back shell width) Clamp nut wrench Thickness: 10 or more Tighten ● Torque wrench Recommendation: Tightening guide 357J-50494T Recommended jigs and tools: Clamp nut wrench (357J-51334T) Bit (357J-51345T) Torque wrench (CL6N×8D, Tonichi Mfg.) ※ Recommended tightening jig :(357J-50494T) ※ Recommended adhesive : Screw lock 1401B (Three Bond Co,.Ltd) Material No. TC-504 ※ 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 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 9/10 Material No. TC-504 Page 10/10 ※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 for takes care not to cable damage. ① ② Plug connector ③ Plug connector Plug connector Conduit connector Conduit connector Conduit connector Conduit Cable Conduit 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 Saddle