CM10-SP S- -D Plug Connector (Crimp type) Cable Assembly Manual

Transcription

1 CM10-SP S- -D Plug Connector (Crimp type) Cable Assembly Manual DDK Ltd. 2ND Production engineering department assembly group 14 Matsuyama-cho, Moka-shi, Tochigi TEL : Date of Issue: July 3, 2007 TC-583 Revision Revision TC-504 Revision A 7/3/07 New Issue B 2/13/08 T-2166 C 5/13/08 T-2203 D 6/24/08 T-2253 E 2/25/09 T-2487

2 TC-583 1/11 Contents 1. Outline 2 2. Specifications Applicable connectors 3. Cable Assembly Process 3-1. Cutting a cable Inserting parts Stripping a cable Crimping a contact Inserting a contact Tightening an back shell Inserting a bushing and a cable clamp Tightening a clamp nut 9

3 1. Outline TC-583 2/11 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 CM10-SP2S-S-D CM10-SP2S-M-D CM10-SP2S-L-D CM10-SP10S-S-D CM10-SP10S-M-D CM10-SP10S-L-D Drawing number 115J-AP J-AP J-AP J-AP J-AP J-AP

4 3. Cable Assembly Process 3-1. Cutting a cable TC-583 3/11 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-X-D + 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 Cable Back shell Clamp nut 3-3. Stripping a cable Strip the cable to a length of 19.5 to 20.5mm and also strip the core wire to a length of 3 to 3.5mm. Note! Take care the cable peel length. Take care not to damage anything. For CM10-SP10S-X-D strip 1mm longer than others.(avoiding the cable tension in the process of contact insert to the housing.) 19.5 to 20.5 (No.10 +1mm) Sheath Core wire 3.0 to 3.5 Wire cable

5 3-4. Crimping a contact TC-583 4/11 With the crimping tool, crimp each contact on each cable. Applicable contact for CM10-AP S-x-D Contact crimping tool Crimp machine CM10-#22SC(C1)(D8) 357J-50446T AP-A50539T CM10-#22SC(C2)(D8) 357J-50447T AP-A50540T CM10-#22SC(C3)(D8) 357J-50448T AP-A50540T CM10-#22SC(C4)(D8) 357J-52667T AP-A52666T Applicable cable Crimp height (Wire section) AWG AWG AWG AWG AWG AWG AWG AWG AWG AWG 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-x-D (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 Crimping drain wire Difference of total length :less than 1mm (except for No.10)

6 3-5. Inserting a contact TC-583 5/11 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 th e 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 Wire 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-SP2S- -D, Lance insert the contact so that the lance and the terminal number face the opposite direction. Terminal No. * * Using a pull out tool for pulling up inserted contact. Jig/Tool Used : Contact removing jig (357J-50548T) Contact CM10-SP10S-x-D * Refer to the instruction manual in case of using pull up tool. Terminal No. * As Lance falls down easily after pulling up, set up to original position before re-insert. Lance Contact CM10-SP2S-x-D

7 3-6. Tightening back shell TC-583 6/11 (a) To prevent loosening, the adhesive should be applied to the back shell by two threads around the circumference. *To prevent loosening, the adhesive should be applied to the angle back shell. (b)temporarily tighten the back shell coupling on the straight back shell. Straight back shell Adhesive (2threads) Straight back shell Temporary tightening Back shell coupling 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 convexity Back shell concavity and convexity

8 (b) Fix the straight back shell width 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 straight back shell. Recommended tightening torque: 5 N m TC-583 7/11 Note! Accurately fit the wrench on the back shell coupling. To remove, take the reverse steps. Back shell Back shell coupling Tightening guide Set 19 Tightening guide BS Wrench Referential dimensions for back shell tightening guide 17 (Back shell width) Back shell wrench 20 Tighten Thickness:10 Recommendation: Tightening guide (357J-50494T) Jig/Tool Used : Back shell wrench (357J-51333T) Bit (357J-51344T) Torque wrench (CL6N 8D, Tonichi Mfg.) *Recommended tightening guide: (357J-50494T) *Recommended adhesive: 1401B (three bond Co., Ltd.)

9 3-7. Inserting a bushing and a cable clamp TC-583 8/11 Insert the bushing and the cable clamp into the back shell. Back shell Bushing Cable clamp Insert Cable Note! After the Bushing insert, confirm that cable position should be inside of Bushing.

10 3-8. Tightening a clamp nut TC-583 9/11 (a) Temporarily tighten the clamp nut on the back shell. *To prevent loosening, the adhesive should be applied to the back shell. (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. To remove, take the reverse steps. Temporary tightening Recommendation Adhesive (2 threads around the circumference) Tightening guide Clamp nut Tightening guide 19 Set Back shell Referential dimensions for back shell tightening guide 17 (Back shell width) 20 Clamp nut wrench Thickness: 10 Tighten Torque wrench Recommendation: Tightening guide (357J-50494T) Jig/Tool Used : Clamp nut wrench (357J-51334T) Bit (357J-51345T) Torque wrench (CL6N 8D, Tonichi Mfg.) *Recommended tightening jig :(357J-50494T) *Recommended adhesive: 1401B (three bond Co., Ltd.)

11 TC /11 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

12 TC /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 Plug connector Conduit connector Plug connector Conduit connector Plug connector Conduit connector Conduit Cable Conduit 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