DDK Ltd. CM10-AP2S-S User manual

CM10-AP××S-×(D6)
Angle Plug Connector
(Weight saving type󲸤
󲸤󲸤
󲸤Cri p Type)
Cable Asse bly Manual(Standard Type)
Date of Issue: February 16, 2009
Material No. TC-604
DDK td.
2ND Production engineering department assembly group
14 Matsuyama-cho, Moka-shi, Tochigi
TE : 0285-82-4463
󰧖󱇈
󰕛 󰬗 󰩆 󰧖󱇈 No.
󲷠 ’08.3.26 󰨣󲀅󱑯󱼽
󲷡 ’08.5.13 󰈻󰬇󲎜󱕒 No.T-2205
Revision
Date Revision No.
C 16/02/09
New Issue

Material No. Page
TC-604 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. Crimping 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. Page
TC-604 2/11
1. Outline
This Cable Assembly Manual explains how to assemble the wire to the CM 10 angle plug connector.
(Crimp Type)
2. Specifications
2-1. Applicable connector
Connector name Drawing number
CM10-AP2S-S(D6) 115J-AP12162-1
CM10-AP2S-M(D6) 115J-AP12162-2
CM10-AP2S- (D6) 115J-AP12162-3
CM10-AP10S-S(D6) 115J-AP12160-1
CM10-AP10S-M(D6) 115J-AP12160-2
CM10-AP10S- (D6) 115J-AP12160-3
3. Cable Assembly Process
3-1. Cutting a cable
Cut the cable to the following dimensions:
Note! Not to change cable length.
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 da age anything.
* When aking CM10-AP10S(D6), strip the cable for No. 10 ter inal in a way that akes the A
length 1 longer than other cables. (To avoid the cable tension when inserting a contact to
the housing in a later process.)
Product name A length
CM10-AP XX S-S(D6)
CM10-APXX S-M(D6)
30±0.5mm
CM10-AP XX S- (D6) 45±0.5mm
A
(A+1mm for No. 10 terminal only)
Cable core Sheath
*Cable length after cutting = easure ent A for CM10-AP××S (D6)+ Cable length
= A + Cable length Product name A length
CM10-AP XX S-S(D6)
CM10-APXX S-M(D6)
40±0.5mm
CM10-AP XX S- (D6) 55±0.5mm
Cable length

Material No. Page
TC-604 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.
* To insert the angle back shell, bend the cable.
3-4. Stripping a core wire
Strip the cable’s core wire to the length 3.0 to 3.5mm.
Note! Do not istake the length of the core wire to be stripped.
Do not leave cut or scratch to the cable core.
Bushing Cable clamp
Clamp nut
Angle back shell Cable
Insert
Cable
Bend
Angle back shell
Sheath
Core wire
3.0 to 3.5 Cable core

Material No. Page
TC-604 4/11
3-5. Crimping a contact
With the crimping tool or crimping machine, crimp each contact on each cable.
Note! Make sure that the core wire does not co e out of the contact.
When soldering, ake sure that the solder does not stick to the circu ference of the solder
cup.
When using a drain wire, attach a heat shrink tube to the drain cable after soldering.
* When aking CM10-AP10S(D6), the cable for No. 10 ter inal is 1 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 ter inal ust be 1
or less.
Product name A length
CM10-AP××S-S(D6)
CM10-AP××S-M(D6)
39 to 42mm
CM10-AP××S- (D6) 54 to 57mm
Contact
Cable
Heat shrink tube
A
Difference of total length :less than 1mm
(except for No.10)
Crimping drain wire
Connector name
Applicable contact
Contact
crimping
tool
Crimp
machine
Applicable
cable
Crimp height
(Wire section)
AWG20 1.05
CM10-#22SC(C1)(D8) 357J-50446T
AP-A50539T
AWG22 0.94
AWG23-24 0.71
AWG26 0.67
CM10-AP10S-X(D6)
CM10-#22SC(C2)(D8) 357J-50447T
AP-A50540T
AWG28 0.64
AWG16 1.25
AWG18 1.15
CM10-AP2S-X(D6)
CM10-#22SC(C3)(D8) 357J-50448T
AP-A50541T
AWG20 1.05

Material No. Page
TC-604 5/11
Terminal No.
Contact
ance
CM10
-
A
P10S
-
X
(D6)
ance
Terminal No.
Contact
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 confir ing the correct position.
Note! Before inserting the contact, check that the cla p nut, cable cla p, bushing and angle back
shell is inserted.
Take care not to insert the contact upside down as shown below.
* Insert the contact so that the ter inal
nu ber face the sa e direction.
However, in case of CM10-AP2S(D6), insert the
contact so that the lance and the ter inal
nu ber face the opposite direction.
* Using a pull out tool for pulling up inserted contact.
Tool No.: 357J-50548T
Refer to the instruction anual in case of using
pull up tool.
* As Lance falls down easily after pulling up,
set up to original position before re-insert.
Terminal No. 10 only
(Grounding wire or drain wire)
Housing
Contact Cable
Insert
Core wire
CM10
-
A
P
2
S
-
X
(D6)

Material No. Page
TC-604 6/11
Adhesive
(To be coated to two
threads of the
circumference)
Angle back shell
Back shell coupling
Angle back shell
Back shell coupling
Plug shell concavity and
convexity
Back shell concavity and
convexity
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.
● Recommended adhesive: 1401B (Three Bond Co., td.)
(2) Rotate and temporarily tighten the back shell coupling by setting the connector and the angle back shell
to the specified angle.
* When tightening te porarily, atch the concavity and convexity of the plug shell with those of the
angle back shell.
(You can confir the correct connection of concavity and convexity
waving lightly back shell just
before inserting to BS coupling.)

Material No. Page
TC-604 7/11
* Recommendation:
Tightening guide
(357J-52658T)
Angle back shell
Angle back shell
tightening wrench
Torque wrench
Fix the back shell
Fix the back shell
Back shell coupling
19
Set
Set
Tighten
* Reference dimension for
fixing the back shell
(Back shell 2
surface width)
(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: 5Nm
Note! When setting the work to the wrench, adjust it to the 2 surface width.
To re ove, take the reverse steps.
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.
 Recommended jigs and tools : Back shell wrench (357J-51333T)
Bit (357J-51344T)
Torque wrench (C 6N x 8D), Tonichi Mfg.)
* Recommended tightening guide: (357J-52658T)
15

Material No. Page
TC-604 8/11
3-8. Inserting a bushing and a cable clamp
Insert the bushing and the cable clamp to the back shell.
Note! After the Bushing insert, confir that cable position should be inside of Bushing.
Insert
Cable clamp
Bushing
Cable

Material No. Page
TC-604 9/11
*Recommended
adhesive
(to be coated on
2 threads of the
circumference) Tighten
temporarily
* Reference dimension for fixing the back shell
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.
Reco ended adhesive: 1401B (Three Bond Co., Ltd.)
(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! To set the work to the wrench, adjust the 2 surface width.
In case of squeezing the cla p nut with excessed torque provided as above,
the cla p nut ay be broken. Please use the torque wrench.
To re ove, take the reverse steps.
 Recommended jigs and tools : Clamp nut wrench (357J-51334T)
Bit (357J-51345T)
Torque wrench (C 6N×8D, Tonichi Mfg.)
* Recommended tightening guide :(357J-52658T)
Torque wrench
Fix the angle back shell
Angle back shell
Clamp nut
Set
Tightening wrench
Fix the angle back shell
Set
Tighten
19
(Back shell 2
sruface width)
* Recommendation:
Tightening guide
(357J-52568T)
15

Material No. Page
TC-604 10/11
*To connection
(1) Set the  mark of each other’s connectors.
(2) Each other’s key (concavity and convexity) are fit in. Push it straight, take care not to tilt.
*To re ove, rotate the coupling and pull out to straight.
Receptacle connector key
󲷇Convexity󲷈 Plug connector key
(Concavity)
Push it straight
Coupling
(2)
Pull out to straight
(1)
Rotate the coupling
Receptacle connector
mark
Plug connector
mark

Material No. Page
TC-604 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.
 Recommended conduit & connector : NIPPON F EX CO. TD
Conduit
Tipe:VF Tipe:SR Tipe:FBN Tipe:EM
Tipe:VFS Tipe:SRK etc.,
Connector
Tipe:RCM
* NIPPON F EX CO., TD home page → http://www.nipolex.co.jp
(1)
Plug
connector
Conduit
Connector
(nipple)
Cable
(2)
Plug connector
Conduit
connector
Conduit
Plug connector
Conduit
Conduit
connector
Protective cover
(Rubber etc.)
Saddle
(3)