HRS DF62W Series User manual

1. Scope
This document specifies the steps from crimping the DF62W-series crimped terminals to
cables (AWG20 to AWG30) to inserting the terminals to crimping sockets,and inserting the
terminal into the crimp case, and the procedure for mounting the panel of the DF62WP
series.
2. Connectors
Crimping cases
DF62W # –EP –2.2 C
❻

Crimping cases (Panel waterproof type)
DF62WP –＊/＊/＊/＊EP –2.2 C






Water proof pin
DF62W –WP

Name: DF62W
Wire seal
#=None or A to E
No. of poles: 2 to 9
Connector types
S : Socket
EP: In-line plug
Contact pitch: 2.2 mm
❻Shape of connection/terminal
C: Crimping case
Name: DF62WP
No. of poles: 2 to 9
“/” Indicates that the connector is a
composite connector with a number of
poles separated by it.
Connector types
EP: In-line plug
Contact pitch: 2.2 mm
Shape of connection/terminal
C: Crimping case
Application
WP: Waterproof pin
COUNT
DESCRIPTION OF REVISIONS
DESIGNED
CHECKED
DATE
4
12
DIS-H-00006326
KI.SUGAWARA
ST.WADA
20201006
TITLE
DF62W Series Cable Assembly Procedure
APPROVED
KI.AKIYAMA
20140215
CHECKED
OM.MIYAMOTO
20140214
DF62WP series panel installation procedure
DESIGNED
KT.ISHII
20140213
WRITTEN
KT.ISHII
20140213
TECHICAL SPECIFICATION
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FORM HC0011-9-1
HIROSE ELECTRIC CO.,LTD.
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FORM HC0011-9-2
Crimped terminals
DF62W –EP 2226 PCF A

Application
EP: In-line
Compatible cables
2022: AWG20 to 22 2226: AWG22 to 26
2830: AWG28 to 30
Shape/packing
SCF : Socket terminal, reeled
SC : Socket terminal, separate
PCF : Plug terminal, reeled
PC : Plug terminal, separate
Plating
A: Gold plating
Blank : Tin plating

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FORM HC0011-9-2
3. Steps for harnessing
3.1. Cable stripping
Strip cables in accordance with Crimping Quality Standards (ATAD-H0762/0763).
In so doing, make sure there is no scratch on cable cores.
3.2. Crimping
Crimped terminals to cables using an applicator (AP105-DF62W-**), and check the crimping
height and shape in accordance with the Table of crimping conditions and Crimping Quality
Standards (ATAD-H0762/0763). (** = 2022, 2226, 2830)
3.3. Insertion to crimping terminal sockets
Insertion to DF62W-＊EP-2.2C and DF62W-＊S-2.2C
Hold the cable of a crimped terminal, and insert it to each terminal hole of crimping sockets.
(Insert the terminal in the direction of arrows below.)
*The figures show insertion to DF62W-2poles connector.
For insertion, place the crimped terminal and crimping socket lock in the following direction.
Before inserting terminal
After inserting terminal
Lock: Right side
Plug terminal
Socket
Socket terminal
In-line plug
Direction of insertion
Contact No.: Upper
Lance holder: Upper
Lock: Left side
Contact No.: Upper
Lance holder: Upper
Figure 3-1. Terminal insertion

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FORM HC0011-9-2
Insert the crimped terminal to pass through the hole of wire seal.
To maintain performance reliability,insert the crimp terminal straight.
Horizontal insertion 
Tilted insertion 
Hole of wire seal
Hole of wire seal
Figure 3-2. Terminal insertion
Figure 3-3. Prohibition of diagonal insertion

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FORM HC0011-9-2
Check that the lance of a crimping socket has been caught at the lance holder of a crimped
terminal.
(Slightly pull the terminal to check.)
*To remove the crimped terminal halfway through insertion, pull the cable while pressing wire
seal to prevent coming off.
Insertion to DF62WP series
*The figures show insertion to DF62WP-3/4/6/2EP-2.2C
Hold the cable of a crimped terminal, and insert it to each terminal hole of crimping sockets.
(Insert the terminal in the direction of arrows below.)
Crimped terminal
lance holder
Socket lance
In-line plug lance
Target (5.85 mm)
Target (5.55 mm)
Plug terminal
In-line plug
Direction of insertion
Before inserting terminal
After inserting terminal
Figure 3-4. Checking the lance
Figure 3-5. Terminal insertion (DF62WP)
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FORM HC0011-9-2
For insertion, place the crimped terminal and crimping socket lock in the following direction.
To maintain performance reliability,insert the crimp terminal straight.
Do not mistake the terminal hole. (Insert the terminal in the direction of arrows below.)
terminal hole
2poles
Lock: Right side
Lance holder: Upper
Horizontal insertion 
Tilted insertion 
terminal hole
6poles
terminal hole
4poles
terminal hole
3poles
Figure 3-6. Terminal orientation (DF62WP)
Figure 3-7. Prohibition of diagonal insertion (DF62WP)
Figure 3-8. Terminal hole position (DF62WP)

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FORM HC0011-9-2
Check that the lance of a crimping socket has been caught at the lance holder of a crimped
terminal.
(Slightly pull the terminal to check.)
*To remove the crimped terminal halfway through insertion, pull the cable while pressing wire
seal to prevent coming off.
3.4. Insertion of waterproof pin
Compatible series : DF62W-＊EP-2.2C , DF62W-＊S-2.2C
If you use waterproof pins, insert them to each holes with designated terminal numbers.
(Insertion direction is shown by arrows in the figure below.)
Before inserting waterproof pin
After inserting waterproof pin
Waterproof pin
Direction of insertion
Target (1.7 mm)
Crimped terminal
lance holder
In-line plug lance
Figure 3-9. Checking the lance
Figure 3-10. Insert waterproof pin
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FORM HC0011-9-2
To maintain performance reliability, insertion insert the waterproof pin straight.
No orientation
Direction of insertion
Direction of insertion
This surface is waterproof surface, so take care not to damage the surface.
Horizontal insertion 
Tilted insertion 
Figure 3-11. Orientation of waterproof pins
Figure 3-12. Prohibition of diagonal insertion of waterproof
pin

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FORM HC0011-9-2
Insert a waterproof pin until it touches crimping socket.
*Insertion more than the target dimension could cause degradation of waterproof
performance.
*To insert the waterproof pin over the target dimension, it has the possibility to fall to a low
level of waterproof.
3.5. Repair of crimped terminal
To remove crimped terminals that have been inserted, pull the cable using the dedicated
Removing jig (DF62W/RE-MD) while pushing up the crimping socket lance.
Using crimping socket after repair could induce decrease of lance strength and / or wire seal
damage. Use new socket to avoid such failures.
Target (1.55 mm)
Target (1.85 mm)
To tap the waterproof pin to socket.
Removing jig
(DF62W/RE-MD)
Socket lance
In-line plug lance
In-line plug lance
(DF62WP)
Figure 3-13. Depth of waterproof pin insertion pin
Figure 3-14. Repair of crimp terminals ①
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FORM HC0011-9-2
Insert the removing jig along the lance of crimping socket.
(Check the appearance with the hand lens.)
Additionally insert the removing jig to push up the socket lance.
Keep the lance position and pull the cable.
Direction of insertion
Direction of insertion
Direction of insertion
Direction of insertion
Push up the lance
Push up the lance
Figure 3-15. Repair of crimp terminals ②
Figure 3-16. Repair of crimp terminals ③

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FORM HC0011-9-2
4. Steps for mounting the panel of the DF62WP series.
4.1. Mounting the panel
4.1-a. Panel insertion
Align the connector using the screw holes on the panel side as a guide.
Insert the connector as far as it will go while maintaining the aligned position.
* The shape of the panel is an example.
If the panel has a shape to prevent reverse mounting, align the orientation with
the protrusion shape before inserting.
Screw hole
Direction of insertion
Reverse mounting
prevention shape
Figure 4-1. Insertion into the panel
Figure 4-2. Reverse mounting prevention shape
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FORM HC0011-9-2
Since the connector may be damaged or the waterproof seal may be broken, insert the
connector straight into the panel and attach it.
4.1-b. Fixed with screws
Install the screws with the connector fully inserted. At this time, do not fix the
screws when the connector is biased in either the vertical or horizontal direction
or when an excessive load is applied.
Horizontal insertion 
Tilted insertion 
Figure 4-3. Prohibition of diagonal insertion
Figure 4-4. Screw fixing

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FORM HC0011-9-2
4.2. Remove from panel
4.2-a. Removing screws
Remove screws.
4.2-b. Removing the connector
Remove the connector from the panel. At this time, push the connector mating
surface side to remove it. Do not pull the cable to remove it as it may cause
the terminal to come off.
Fitting surface
Figure 4-5. Removing Screw
Figure 4-6. Removing from the panel

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FORM HC0011-9-2
5. Notes
*Packing and storage
To pack or store assemblies, make sure overlapped connectors will not apply extreme load to
the lack section.
If load is applied to the lock section under high temperature and humidity for a long period of
time, the lock section will be deformed which could lead poor fitting.
*Excessive external force applied to connectors could cause failure or damage. Therefore,
avoid forced insertion or removal, dropping impact, cable wiring (pull, twist) and such.
Note) Breaking strength of lock is approx. 30 N when connector is pulled in straight
direction. Please avoid excessive force is applied to the connector.
Note) Retention force is approx. 7 N / Pin. Please avoid excessive force is applied to
particular cable.
*When wiring the cable inside the device, make sure that the cable is routed with a margin
so that it will not be in a stretched state or in a state where excessive tension is applied.
*Check with the cable manufacturer for cable flexibility.
*If the rubber seal is damaged, the connector is deteriorated water resistant performance.
Therefore, do not use the connector whose rubber seal is damaged.
*When using the DF62WP series, use the screws shown in the drawing for the
fixing screws.
●Cable bending
When bending the cable, provide a straight part from the end face of the connector as
shown in the figure below and bend it.
(It depends on the flexibility of the cable, but please bend it at the position of 30 mm as a
guide.)
Do not bend sharply from the end face of the connector or stretch the base of the cable
because it will put a load on the terminal contact part and the terminal crimping part
and cause contact failure and waterproof failure.
Sudden bending, tense bending
Straight
Figure 5-1. Cable bending
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Min:30mm
Min:30mm
Bending with a straight
part
Min:30mm
Min:30mm

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FORM HC0011-9-2
Sudden bending, tense bending
Bending with a straight
part
Figure 5-2. Cable bending (DF62WP)
Straight
Min:30mm
Min:30mm
Min:30mm
Min:30mm

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FORM HC0011-9-2
●Cable bunding
When bundling cables, prepare a part that is straight from the end face of the connector
as shown in the figure below, and tie it at least 30 mm away from the end face of the
connector.
Do not bind near the end face of the connector because it will put a load on the terminal
contact part and the terminal crimping part and cause contact failure and waterproof
failure.
Bundling near the end face
Bunding with a straight
part
Figure 5-3. Cable bundling
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Straight
Min:30mm
Min:30mm

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FORM HC0011-9-2
Please crimp with the terminal direction aligned.
If the terminal direction is not allinged, it is necessary to rocate the terminal and insert
into the crimping case. It could cause loosing the contact by stress
●Repair of waterproof seal (DF62WP series)
The waterproof seal may shift by inserting or removing the connector from the panel.
In that case, please use it after returning the waterproof seal to the normal position.
waterproof seal
Misaligned state
Regular position
The terminals are aligned
The terminals are not aligned
Figure 5-4. Terminal binding direction
Figure 5-5. Repairing the waterproof seal
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