Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 C。NTENTS ー. M
Contents
1. avoid possible accidents resulting in personal injury caused by being caught the moving parts of the machine extreme caution has to be taken to keep your hands fingers clothing head or hair away from the CAUTION moving parts and surrounding area Also do not place any matter that is not necessary in the use of the machine near any of the moving parts To protect against possible personal injury when turning the power on take care to keep your hands fingers clothing head or hair away from the moving parts and the surrounding area Also do not place any matter that is not necessary in the use of the machine near any of the moving parts To protect against electric shock and accidents caused by any damaged electrical component be sure to turn off the power switch before connecting or detaching the power plug To protect against possible accidents caused by any damaged electrical component be sure to stop your work and disconnect the power plug for safety purposes in the case of thunder and lightning In the case where the machine is suddenly moved from a cold to warm weather conditions condensation can result To protect against possible accidents due to any damaged electrical component turn the power on only after making sure that no condensation is present SAFETY DEVICE The machine and the safety device of which specifications are intended for the countries other than Japan may differ from the standard ones2. Slide block 276229 Needle bearing 276230 Retaining ring B 276235 276238 276239 276240 44 DC solenoid 276267 DC solenoid bracket 276268 Solenoid stopper 276269 47 Spring hanger 276270 Stud bolt B 276271 Back stop lever 276272 276273 276274 276275 276276 Front cover Ram Back stop spring 2 N Safety switch Safety switch bracket Bolster plate 276278 56 Stopper block 276279 57 Clamp A 276280 3 Q o lt mln Retaining ring C Retaining ring D 276241 3 3 Clamp B 276281 Clamp spring 276282 7 Terminal guide bracket 276289 276290 276291 276292 276293 Ball bearing 276242 Clutch roller 276249 276250 Outer race 276251 Spring pin 276252 Flywheel 276253 2 pi NEw am aJU 18 19 20 21 22 23 24 25 26 66 27 M Clutch cage Terminal guide Flywheel cover Reel cover hook V belt 276254 71 Grease nipple Motor pulley 276255 72 Noise absorbing 276295 33 Flywheel collar 276256 73 Power cord 34 Release lever 276257 74 Foot switch 276297 35 Clutch stopper 276258 75 Work light 276298 276259 276260 276261 276262 276263 Count
3. of the machine 1 Install the belt according to 8 2 2 Attaching the V belt 2 1 The solenoid may be improperly positioned Check the installing position of the DC solenoid bracket and adjust it if necessary 3 The crimping machine fails to 1 The V belt is not installed operate even when the foot switch is depressed 2 The stop position of the clutch stopper is not normal Amateur 5 06mm 2 2 Dust or other particles may gather in the gap existing between the amateur of the DC solenoid and the pipe This can cause suction force to be inconsistent Remove the DC solenoid and wipe it clean with a piece of cloth or the like The same difficulty can also arises in the event that the DC solenoid has deteriorated with time If the clutch stopper stop position cannot be corrected by removing the foreign matter replace the DC solenoid valve with a new one Contact our Production Engineering Department with any or questions regarding any trouble other than those described in this section Trouble Corrective measure DANGER To protect against shock hazards open the cover if necessary after turning the power off and waiting for a minimum of five minutes or more 4 Double placement or successive 1 Malfunction of the foot switch 1 1 Remove the applicator Then placement is sometimes performed depress the foot switch securely during crimping operations approx
4. Warning label Flywheel cover A rotating component is installed inside the cover Danger of involvement or being caught is present Main unit The cover prevents involvement of hands head etc by the flywheel etc Warning label Extreme heat Applicator If touching you could get burns Safety cover The cover prevents Warning label contact between fingers and the press Electrical components are installed inside Danger of electric shocks is present Safety instruction in use The minimum safety instructions to be followed when operating the crimping machine are indicated Warning label Foot switeh cover Danger of cuts on fingers is present Never place fingers inside the safety cover The cover protects feet against hazards iv CONTENTS 1 MODEL oe M NE 1 2 SPECIFICATIONS 1 3 CONFIGURATION weidscsscscecccscsssssucaencaccssasisdeaveagesasinubanoieasgiscosssacsessiatsssterenssoes 1 Ay INSTALLATION 5usceesextesasekentesnutv cccuntysexeavasnstactscostsnansbes 2 S OPERA TION 3 1 Preparation p 3 2 Checking the performance before putting the machine into service 3 3 Checking the operation cc escsecossccosssssccessccesevesvesescorseesossvessc
5. plate Foot switch Clamp lever Back stop lever Flywheel counter Main shaft Motor pilot lamp Solenoid link Solenoid Power pilot lamp Fuse Main power switch Safety switch Motor start switch 4 INSTALLATION CAUTION This machine is heavy in weight Moving or installation should be carried out by two or more persons Take precautions not to allow the machine to fall or drop Dimensions of rubber mal recommended 1 Place a rubber mat on the work bench that is stable and 270 leveled Place the machine on the rubber mat 2 Fit the bolts in two mounting holes and tighten them 5 OPERATION 1 Preparation CAUTION To protect against shock hazards and possible accidents due to abrupt start of the machine do not power on the machine until you have completed the preparation 1 Check to be sure that the applicator has been detached 2 Make sure that main power switch 1 mounted on the right hand side is in the OFF position 3 Connect foot switch cord 2 to metal receptacle 3 4 Connect power cord to metal receptacle 2 2 Checking the performance before putting the machine into service WARNING Extreme caution has to be taken not to allow hands fingers head and clothing to be involved caught in the moving parts of the machine 1 Open flywheel cover 6 2 Press solenoid link in the direction of arrow to engage the clutch 3 Attach han
6. C Relative humidity under operating conditions 35 to 85 4 Condensation can be observed when the environment of the machine is changed abruptly from cold to warm To avoid accidents or damage do not operate this machine in condition where the humidity is greater than the upper limit of the relative humidity specified above 5 To avoid accidents caused by a damaged electrical part function in the event of thunder and lightning stop your work and pull out the power plug 1 To prevent possible accidents caused by unfamiliarity with the operation of the machine the machine should only be operated by fully trained personnel It is recommended that a training procedure be established by the employer and that the operator be provided with this Instruction Manual for reference 1 To protect against possible accidents resulting in personal injury or damage to personal property i e clothing be sure wear a work uniform or fit clothing with sleeve cuffs fastened 2 The operator should secure their hair with a hat or ponytail to protect his her hair from being caught in the machine 3 The operator should wear safe rubber bottom close toe shoes or work boots Event that requires turn off of the power 1 In the event of abnormal conditions machine failure or power failure the power should be turned off immediately 2 To protect against possible accidents caused by abrupt start of the machine the power must be turned off before con
7. FAX 03 3493 2933 CABLE BESELECONHIROSE TOKYO PHONE 03 3491 9741 uA MES pur Were 09 sata Hirose Electric GmbH Zeppelinstraze 42 73760 Ostfildern Kemnat 9 Hirose Electric UK Lid St im Yan HIROSE KOREA Co Ltd 472 5 Mok Nae Dong Ansen City Seoul 2 ra 2 ae ae L E A E N E E E A a oe 2102 Emperor Group Center 288 Hennessy Road Wanchai Hong Kong Branch Tele Fax 2591 6560 97 06 Printed in Japan
8. Main unit of crimping machine 5 8 Model CM 105 Applicable applicator Mode AP105 CAUTION Be sure to read this Instruction Manual carefully before using it to secure safety in operation In addition save this Instruction Manual so that it is available whenever INSTRUCTION MANUAL necessary for review H RIC CO SAFETY INSTRUCTIONS When operating this machine there is always the possibility of contact with the moving parts The machine operator and maintenance personnel are required to read the following SAFETY INSTRUCTIONS so as to handle the machine taking care not to get hurt To fully understand the description given in this Instruction Manual and the warning labels attached on the machine the warning messages are used in accordance with the below stated classification Please be sure to thoroughly understand the messages and follow the instructions D Description of warning messages Used in the case where it is assumed that misuse of the machine will expose the operator to immediate danger of major injury or death Used in the case where it is assumed that misuse of the machine can expose the operator to danger of major injury or death Used in the case where it is assumed that misuse of the machine can expose the operator to danger of injury and can cause damage to property Determine the degree of impairment referring to the below stated classification Major injury Indicates the loss o
9. adjustment of the machine shall be conducted only by maintenance personnel who have been trained on the machine Any repair and adjustment not specified in this Instruction Manual are prohibited We assume no responsibility for accidents caused by improper repair or adjustment including the use of non genuine part s To protect against possible accidents and electric shock hazards repair and maintenance work including wiring of electrical parts should be conducted by electrical technicians or Hirose engineers In the event that electrical parts need repair and maintenance please consult any of the aforementioned persons To protect against personal injury check to be sure that screws and nuts are tightened after the completion of repair adjusting and or replacement of parts Periodically clean the machine as long as it is commissioned To prevent possible accidents caused by an abrupt start of the machine during cleaning be sure to turn the power off including unplugging it before beginning cleaning In the event that your machine fails to perform normally after repair adjusting works immediately stop operation Contact Hirose for service to protect against personal injury iii SAFETY INSTRUCTIONS TO BE FOLLOWED WHEN USING THE MAIN UNIT OF CRIMPING MACHINE MODEL CM 105 To protect against shock hazards open the cover if necessary after turning the power off and waiting for a minimum of five minutes DANGER
10. d turning handle 8 to main shaft Q9 4 Turn hand turning handle 8 in the direction of rotation Simultaneously with the turning of the handle ram unit vertically moves 5 After the vertical motion of ram unit 00 is checked further turn hand turning handle 8 in the direction of rotation until it stops with a click This disengages the clutch 6 Remove hand turning handle 8 from main shaft 9 7 After the vertical motion of ram unit is checked close flywheel cover 8 If flywheel cover 8 is opened the safety switch functions to prevent the motor from starting even if the power switch is set to the ON 3 Checking the operation WARNING Extreme caution has to be taken not to allow hands fingers head and clothing to be involved caught in the moving parts of the machine 1 Connect the plug of power cord 4 to the power supply receptacle 2 Set main power switch to the ON position Power pilot lamp 2 lights up At this time work light lights up and goes corresponding to ON OFF of work light switch 0 3 Press motor start switch 09 This will cause the motor to start At the same time motor pilot lamp l6 lights up 4 Depress the switch mounted in foot switch 6 This w will cause ram unit 19 to make a vertical travel once At the same time counter 18 actuates 5 Set main power switch 00 to the OFF positio
11. ducting inspection repair or cleaning Be sure to turn the power off when the operator leaves the machine 3 To pull out the power plug hold the plug rather than the cord Turn off the power means turning off the power switch and pulling the power plug out of the receptacle This applies to any case where the turn off the power is hereinafter referred to Safety instructions in each category of work following the delivery of the machine Transportation 1 To protect against possible accident or damage the machine should be lifted by two or more persons Use an eye bolt attached on the machine and an apparatus such as chain block specifically designed to lift heavy cargo To move the machine a dolly is recommended 2 The machine shall be lifted or moved in such a way that secures safety to avoid falling and dropping To protect against accidents or damage to the machine re package if necessary to achieve the originally delivered state Prior to re packaging wipe off an oil gathered on the machine Unpacking 1 2 To protect against personal injury carefully check the box for wood nails Draw out nails from the boards The center of gravity of the machine is at the center of the eye bold mounting section Remove the machine out of the container carefully ork ben 1 Use a table or a work bench that will sufficiently withstand the machine weight and the reaction force developed while the
12. ectly closed Trouble Corrective measure DANGER To protect against shock hazards open the cover if necessary after turning the power off and waiting a minimum of five minutes 1 The motor fails to move even when 1 Installing position of safety switch 1 Properly close the flywheel cover the motor start switch is pressed D mounted inside the flywheel Move safety switch to such a cover is wrong This would prevent position that the switch turns on and the switch from turning on fix the switch there Relay is not correctly set it is raised or it fails to operate 2 Properly set the relay or normally replace it with a new one Contact our Production Engineering Department with any questions regarding trouble other than those described in this section Trouble Corrective measure WARNING Extreme caution has to be taken not to allow hands fingers head and clothing to be caught in the moving parts of the machine 2 Fuse frequently blows when the 1 The clutch is not properly engaged motor starts Back stop lever fails to engage with back stop cam 2 1 Adjust to engage the clutch properly according to 5 2 Checking the performance before putting the machine into service WARNING Extreme caution has to be taken not to allow hands fingers head and clothing to be involved caught in the moving parts
13. er 276299 276300 276301 276302 276303 37 Stud bolt 38 Spring hanger Electrical box Motor cover i SIONA Stop ring Link pin 39 40 Handle wl wi win N Nim oS el o Main unit of crimping machine Model CM 105 TAD P0510 June 1997 Date ofrevson CAUTION No part of this manual may be reproduced without the permission of Hirose Electric Co Ltd Description in this manual is subject to change without notice This Instruction Manual has been prepared for clarify Should you find any unclear portion error or omission please for the safety of other contact our Marketing Department It should be understood that notwithstanding the aforementioned item 3 we assume no liability to any claim for loss or failure to earn profit resulting from the use of the machine We assume no responsibility for any damage resulting from your improper use of the machine including your failure to follow the instructions given in this Instruction Manual This includes repair or modification conducted by any third party other than Hirose Electric Co Ltd Please note that servicing of the machine is not available in any country other than Japan HIROSE ELECTRIC CO LTD 1997 HS HIROSE ELECTRIC CO LTD 5 23 OSAKI 5 CHOME SHINAGAWA KU TOKYO 141 JAPAN TELEX J2468237 HRSELE TELE
14. f eyesight wounds burns hyperthermal burns and hypothermal burns electric shocks fracture of a bone poisoning etc attended with aftereffect requiring hospital treatment or attending to hospital treatment for an extended period of time Injury Minor injury Indicates wounds burns electric shocks etc requiring neither hospital treatment nor attending to hospital treatment for an extended period of time Damage to property Indicates damage spread to premises household goods livestock and pets Explanation of warning labels and indication labels Danger of cuts on fingers is Indicates extreme heat present Never place fingers If touching you could get burns inside the safety cover Rotating component is installed ndicates the correct direction of inside the cover rotation Warning label Electrical components are i E e E E installed inside Danger of electric shocks is present SAFETY INSTRUCTIONS J DANGER 1 To protect against shock hazards when opening the cover first turn the power off Then wait for a minimum of five minutes before opening the cover For the purpose of this manual an accident is an event that causes personal injury or damage to property NCAUTION 1 Be sure to read this Instruction Manual and any other instructions or materials supplied with the unit as accessories Basic safety instructions Keep t
15. his Instruction Manual carefully and make it available for reference Safety device and warning labels 1 To avoid possible accidents due to lack of the safety device be sure to operate the machine after ascertaining that the safety device is properly installed at the predetermined position Refer to page iv for detailed description of the safety device 2 If the safety device is detached from the machine for any reason replace it to its original position and check to be sure that it normally functions 3 Be sure to maintain the warning labels on the machine They should be clear and visible at all times If any of the warning labels should come off or become soiled damaged replace it with a new one 1 This machine shall only be used as specified in this Instruction Manual 2 Modifications to this machine is prohibited We assume no responsibility for accidents resulting from modifications Operating environment 1 To avoid accidents caused by malfunction the machine shall be operated under an environment that is not affected by high noise sources electromagnetic waves such as high frequency welders 2 To avoid accidents caused by malfunction the machine shall not be used in such an environment that would subject it to any voltage rating outside of rated voltage 10 The machine shall be used under the following environment for safety Atmospheric temperature under operating conditions 5 to 35
16. imately 100 times to determine whether the foot switch has failed or not 1 2 Conduct proper training of the operator 2 Contact of the relay CR2 has 2 Replace the relay CR2 with a new welded Wa Contact our Production Engineering Department with any or questions with regarding trouble other than those described in this section 10 APPENDIX 1 Electric wiring diagram Symbol Name of product Model C Connector 2P Hirose Electric Co NI CN2 Connector 3P Hirose Electric Co F Fuse 10 A SWI Main power switch 2 SW Motor start switch Matsushita Electric Industrial Co Ltd WD 1011 08 133 Omron TYPE AP A SW3 Safety switch Foot switch PLI WL IM Maruyasu 103 GS Motor pilot lamp Maruyasu 103 RS Work light 40 W Motor 200 W Matsushita Electric Industrial Co Ltd ES DBF 100 V 200 W Omron MY 2 Omron LY 2 Act Giken SD12 AA 48 00T Tamura E610 PP15 Power pilot lamp Relay DC solenoid Counter 2 Major component names Product name Product number Product name Product number Q ty Frame 276224 Retaining pin 276264 2 Eye bolt 276225 42 Release lever spring 276265 EN Oil cup 276226 43 Solenoid link 276266 276227 276228
17. machine is in operation 2 If casters are to be mounted on the main unit of the work bench use durable casters provided with a locking mechanism l iri 1 To prevent electric shocks electrical leak or fire be careful not to strain the cables at any time 2 To protect against hazards from electric shocks electrical leak and fire multiple connection must be avoided Plug the machine direct into a socket 3 Connectors should be secured together Pull out a connector hold at the connector portion zroundi 1 An Electrical Expert should be consulted to properly install an appropriate plug 2 The connect the power plug to a properly grounded receptacle 3 This will protect against hazards from electrical leak and isolation withstanding pressure Before operation To protect against possible accidents resulting in injury or death check to be sure that connectors and cables are in good condition and fastened securely To protect against possible accidents resulting in injury or death never place hands in or near moving parts of the machine 1 Use oil of the type designated by Hirose 2 In the event that oil should gets in your eye or contact your skin immediately wash skin or flush eyes to remove the oil This will protect against irritations and rashes 3 In the event that you should ingest oil by mistake immediately consult a medical doctor to prevent illness Maintenance 1 To prevent possible accidents repair and
18. n and both power pilot lamp 2 and motor pilot lamp 09 will go out CAUTION To protect against possible accidents due to abrupt start of the machine power down the machine before you begin this procedure 1 Attaching the reel terminal 1 Loosen thumb screw D remove flange 2 and pass reel terminal 3 over reel shaft 4 2 Re place flange lightly press it and re tighten thumb screw to the correct position Caution Refer to the instruction manual for your applicable applicator for details 2 Detaching the reel terminal 1 Detach the reel terminal following the same procedure as that taken to attach it 7 ATTACHING DETACHING THE APPLICATOR CAUTION To protect against possible accidents due to abrupt start of the machine power down the machine before starting this procedure INNS 1 Attaching the applicator 1 Turn the power off 2 Toattach the applicator be sure to check the performance before putting the machine into service refer to 5 2 Checking the performance before putting the machine AT cc 243 TE into service to ascertain that the ram is in its top dead center D Thoroughly remove dust and stains from bottom face Eo 3 2 of the applicator base and top face contact plane 3 of the bolster plate 4 wa Keeping terminal feed lever held tilted in the direction of the arrow lift shank do n
19. nside flywheel 2 2 Fit the V belt in the slit on motor pulley 3 3 Then pressing V belt against the slit on flywheel carefully turn flywheel 2 in the direction of arrow until the V belt fits in the slot 2 3 How to adjust the slack of the V belt Adjust the slack of V belt D by changing the installing position of motor 5 up or down 1 Remove two mounting screws M4 from motor cover 2 Loosen four bolts 5 used to mount motor 5 to such an extent that allows the motor 5 to move If these bolts are excessively loosened in this step motor will drop by gravity Make a cushion with a shop cloth and place it in the space provided by lifting motor 5 to avoid hands and fingers being caught in the space 3 While in this position move the mounting position of motor 5 up or down while checking the extent of slack of V belt CD 4 Tighten four bolts M5 to fit the motor to a position that allows the V belt to slack appropriately Re check the slack of V belt D Tightening the bolts can change the slack of the V belt 5 Finally attach motor cover 4 in position 9 TROUBLESHOOTING Before troubleshooting the following has to be checked 1 Is the power plug connected to a 100 V power supply receptacle 2 Has the fuse blown 3 Are connectors fitted properly Power cord foot switch cord inside the electrical box 4 Is the flywheel cover corr
20. osssosesssossosecesoesaseeassooese 4 6 ATTACHING DETACHING THE REEL TERMINAL e eee 4 7 ATTACHING DETACHING THE APPLICATOR eee ee eene eene 5 1 Attaching the applicator PER N TG ENTE eoe E uM 5 2 Detaching the applicator ene aoa eh ces ER ES P0 5 8 MAINTENANCE 65565 i T UU HI Neid 6 1 ERE UIRTUTEM 6 2 Inspection Perte T 6 9 TROUBLESHOOTING neret Fiet eoe Pen ke oo aep RES 8 10 APPENDIX di 11 1 Electric 11 2 Major component names 12 1 MODEL CM 105 CL901 0005 4 2 SPECIFICATIONS Specification Pressure applied 14 x 10 N 1 5 ton Stroke 30 mm 1 cycle machine tact 0 3 sec Power consumption Motor 200 W work light 40 W 100 VAC Outside dimensions With the recl terminal attached 900 mm height x 640 mm width x 410 mm depth Weight Applicable applicator Oil cup Eye bolt Flange Work light Flywheel Reel support ywheel cover Electrical box Ram Power cord Motor cover Bolster
21. ot draw it out to fit it in slit 6 on the main unit 5 Place the applicator on the top face of bolster plate 3 and slide it forward until it is pressed against stopper block Press clamp lever 8 in the direction of arrow until it 6 lt A m D is secured At this time make sure that shank is attaching on ram D Caution This completes the installation of the 3 iE applicator Never carry out crimp in this state with no material loaded 2 Detaching the applicator 1 Loosen clamp lever 8 by turning it in the direction of arrow and pull the applicator until it comes off 8 MAINTENANCE CAUTION 1 To prevent possible accidents repair and adjustment of the machine shall be conducted only by trained maintenance personnel Any repair and adjustment beyond the specifications covered in this Instruction Manual is prohibited We assume no responsibility for accidents caused by improper repair or adjustment including the use of non genuine part s 2 To protect against possible accidents and electric shock hazards repair and maintenance work including wiring of electrical parts should be conducted by electrical technicians or HIROSE engineers In the event that electrical parts need repair or maintenance please consult any of the aforementioned persons 1 Lubrication CAUTION To protect against possible accidents due to abru
22. pt start of the machine power down the machine before 1 1 Sliding section of the ram 1 Once a week apply four or five drops of oil in oil cup D on the top of the machine Designated oil ISO VG32 Caution Avoid excessive oiling 1 2 Sliding section of the clutch unit 1 Once a month apply grease lightly on clutch claw back stop claw 3 and surrounding area 2 Once every six month apply 2 to 3 cc of grease to helical gear D Designated grease Grease for centralized lubrication NLGI 2 Caution Avoid excessive greasing 2 Inspection WARNING 1 Extreme caution has to be taken not to allow hands fingers head hair or clothing to be caught in the moving parts of the machine and V belt 2 To protect against possible accidents due to abrupt start of the machine power down the machine before starting this procedure 2 1 Checking the V belt for damage and slack 1 Check to be sure that the V belt has no abnormal scratches and stains 2 With respect to the degree of slack make sure that the V belt sags approximately 10 mm in the direction of the arrow when a 20 N load is applied 2 2 Replacing the V belt Detaching the V belt 1 Hold V belt with a screwdriver to allow V belt to come off the slit on flywheel 2 Now carefully turn flywheel 2 in the direction of arrow until the V belt comes off Attaching the V belt 1 Pass V belt D i
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