M。deー APー05
Contents
1. Visus ie ERR VERE AERER E M 6 MaintenanGe oov ses ori esccsas coxa po vu ed ea a eU eu obo SE OE UU EHE aae uno ck e UR iaa EUIS 8 D 1 Sliding section of the ram 44 11 e Lees eene eene e eere tenet eene tenet eno eene etos ete ene eoa 8 1 2 Sliding section of the terminal feed mechanism eeeeeeeeeeeeeeete 8 2 Routine maintenance and inspection eere eee eerte eee eene teen net tn etta sterne tena s eena 8 3 Replacing the expendable parts eeeeee eere eee eene eese eee ee en ee een ete n estne eene tene senue 9 3 1 Replacing the crimper eere een eene eene etra e ea oa tasa eene deoa aeta tea Peta pae een ae eee p a epa 9 3 2 Replacing the anvil sissss iscssccccsensssoscicassesdacectscusesasapdescutsansasbnesaconsaonspansedenasuceusvebane 9 4 Expendable parts 0 ccssscssoscssescssercsscessoeadsnsssenascnnsonncssonsvesssescseesssosboesboossovesscosseosese 9 7 Froubleshooting scascssiassabersiscdncsdcauasosedunsceceorseainesndeiasaiessassestiviisussevuse LO 1 Troubles with respect to functions of the applicator eere eere 10 2 Troubles with respect to crimping quality cessere eere eere eene renes 10 8 Appendix ioo ri sets eee e ore redison eene tke eene eise ioter ie es L 1 Major component names qu 11 2 Expansio2. tighten fixing screw 1 l SNe 4 al u n a 3 How to adjust the crimp height Caution To carry out crimping operation refer to the description of operation given in the Instruction Manual for the main unit of the crimping machine Model CM 105 In addition check to be sure that the crimp positions terminal is attached to the correct position 1 Check the crimp height requirement for the electric cable to be crimped 2 The terminal has two crimping position i e cable core section and insulation section Set the related crimp heights to the required values following the steps of procedure described below Adjusting the cable core crimp height Set wire disk 1 and spacer disk respectively to A and W Turn the disks so that the predetermined setting positions are brought to the front Carry out crimping Measure the cable core crimp height using a point blade micrometer to check the difference between the required height and the measured height Set the position of wire disk and that of spacer disk within the range of the required crimp heights using the values given below as reference For wire disk the crimp height is reduced in the order of A B C and D in increments of approximately 0 12 mm For spacer disk the crimp height is reduced in the order of W X Y and Z in increments of approximately 0 03 mm Adjusting the insulation crimp height Se
3. KU TOKYO 141 JAPAN TELEX J2468237 HRSELE TELE FAX 03 3493 2933 CABLE BESELECONHIROSE TOKYO PHONE 03 3491 9741 Phone 805 5227958 Hirose Electric U S A Inc 2688 Westhills Court Simi Valley Calif 93065 6235 TeleFax 805 5223217 eme 9 o9 ow SSS s 9 9 0 b o 9 v 9 v o 9 o9 opos t 9 9 9 9 9 9 e s t soo s vo mo n o m 9 oa dos os n Phone 0711 4560021 Hirose Electric GnbH Zeppelinstraze 42 73760 Ostfildern Kemnat Tele Fax 0711 4560729 Crownhill Business Centre 22 Vincent Avenue Phone 0908 260616 Hirose Electric UK Ltd Crownhill Milton Keynes MK8 0AB Tele Fax 0908 563309 Phone 02 864 5075 HIROSE KOREA Co Ltd 4725 Mok Nae Dong Ansen City Seoul Tele Fax 0345 491 9886 i i Phone 2803 5338 Hirose Electric Co Ltd 2102 Emperor Group Center 288 Hennessy Road Wanchai Xi Hong Kong Branch Tele Fax 2591 6560 96 11 Printed in Japan TAD P0504 Datcofrevison 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 resul
4. the applicator P M 2 4 Crimping OPEK a tlOMicscssscvcsiaccsccsescnssssassivescnbacd ence vasssvaacsncusestscooussarsertenco 4 1 Attaching detaching the reel terminal eene 3 1 Attaching the reel terminal to the main unit of the crimping machine 3 2 Detaching the reel terminal from the main unit of the crimping machine 3 3 Attaching the terminal to the applicator eere esee eere eene ener tn ntes tn aera ttnntno 3 4 Detaching the terminal from the applicator 4 eee eee eee eren enne rn nerunt 4 4 2 Preparing an electric cable gdtcastaassunedatasdeavenssusiesenss 4 1 Processing the termnimal ccscccccosscocsrssccssvovscccessassvssasesesccsossccscssscsessosssenssosessenenesens 4 4 3 Making preparation for crimping operation sae aussuuwiacuiecauisieacaut 4 D How to conduct crimping operation ccsssscssscesssssecsscsssssssccrecessscessesssseoossnees 4 2 How to adjust the position of the terminal eere eene eene eere eene entente 5 3 How to adjust the crimp height ssccccsssssssscesccressssscessseeccserecssseccessesenseeensserens 6 5 Crimping Quality P H 7 5 1 Crimping conditions ccccscecscccsvessesseesesccsssscnsoonecsstnssissscsscesscesscsosccoscess 7 5 2 Crimping quality standards
5. 8 Appendix 1 Major component names Q 1 Item Product name Product name Q ty vil holder 1 E vil holder pin N 3 Mounting plate A 7 Shear plate Z Mounting plate B 8 ire anvil Insulation anvil Adjust block B Cut off punch 7 Cut off punch spring tem ES pw Ea EJ EI E E Adjust block pin a Cut off die e pe E El E ES Terminal guide Cut off die pin Terminal rail Wire stopper w amp amp eB o B A a 5 ia zZ 2 n o e ec O lt n Mm 2 e 5 11 Feed rod Stud bolt 3 3 39 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 12 Feedrotler Scrap guard is Roerpm O O 7 Safety cover bolt faa Adustrod 000000 Safety cover washer as Pivot block 3 Safety cover thumb screw 1s Resismgrng A __ so Safety cover Gems es Tis Radice ts 20 pivotbus st weas Tt mus x a 1 5 mew 3 e mm 24 Fed ngerpin __ se Insulationcrimp height adjusting dial 1 IET eS EUH uum i else c susp es 28 Campos ea Crimperspaer tt oee o Eo 7 03 EA aa E passu a 3s m Dugseksng 6 Actuator 000000 o ce Applicator Model AP105 NOTE This Parts List is for the standerd model Some parts may be changed in accordance with the destination 12 H5 HIROSE ELECTRIC CO LTD 5 23 OSAKI 5 CHOME SHINAGAWA
6. AUTION To protect against possible accidents due to abrupt start of the machine start your work after disconnecting the power to the main unit of the crimping machine 1 How to conduct crimping operation 1 Set wire disk T spacer disk and insulation crimp height adjusting dial as illustrated to the positions same as shown in the sketch on the left A W 1 positions 2 Connect the power plug of the main unit of the crimping machine to the power receptacle and turn on the main power switch 3 Lightly press the stripped end of the electric cable against wire stopper at a position that is almost just above the terminal Caution If crimping is carried out with the electric cable separated from wire stopper 4 or excessively pressed against it crimping quality deficiencies can result 4 Depress the foot switch Then crimping performance is carried out by the up and down movement of the applicator ram every time the ram unit of the crimping machine makes an up and down movement 2 How to adjust the position of the terminal am 1 Loosen pivot block fixing screw 1 with the terminal wr Ix T set in position j 2 If terminal is situated on the left of anvil 3 turn the feed adjusting shaft in the direction of arrow If the terminal is situated on the right A turn it in the direction of arrow B 3 Once the terminal is brought to just above 5 the anvil
7. Applicator Model AP105 Main unit of applicable crimping machine Mode CM 105 INSTRUCTION MANUAL 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 necessary for review Because of the machine s design there is always a possibility of contact with moving parts The operators of the machine and the maintenance personnel who are in charge of maintenance and repair work are required to read the following SAFETY INSTRUCTIONS so as to avoid injury To fully understand the descriptions 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 I 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 of eyesight wo
8. Cross section of crimped section Err ae NNI mima c leg e DENT HESS x Stripping length Crimp burr height Rolling 6 Maintenance Caution 1 To prevent possible accidents caused by unfamiliarity with the operation of the machine repair and adjustment of the machine shall be conducted only by maintenance personnel who has a full knowledge of the machine Any repair and adjustment beyond the range covered by the instructions given in this Instruction is prohibited We assume no responsibility for accidents caused by improper repair or adjustment or the use of non genuine part s 2 To conduct maintenance works be sure to detach the applicator from the crimping machine prior 1 Lubrication 1 1 Sliding section of the ram 1 Periodically once a week apply a light coating of grease to side face 1 rear face and cam follower section of the frame Designated grease NLGI No 2 grease for centralized lubrication Caution Avoid excessive oiling 1 2 Sliding section of the terminal feed mechanism 1 Periodically once a week apply a few drops of oil to feed rod and adjust rod Designated oil ISO VG32 Caution Avoid excessive oiling 2 Routine maintenance and inspection 1 Check to be sure that no carrier chips and dust gather in each sliding section 2 It is recommended to store the machine when not in use in a clean and dry place to av
9. er that is not necessary in the use of the CAUTION machine nesr by SAEETY DEVICE For the machine and the safety device of which configurations are given below the machine is made to specifications intended for Japanese home market and the safety device is mounted on and supplied with the machine The configurations may differ with destinations and specifications Applicator Safety cover The cover prevents contact between fingers and the press Warning label A rotating component is installed inside the cover Main unit Danger of contact injury is present Danger of cuts on fingers is present Never place fingers inside the safety cover iii Safety instruction in use Flywheel cover The cover prevents contact of hands head etc by the flywheel etc Warning label If touching you could get burns Warning label Electrical components are installed inside Danger of electric shocks is present The minimum safety instructions to be followed when operating the crimping machine are indicated Foot switch cover The cover protects feet against hazards CONTENTS Ds SPOCHICATIONS m yan ilc E MU UL 3 Attaching detaching the applicator eeeeeeeeeeee eene Z D Attaching the applicator to the main unit of the crimping machine 2 2 Detaching
10. erators who have been trained for proper operation and provided with sufficient knowledge of safe operation by the employee For this purpose the employer shall establish a training plan and implement it for the operators beforehand Working wear To protect against possible accidents resulting in personal injury by your cloths being caught in the machine be sure wear a work uniform and securely fasten buttons on the sleeve cuffs and close the zipper on the top center plait of the uniform if any Avoid wearing loosely fitted clothing The operator should fasten hair securely to avoid his her hair from being caught in the machine The operator should wear close toe rubber sole shoes SAFETY INSTRUCTIONS IN EACH CATEGORY OF WORK FOLLOWING THE DELIVERY OF THE MACHINE Transportation 1 The machine shall be moved in such a way that secures safety avoid falling and dropping 2 To protect against unexpected accidents or drop accidents the machine shal be repackaged if necessary to achieve the originally delivered state or better Prior to repackaging wipe off oil gathering on the machine Unpacking 1 The machine is shipped in a corrugated cardboard box Be sure to take the machine out from the box while cautiously avoiding dropping the machine 1 2 3 Use oil of the kind designated by us or an equivalent for the machine In the event that oil should get in your eye or contact your skin immediately wash to re
11. l terminal from the main unit of the crimping machine 1 Detach the reel terminal following the same procedure as that taken to attach it 3 Attaching the terminal to the applicator 1 Turning cam lever 1 in the direction of arrow insert terminal along terminal guide Caution Take care to avoid paper tape from entangling around the terminal 2 Furthermore lift screw 4 in the direction of arrow B and insert the terminal into the applicator until it goes slightly beyond just above anvil 5 in terms of the rightward direction 3 Lower screw in the direction of arrow Check to be sure that the top of gathering pallet 5 fits in pilot hole in the terminal carrier Draw the reel terminal slightly in the direction of arrow D and turn cam lever T in the direction of arrow This completes the installation of the terminal 4 Detaching the terminal from the applicator Turn cam lever 1 in the direction of arrow and lift gathering pallet in the direction of arrow B Then draw out the terminal in the direction of arrow until it comes off 4 2 Preparing an electric cable 1 Processing the terminal 1 Be sure to strip the covering at the top of the electric cable in prior Refer to the stripping length given in 2 When stripping the covering carefully avoid the cable core from breaking being nicked loosening and bending 4 3 Making preparation for crimping operation C
12. move it to protect against irritations and rashes In the event that you should swallow oil by mistake immediately consult a doctor to prevent diarrhea and emesis Maintenance 1 To prevent possible accidents caused by unfamiliarity with the operation of the machine repair and adjustment of the machine shall be conducted only by maintenance personnel who have full knowledge of the machine Any repair and adjustment beyond the range covered by the instructions given in this Instruction Manual is prohibited We assume no responsibility for accidents caused by improper repair or adjustment or the use of non genuine part s To protect against personal injury check to be sure that screws and nuts are not loosened after the completion of repair adjusting works and replacement of parts Periodically clean the machine as long as it is commissioned To prevent possible accidents caused by abrupt start of the machine during cleaning be sure disconnect the machine prior to cleaning In the event that your machine fails to perform normally after repair or adjusting immediately stop operation and contact us for service so as to protect against personal injury ii machine extreme caution has to be taken to keep your hands head and fingers away from the moving 1 1 To avoid possible accidents resulting in personal injury caused by being caught in the moving parts of the parts and the area surrounding them Also do not place any matt
13. n RIS Me 12 1 Specifications Adjustment of the wire crimp height Adjustable in 16 stages by turning dial Adjustment of the insulation crimp height Adjustable in 8 stages by turning dial Outside dimensions 170 mm length height x 170 mm width x 80 mm depth with the ram placed in its lower dead center Main unit of applicable crimping machine Model CM 105 2 Configuration Feed lever oe Shank Ta hia Wire disk ik eir Spacer disk Ram Insulation crimp height adjusting dial Safety cover CRD irae LIOS JT e 3569 SES Wire stopper e lew ey T7 E nis CZ SN f E SSA Terminal rail Cam lever 3 Attaching detaching the applicator CAUTION To protect against possible accidents due to abrupt start of the machine start your work after disconnecting the power to the main unit of the crimping machine 1 Attaching the applicator to the main unit of the crimping machine 1 Turn off the power to the main unit of the crimping machine 2 To attach the applicator to the main unit of the crimping machine be sure to check the performance before putting the machine into service referring to the Instruction Manual for the main unit of the crimping machine Model CM 105 to make sure that the ram is in its top dead center E 3 Thoroughly remove dust and stains from bottom face Q of the applicator base and top face contact plane of the bolster plate 4 Keeping
14. ng table supplied with the applicator when ordering Attach each part to the machine so that the inscribed number appearing on the part faces toward the operator Wesme 6 onma 7 Troubleshooting Before starting troubleshooting the following has to be checked 1 Are the correct crimpers and anvils attached 2 Is the applicable terminal used 3 Is the electric cable that falls within the applicable range used 1 Troubles with respect to functions of the applicator Caution N To carry out troubleshooting be sure to detach the applicator from the crimping machine in prior 1 The terminal is not fed smoothly The terminal is not fed 1 The feed finger is mounted out of position and is not aligned with the center of the pilot hole 1 Re adjsut the mounting position of the feed finger 2 Top of the feed finger has worn out Replace the feed finger with a new one 3 Cam follower has worn out 3 Replace the cam follower with a new one 2 Terminal deforms to take S shape during clamping Scrap guard is attached to a wrong position and comes in contact with the reel terminal carrier Re adjust the attaching position of the scrap guard 2 Cut off punch has scratches and marks impairing smooth up and down movement of the terminal Replace the cut off punch with a new one 2 Troubles with respect t
15. o crimping quality Caution AN To carry out troubleshooting be sure to detach the applicator from the crimping machine in prior 1 Re attach the anvil and shear plate properly 1 Crimp shape is defective Bent up and bend down 1 Anvil and shear plate are improperly attached and fail to be closely fitted against the base plate 2 Crimper has worn out broken to cause the terminal to bite After the completion of crimping the terminal deforms when wiping off the terminal with the wire stopper Bent down Replace the crimper with a new one At this time it is recommended to replace also the anvil with a new one since it is supposed that the anvil has also worn out 1 Terminal is attached to a position that 1 Re adjust the position of the terminal is not aligned with the center of the referring to 4 3 2 How to adjsut the anvil position of the terminal 3 Crimp shape is defective Scratches 1 Crimper has extraordinarily worn out 1 Replace the crimper with a new one and peel off of plating breakage and scratches 4 Crimp shape is defective Burrs 1 Anvil has extraordinarily worn out 1 Replace the anvil with a new one breakage and scratches Contact our Production Engineering Department for consultation or questions with respect to any trouble other than those 2 Crimp shape is defective Twist or rolling described above
16. oid dust and dirt 3 To put the machine into service be sure to check in prior that proper expendable parts are installed on the machine 3 Replacing the expendable parts 4 Expendable parts 3 1 Replacing the crimper 1 Remove crimper mounting bolt and detach each part of the crimper 2 Set the respective parts of the crimper in position following the correct order and secure them with crimper mounting bolt QD At this time be sure to check that the crimper is closely fitted against top surface B or the ram holder Caution Set each crimper that the side on which indications are given faces toward the operator Be sure to remember to put insulation spacer in insulation crimper Q If not the adjustment using crimp height adjusting dial D will be rendered ineffective 3 2 Replacing the anvil 1 Remove two anvil mounting bolts D and detach each part of the anvil 2 Set the respective parts of the anvil in position following the correct order and secure them with two anvil mounting bolts D At this time be sure to check that the anvil is closely fitted against base plate E Caution Set each anvil that the side on which indications are given faces toward the operator Extra caution is needed at the time of attaching the anvil since cut off punch applies a lifting force by means of its spring Parts D to have inscribed marks Specify HRS code according to the Spare part mounti
17. t insulation crimp height adjusting dial to 1 Turn the dial so that the predetermined setting position is brought to the top If you pull up insulation crimp height adjusting dial 3 you can turn it Caution Dial incorporates a spring If you release the dial it will automatically return to its home position It is necessary however to check that the dial has properly returned to the home position Carry out crimping Measure the insulation crimp height and check the difference between the required height and the measured height Set the position of insulation crimp height adjusting dial within the range of required crimp heights using the values given below as reference For insulation crimp height adjusting dial S the crimp height is reduced in the order of 1 2 3 to 7 and 8 in increments of approximately 0 1 mm for white numerals or approximately 0 05 mm for blue numerals Caution Once you have completed the adjustment of the positions of the all disks and dials carry out crimping again to be sure that each crimp height satisfies the requirements 5 Crimping quality 5 1 Crimping conditions Refer to the Crimping condition tag issued by us for the crimp height and tensile strength Cable core crimp height Covering crimp height ai Cross section YY Cross section ZZ 5 2 Crimping quality standards Refer to the Crimping quality standards issued by us for the crimping quality K
18. terminal feed lever held tilted in the direction of the arrow lift shank do not 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 6 Press clamp lever in the direction of arrow until it is secured At this time make sure that shank is attaching on ram D Caution This completes the installation of the applicator Never carry out a false placement in this state 2 Detaching the applicator 1 Loosen clamp lever 8 by turning it in the direction of arrow B and pull the applicator until it comes off 4 Crimping operation CAUTION To protect against possible accidents due to abrupt start of the machine start your work after disconnecting the power to the main unit of the crimping machine 4 1 Attaching detaching the reel terminal 1 Attaching the reel terminal to the main unit of the crimping machine 1 Loosen thumb screw 1 remove flange 2 and pass reel terminal 3 over reel shaft 2 Re place flange lightly press it and re tighten thumb screw to the correct position 3 Turning reel terminal in the direction of arrow draw out terminal together with paper tape 4 Insert terminal into the applicator from terminal guide through the left hand side of the main unit of the crimping machine 2 Detaching the ree
19. ting 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 1996
20. unds burns hyperthermal and hypothermal burns electric shocks fracture of a bone poisoning etc requiring emergency of extended medical care Injury Minor injury Indicates wounds burns electric shocks etc requiring medical treatment Damage to property Indicates damage to the machinery and or the surrounding area NcAUTION Basic safety instructions 1 Be sure to read this Instruction Manual and all the instructions and other materials supplied with the unit as accessories Save this Instruction Manual and make it available for review whenever necessary Safety device and warning labels 1 2 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 iii for detailed description of the safety device Once the safety device is detached from the machine replace it to its original position and check to be sure that it functions properly Application 1 2 This machine shall only be used for its originally intended purpose while following the instructions specified in this Instruction Manual Modifications to this machine is prohibited We assume no responsibility for accidents resulting from modifications Training 1 To prevent possible accidents caused by unfamiliarity with the operation of the machine the machine shall only be allowed to be used by the op
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