AP-105 アプリケーター取扱説明書
Contents
1. 1 1 xii 2 1 22. NO CO c1 A oO Xi AP105 SHIR 1 KRY RARE JO E MHH EY AL see KER ELTE N H As Ed Se E A ae ERRERA AN E UL et Er A te Brfgh png pen KHI PA AROS HA PR RR VEI AR BRE Hs Bz WL de ET AY Se AE E AY Pt
3. o FBODfS Edo D o TERRERO Ex For safe operation 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 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
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5. HRS LEWIS 0 2 D om EN 3 Replacing the expendable parts 3 1 Replacing the crimper Things to be prepared Hexagonal wrench key for M8 bolt Hexagonal wrench key for M4 bolt 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 At this time be sure to check that the crimper is closely fitted against top surface or the ram holder Caution 1 When setting the crimper carefully clean the crimper mounting section of the ram holder and the crimper so that there is no dust or stain there 2 Set each crimper that the side on which indications are given faces toward the operator 3 Be s
6. 2006 tt 141 5 5 23 2 7 J 3 13 TEL 045 402 7725 FAX 045 402 7861 HIROSE ELECTRIC CO LTD BAR 141 A ABA IA EBE 5 23 OSAKI 5 CHOME SHINAGAWA KU TOKYO 141 JAPAN XSF se ane bi Mini TH5325 9 TELEX J2468237 HRSELE TELE FAX 03 3493 2933 AKA iss iB ARA RE CABLE BESELECONHIROSE TOKYO PHONE 03 3491 9741 222 7 3 13 TEL 045 402 7725 FAX 045 402 7861 Hirose Electric U S A Inc 2688 Westhills Court Simi Valley Calif 93065 6235 Phone 805 5227958 Tele Fax 805 5223217 Hirose Electric GmbH Zeppelinstraze 42 73760 Ostfildern Kemnat Phone 0711 4560021 Tele Fax 0711 4560729 Hirose Electric UK Ltd Crownhill Business Centre 22 Vincent Avenue Phone 0908 260616 ee c Crownhill Milton Keynes MK8 0AB Tele Fax 0908 563309 HIROSE KOREA Co Ltd 472 5 Mok Nae Dong A
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12. Height gauge To measure the crimp height of cable core wire of our GT terminal a specifically designed height gauge shown below Top end of the gauge has a specific shape Product name DF1B height gauge Distributor Yokoyama Kiko Co Ltd 2 1 19 Honcho Ohmori Ohta ku Tokyo 143 03 3765 6621 Fax 03 3765 6603 The height gauge is not available directly from us The height gauge can be used also for other models of our crimping type connectors GT DF1B 143 2 1 19 03 3765 6621 03 3765 6603 1
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17. 4 9 B C F 4 2 1 D r 2 HAN TERA AMV Dee WARS AT AS BH 4 3 EE gt Ez 4 76 DODULOHBRFE JZUYTZ 1 OR Setting Positions l AK 1 m CTO SS at T ED Poy U A W 1 1 4 NN oo 4 2
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19. 9 9 92 3 4 A BA 3 Adjusting the position of the feed finger 1 Loosen feed finger mounting screw using a hexagonal wrench key for M4 direction A 2 Adjust feed finger to the center of the pilot hole of the carrier 3 Tighten feed finger mounting screw with a hexagonal wrench key direction B Caution After tightening the screw check again the position of the feed finger 4 Adjusting the mounting position of the scrap guard 1 Loosen scrap guard mounting screw using a hexagonal wrench key for M4 direction A 2 Adjust the height so that scrap guard does not come in contact with carrier coming out from the cut off punch Adjust the longitudinal position so that crimper does not come in contact with scrap guard 3 Tighten scrap guard mounting screw 9 with a hexagonal wrench key direction B 5 How to adjust the position of t
20. 2 3 1 2 3 4
21. GT 6 GT GT 1 2 3 758 1 0 1mm 0 05mm 2 How to adjust the crimp height Caution In prior to the press operation be sure to manually operate the press to check the location at which the terminal is crimped At this time set wire disk to A spacer disk to W adjusting dial amp to 1 and adjusting dial GT 4 to 1 Things to be prepared Crimping condition list Crimp height measuring instrument Point blade micrometer and the like 1 Check the crimp height requirement for the electric cable to be crimped 2 The terminal has three crimping positions i e cable core section C shield section D and sheath section E Adjust the related crimp heights to the required values following the steps of pro
22. D DF1B QQ A v 74A20 Old A gt B gt C gt D 1 EZ BS CH 0 12mm Old WXYZ 1 0 03mm D 9 9 l2 3 7 8 1 0 1mm 0 05mm 2 GT 1
23. 1 2 10 3 4 5C 35C 35 85 5 6 1 1
24. 11 1 1 2 1 2 3 1
25. 0 3 9 Zii BAM D M4 D A Jis 4 2 O 1 M4 9 A 3 e T BAM 5 X 1 2
26. 5 O 6 O 4 4 1 SRM BUSCA TREAT 1 D FMRI O HPROAK wiletint O uuu 2 HRM ARER O 3 WK A Ti eosin 4 iUm f FIEREN Tae lar 2 1 SERIA MUERT 4 2 gE 3 1 9 O 3 O C 9
27. FTIT ZILBER lt jel 3 F299 oS RI 4 1 2 m O LET Jh VA 5 Q9 db cid ru 6 O ZRA Q pateram 2 1 0 3 Attaching detaching the
28. jem ees 2 3 Attaching the terminal to the applicator 1 Turning cam lever in the direction of arrow B insert terminal along terminal guide Caution Take care to avoid paper tape from entangling around the terminal 2 Furthermore lift screw in the direction of arrow C and insert the terminal into the applicator until it goes slightly beyond just above anvil in terms of the rightward direction At this time inserting the terminal while pressing cut off punch in the direction of arrow D will allow the terminal to smoothly into the applicator 3 Lower screw in the direction of arrow E Check to be sure that the top of feed finger D fits in pilot hole BD in the terminal carrier Draw the reel terminal slightly in the direction of arrow F and turn cam lever in the direction of arrow C This completes the installation of the terminal 4 Align the terminal to the crimping position turn on switch mounted on the electrical box and check how terminal presence absence checking sensor amplifier respond When the terminal is placed at the best position both the red and green indicator lamps simultaneously light up Refer to the Instruction Manual for the fiber sensor supp
29. Oak FU D 4 ZKE E Q F O C ON O 4 9 XH B W C F 1 1
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32. ON 3 ON 4 AWG30 ROBH Q o 1 fi S 4 3 Making preparation for 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 Be sure to check the crimping conditions crimp heights and crimping quality standards crimp shape in prior to the preparation for crimping operation while referring to the Table of crimping conditions and the Crimpi
33. 2 0 4 0 6MPa 0 4 O 6MPa 3 3 ROR For returning For feeding DEH A DEY O 2 1 S 6 Lio 8 Troubl
34. 2 3 ee ERT Wal 1 2 3 1 2 F 1 1 1 2 3
35. kk 19 2 21 OPE EPEA a E 23 4 i 23 5 nn 25 Sr ARMEN 27 abf z curl e 27 2 lt 3 1 3 kk 33 xiii CONTENTS Pa DOCCINIC AON som eaa 2 2Conlgourailom ce ea EE Ea EEE esaa 2 3 Attaching detaching the applicator leeeeeeee eee reee rennen nnne 4 3 1 Attaching the applicator to the main unit of the crimping machine 4 1 Attaching the applicator to the main unit of the crimping machine 4 2 Detaching th applicalor ee 4 3 2 Weng ana DI NG NN 6 CA AIG ANGE DI 6 A CAMPING ODGGANOM RRB 6 4 1 Attaching detaching the reel terminal eese Leserreise seen nennen nnn 6 1 Attaching the reel terminal to the main unit of the crimping machine 6 2 Detaching the reel terminal from the main unit of the crimping machine 6 3 Attaching the terminal to the applicator ee 8 4 Detaching the terminal from the applicator ee 8 4 2 Preparing an electric cable e eee eee iere eere nennen nnn
36. Vi PRE GT 1 2 3 7 gt 8 1 0 1mm 1 KERAF 0 05mm e 1 QR AR 2 MAWAR Ree ee cE UR o 5 1 wai OA X X Y Y Z Z 23 A B XX YY Z Z 5 2 Y Y X e 8 6 oD Z7 OE F TUE eL ID e A TS TT
37. 1 Pe3 JAAR IE 3 1 PT 4 1 P17 Eran 2 Troubles with respect to crimping quality Caution N To carry out troubleshooting be sure to detach the applicator from the crimping machine in prior 1 Crimp shape is defective 1 Anvil is improperly attached and 1 Re attach the anvil and shear P18 Bent up and bend down fail to be closely fitted against the plate properly base plate 2 Crimper has worn out broken to 2 Replace the crimper with a P18 cause the terminal to bite After new one At this time it is the completion of crimping the recommended to replace also terminal deforms when wiping off the anvil with a new one since the terminal with the wire stopper it is Supposed that the anvil Bent down has also worn out 2 Crimp shape is defective 1 Terminal is attached to a position
38. I Applicator H35 A Dp 1 Main unit of applicable crimping machine 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 eA r1 A LS pM IR A HIROSE ELECTRIC CO LTD T
39. A O 4 2 1 3 2 Wiring and piping 1 Wiring and piping 1 Connect foot switch cable of the press to foot switch connector on the electrical box 2 Connect one end of junction cable to the foot switch connector mounted on the press and the other end to junction cable connector mounted on the electrical box 3 Connect one end of junction air hose to applicator and the other end to regulator of the electrical box 4 Connect the compressed air supply to regulator of the electrical box At this time the compressed air pressure shall be 0 4 to 0 6 MPa Caution Pay attention to the feed lever when connecting the compressed air supply to the regulator since the feed lever can move 5 Insert terminal presence absence checking sensor cord coming from the rear face of the applicator into sensor amplifier Refer to the Instruction Manual for the fiber sensor supplied with the electrical box for how to insert the cord 6 Connect power cord plug
40. HE D O dO DEG HARA GTO A W 1 1 2 ON 3 ON 4 O G9 AWG30 5 iB JA JF 1 Setting Positions an an an 4 o Ar 9 GT DF1B 143 8 1 19 TEL 03 3765 662 1 FAX O3 3765 6603 x
41. 3 6 Procedure for crimping 1 Set the disks of the applicator respectively to A W 1 and 1 Then attach the applicator to the crimping machine 2 Turn on the power and air supply to the crimping machine 3 eine is operation Place an electric cable Depress the foot switch Take out a completed harness while shifting it by hand to the right 4 Adjust the crimp height Refer to 5 1 Crimping conditions page 14 5 Adjust the crimp shape Refer to 5 2 Crimping quality standards page 14 6 Carry out the crimping quality inspection 7 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 To conduct maintenance works be sure to detach the applicator from the crimping machine prior A 1 Lubrication 1 1 Sliding section of the ram 1 Periodically once a week apply a light coating of grease to
42. 28 1 Major component Name S a 28 2 Electrical box wiring GIOS 32 3 Air pressure Cte ut aa EA NE 34 XIV TTYT7 2 2 4 3 1 0 4 1 ratrak k raknak rA EEEE AAEE E AEAEE AEEA AEAEE EEEE EEEE E EEEE EEEE EEaren rannet 4 2 SA ESE A A A A E 4 3 2 ES CRA TB MM 6 MUNI M mm 6 dE ere 6 4 1 6 CEntre EEEE 6 2 MERI EIRE BIET REM 6 3 8 4 JA BURLSETREEDMR E enero boasts 8 4 2 es 8 ooo 8 4 3 0 10 RUNS IIT Nc 10 2 12 SM BS CJDU PNNEET D OOo Omm 14 ONIS IA 14 5 2 ERR 14 GJE I O a E E C 16 2 16 16 QNS TUM T EE 16 COE aAA 16 PR 16 EE A E A A A E 18 oo 18 18 EE eo 18 Bo 20 1 20 2 22 Ens dE SANE ERR u 24 4 RE FB FASS SE AT E SM 24 5 ene ne ee ere 26 O UU em 29 CE c
43. 2 9kg CM 105 2 Configuration 2 Applicator front side Shank Wire disk Spacer disk Ram ESL Junction cable Adjusting dial PKB Safety cover Adjusting dial GT GT Cable stopper Scrap guard Base plate Terminal presence absence checking sensor amplifier Power switch Regulator Air pressure regulating knob Junction air hose Li ud A A Ez e Terminal presence absence checking sensor cord a box There are cases where the shape may vary in accordance with the models 2 3 A Q E P Am ETE 3 1 Hite AN OR filt 1 1 OFF 2 CM 105
44. 9 3 O O O 4 9 0 4 O 6MPa 5 QO Fal Cet 6 9 Ce Ir cts 1 1 2 O 3
45. 5 Crimping quality 5 1 Crimping conditions The crimp height and tensile strength varies depending on the manufacturer and product name Refer to the Cable by cable crimping condition tag issued by us for the crimp height and tensile strength E 5 5 1 Ni In case of stranded wire NO O Cable core wire crimp height A Shield crimp height Sheath crimp height ep ERIE AK tr BE BE ilice K tras BE BAIN teas IE 5 2 Crimping quality standards Check to be sure that the crimped terminals satisfy the crimping quality standards given below Strip length position Crimp burr height no L4 K N Measuring location and dimension mm i l Cross section XX XX Cross section ZZ ZZ Cross section YY YY In case of solid wire MAIO Cross section XX XX Cross section ZZ ZZ Cross section YY YY 5 2 uy Ts ee TTT Cross AL section YY Enlarged view of X section section ZZ YY X ZZ nm
46. E 29 2 ee ern 32 3 34 XV 1 16 8 8 Kt 170 mm X 230 mm X 80 mm 5 kg 2 9kg CM 1052 2 GT 1 Specifications Outside dimensions 170 mm length height x 230 mm width x 80 mm depth with the ram placed in its lower dead center Applicator 5 kg _ Electrical box 2 9 ko Main unit of applicable crimping machine Model CM 105 1 A 170mm x 230mm x 80mm 5kg
47. 2006 CAUTION 1 No part of this manual may be reproduced without the permission of Hirose Electric Co Ltd 2 Description in this manual is subject to change without notice 3 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 4 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 5 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 HIROSE ELECTRIC CO LTD 2006 1 2 3 4 5 4 3 5
48. 23 24 26 L9 26 Lave INT 27 28 Je AQUA E 29 30 2 7o J l7 ol we 93 So 34 35 FH A 96 37 99 GT 89 Je p L F A 40 B Al AP AS p 88 aac Ve NS 88 45 90 9
49. Hfi P Jc tit Td B JS T am ETE EE 1 HRS BE ilice XR i IREKE m T LR de No EUN 8 1 2 3 4 o 1 1 A CIAL 75 w 2 2 Uds 3 3 Hels Glee vic 1 ew VP 1 2
50. aine NLGI 2 S 1 2 AP No 2 1 1 1 LM 3 ISO VG32 68 a 1 1SO 32 68 32 32 2 1 O 2
51. be sure to wait for a sufficient period of time until there is no possibility of presence of water drops inside the machine before turning the power on 6 To avoid possible accidents caused by breakage or maloperation of the electrical parts be sure to stop operation and disconnect the power plug for safety in case of thunder and lightning 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 operators 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 1 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 2 The operator should fasten hair securely to avoid his her hair from being caught in the machine 3 The operator should wear close toe rubber sole shoes Cases which require the power to be turned off Turn off of the power means the state where the power switch is turned off and power plug is detached from the receptacle This will also apply to the following Ld asparagus _ 1 If there
52. Cylinder bracket Terminal reformer holder Cylinder head shank Terminal reformer Terminal reformer pi 88 89 90 Fixing nut KR HB Ol A 9 1 MM JAR VERE A B A B I wv 0 ua 0 o oo rr LI 16 fads 17 B 18 19 20 21 22 23 24 25 26 27 28 29 30 fedis d 31 ERRAT 32 Hm ibas ds 33 KB BT as 34 35 36 37 38 39 Sh 40 HEFT 4l HERP SSE 42 HEAT Stal at 43 A a A Mm A eae e fh ee sh ep meje e e e eje e ae e eje e sib RR nm me eje e e ae aae B es LM 9t LM 1H dg A Ee Ge fp EH Ef Ge PPS EAN EAE A ER IE ZZ d FAB Bi o E JH ERE JH ae 2X Jc Ed BR INC IE A
53. 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 3 1 Attaching the applicator to the main unit of the crimping machine 1 Attaching the applicator to the main unit of the crimping machine 1 2 6 Turn off the power to the main unit of the crimping machine 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 Thoroughly remove dust and stains from bottom face of the applicator base and top face contact plane of the bolster plate Press feed rod in the direction of the arrow lift shank the shank shall not be fully drawn out until it fits in slit on the main unit Place the applicator on the top face of bolster plate and slide it forward until it is pressed against stopper block At this time make sure that shank is attaching on ram Press clamp lever in the direction of arrow until it is secured 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 Q by turning it in the direction of arrow and pull the applicator until it
54. height is reduced in the order of 1 2 3 through 7 and 8 in increments of approximately 0 05 mm 3 Adjusting the sheath crimp height Set adjusting dial GT to 1 Turn the dial so that the predetermined setting position is brought to the top You can turn adjusting dial GT by removing fixing screw B Carry out crimping operation Then measure the sheath crimp height to check up the difference between the required value and the measured value Position adjusting dial GT within the range of required values referring to the values given below For adjusting dial GT the crimp height is reduced in the order of 1 2 3 through 7 and 8 in increments of approximately 0 05 mm After the completion of adjustment be sure to tighten fixing screw B Caution 1 At every adjustment of the crimp height be sure to detach fixing screw D before the adjustment and re attach it after the completion of the adjustment 2 Once you have completed the adjustment of the positions of all disks and dials carry out crimping operation again to be sure that the respective crimp heights satisfy the requirements At this moment be sure to crimp the electric cable and check the crimp height 2 AAR 9 HEBR O BS GTO A W 1 1
55. side face rear face and cam follower section of the frame Recommended grease standard NLG1 No 2 Caution 1 The value given above represents hardness 2 specified by the U S National Grease Association Grease that is equivalent to the above is for example Epinoc Grease AP2 Nisseki or Albania Grease No 2 Showa Shell 2 Avoid excessive oiling 1 2 Sliding section of the terminal feed mechanism 1 Apply a few drops of oil respectively to feed rod and LM guide periodically once a week Recommended oil standard ISO VG32 68 Caution 1 The value given above represents viscosity 32 to 68 designated by ISO standard Oil that is equivalent to the above is for example Turbine Oil 32 Nisseki or Teras Oil 32 Showa Shell 2 Avoid excessive oiling 2 Routine maintenance and inspection 1 Check to be sure that no carrier chips and dust gather in each sliding section The residue of plating is apt to adhere to the section Periodically at the end of the daily work at the time of replacement of the reel etc wipe there with waste soaked with alcohol Or the like 2 It is recommended to store the machine when not in use in a clean and dry place to avoid 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 6 A W 1 1
56. tir ERIE ER da 2 ZY HY IRIRE EU GT 2X Hs At e A 2X Hs At d B RBG dg V ZI HL TH AP105 Applicator Model AP105 Air cylinder type AP105 2 Buh Y J ABER CM 105 CN2 1 aor DB2 SW AC100V NKK M 201 1E HT 2402 G S FX4NASR G2VN 237P Foot switen g kA jm o 2 Electrical box wiring diagram 2 Electrical box Press CM 105 CN2 1 FOOT SW CM 105 R CN2 3 DB2 SW AC100V if HT 2402 DB1 Rectifier pl hen C G D DB2 S R NK i A Noise killer SW C G DB 2 o NK ri H S terminal siabllzer o ssrsgus PNK seems 3 AZT PL LISSE JDASe5X40 AEDEM SMC 1t AS1201F 5M 06 TAC 4P R150 2 3 Air pressure circuit Type Made by Koganei JDAS25X40 Made by SMC AS1201F 5M 06 Made by Koganei TAC 4P Made by Koganei R150
57. to the power receptacle 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 remove flange and pass reel terminal 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 A 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 reel 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 2 1 9 L 2 3 e 4 0 4 0 6MPa
58. 1 Re adjust of the position of the Twist or rolling that is not aligned with the center terminal is necessary of the anvil 3 Crimp shape is defective 1 Crimper has extraordinarily worn 1 Replace the crimper with a Scratches and peel off of out breakage and scratches new one plating 4 Crimp shape is defective 1 Anvil has extraordinarily worn out 1 Replace the anvil with a new P18 Burrs breakage and scratches one Contact our Production Engineering Department for consultation for use or any unclear points 2 AS Wot m 1 1 RARER 1 P18 ety ee Fr 2 FEA i HEAL MI REBT BL 2 i8 PNK Ade Fb ta ty Pls EEA TIRE n H FR 2 Lm T MESIS A i ES 1 3 1 Xe S de om S 1 id S BOTE SE E d 4 1 i ERIM E hist 3 2
59. 2 res emman Asamwce Oo ws estes soe MEMO Instruction Manual Number TAD P0065 TAD P0065 July 2006 2006 7 M First edition c zERA 1 2 3 4 3 b
60. Appendix 1 Major component names Stopper bolt B Cylinder retaining plate Housing Base plate Mounting plate A Air cylinder Mounting plate B Half union Adjust block A Adjust block B Adjust screw Valve washer Valve nut Valve Adjust block pin Hose Terminal guide Speed controller Hose elbow LM rail LM guide Feed lever Terminal rail Drug stock Cam boss Cam lever Cam shaft Feed finger pin Stopper bolt holder Stopper bolt A Safety cover bolt Drag stock bolt Drag stock spring Retaining ring B Terminal support Safty cover spacer _ O O N OODIIOJ mm IOOOo OW A OO N Anvil holder Safety cover washer 20 Terminal Support Spring Safety cover thumb screw 21 Anvil holder pin Safety cover 22 Wire anvil Ram 23 Shield apindle Ram pin 24 Insulation anvil Shank 25 Cut off punch Wire disk 26 Cut off punch spring Spacer disk 27 Cut off die Disk ball 28 Cut off die pin Disk spring 29 Feed rod Adjusting dial 30 Sensor plate Feed cam 31 Sensor Shoulder screw 32 Wire stopper Shoulder spring 33 Scrap guard Wire crimper 34 Finger holder Shield crimper 35 Feed finger Insulation crimper 36 Feed finger spring Insulation spacer 37 Roller pin Actuator 38 Feed roller Adjusting dial GT 39 Guide plate Wire clamp spring A 40 Push rod Wire clamp spri 41 Push rod spring Wire clamp 42 Push rod guide Actuator spring pin
61. Application 1 This machine shall only be used for its originally intended purpose while following the instructions specified in this Instruction Manual Hirose assumes no responsibility for any use of the machine other than the intended use 2 Modifications to this machine is prohibited We assume no responsibility for accidents resulting from modifications Operating environment 1 To avoid possible accidents caused by maloperation of the machine use the machine under the environment that is not affected by a substantial noise source electromagnetic wave such as a high frequency welder 2 To avoid possible accidents caused by maloperation of the machine never use the machine under the environment where the voltage exceeds 10 of the rated voltage 3 To avoid possible accidents caused by maloperation of the machine put any device such as an air cylinder that operates by the pneumatic pressure into service after checking to ascertain that the specified pressure is provided 4 To ensure safety in operation use the machine under the following environment Ambient temperature during operation 5 C to 35 C Relative humidity during operation 35 to 85 96 5 When the operating environment of the machine is suddenly changed such as in the case where it is moved from a cold place to a warm place dew condensation can occur To avoid possible accidents caused by breakage or maloperation of the electrical parts due to dew condensation
62. CR O 3 QD 4 mT OEE OKENN WAS FE TTI lela BOTTA vin TARS Zia wt All ERY D 9 1 B ES xc J s 9 pPwUL Je Ju s EF A o LA LIS I m O B 7 B 1 9 J 11 LM 12 LM 13 JILLA 14 15 ww 2 16 2 A lz Uefa XB 2 7 vbt 18 cq x e 19 20 ei
63. HEKE Li EL ERRARE R 14 6 D A W 1 CRY FU FEEHRECNBXO NT e HmEE 5 1 P 13 5 19 I 2 1 1 1 1
64. SO VG32 68 1 ISO 32 68 32 32 2 2 ACT BE idem Eg Hn PEG ESSE PTS xe HH 2 3 3 4 3 1 M8 M4 1 O 2 CE elle 1
65. cedure described below 3 Set wire disk and spacer disk respectively to A and W Turn the disks so that the predetermined setting positions are brought to the front 4 Set adjusting dial amp to 1 Turn the dial so that the predetermined setting position is brought to the top You can turn adjusting dial by drawing toward you Caution The dial incorporates a spring If you release the dial it will automatically return to its home position It is necessary however to check to make sure that it has properly returned to the home position D Adjusting the cable core crimp height Carry out crimping Measure the cable core crimp height with a DF1B height gauge to find a difference between the required value and the measured value Position of wire disk and spacer disk within the range of the required crimp heights referring to the values given below 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 2 Adjusting the shield crimp height Carry out crimping operation Then measure the shield crimp height to check up the difference between the required value and the measured value Position adjusting dial within the range of required crimp heights referring to the values given below For adjusting dial the crimp
66. comes off Caution When detaching be careful not to allow your hand s or finger s to be caught in the applicator 3 He Hae EAA 3 1 1 1 2 3 4 5 6 OFF CM 105 HARAKET O AMEMO IESUS USE IE as O JUI Ta E HRA O THRO e air Ale RAEN EERST BANTAM HRA O SA ATH DL GOR ar DRT POR 3 2 i m Misi ia 9 1 1 9 2
67. eeding Loosen knob and turn knob in direction B to decrease the feeding Scrap guard is attached to a wrong position and Re adjust the attaching position of the comes in contact with the reel terminal carrier scrap guard Cut off punch has scratches and marks 2 Replace the cut off punch with a new impairing smooth up and down movement one of the terminal Contact our Production Engineering Department for consultation for use or any unclear points 8 2 Carrier deforms to take S shape during 2 clamping 1 KZ WES REMAN SLE 4 ERMER D uU 2 5 3 1 1 l 2 2 3 3 1 1 2 0 4 0 6MPal 2
68. eshooting 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 4 Is the air supply connected to the crimping machine 5 Is the power to the crimping machine turned on 1 Troubles with respect to functions of the applicator A The terminal is not fed smoothly The terminal is not fed Caution To carry out troubleshooting be sure to detach the applicator from the crimping machine in prior The feed finger is mounted out of position and is not aligned with the center of the pilot hole Top of the feed finger has worn out Cam follower has worn out Terminal is not placed on the crimping position just above the anvil Compressed air pressure is not regulated to the proper value 0 4 to 0 6 MPa Compressed air supply to the valve is not Re adjsut the mounting position of the feed finger Replace the feed finger with a new one Consult us for service Replace the cam follower with a new one Consult us for service Place the terminal at the correct crimping position Adjust the regulator so that an adequate quantity of compressed air is supplied 0 4 to 0 6 MPa properly regulated Properly adjust the speed control mounted on the valve Loosen knob and turn knob in direction A to increase the f
69. he terminal If the rolling or twist is defective in shape adjust the position of the terminal Detach the air supply from the regulator of the electrical box Loosen stopper bolt holder fixing bolt with the terminal set in position Then detach stopper bolt holder 3 Loosen stopper bolt fixing nut If terminal D is situated on the left of anvil B turn the stopper bolt in the direction of arrow A If the terminal is situated on the right turn the stopper bolt in the direction of arrow B Once the terminal is brought to just above D the anvil tighten fixing nut QD 3 D M4 RD Pre pH eR ZZ e A 2 XE IA a HERVE TL A P D 3 FAN SARE A DUSHR I RR ZZ B 4 D M4 FARAN eR O A 2 81 1 O FAA O BESIDE TUS 3 FAN SARE ST ARS Bj iP ds IR ZZ B 5 D WABAKI Ta Pax OS 2 PAIGE IE ae aE S
70. ifications 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 es 4 contact between gt fingers and the press Warning label Flywheel cover A rotating component is installed inside the cover Danger of contact injury is present 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 Safety instruction in use The minimum safety instructions to be followed when operating Foot switch cover A The cover protects feet against hazards Warning label Danger of cuts on fingers is present the crimping machine are indicated Never place fingers inside the safety cover viii bom i 1
71. is any sign of abnormal conditions or failure or in the case of power failure be sure to immediately turn the power off 2 To avoid possible accidents due to an abrupt start of the machine be sure to turn the power off in prior to inspection repair or cleaning of the machine or before leaving from the machine 3 Where it is necessary to detach the power plug be sure to pull it out while holding by hand the plug instead of the cord Safety instructions in each category of work following the delivery of the machine 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 shall be repackaged if necessary to achieve the originally delivered state or better Prior to repackaging wipe off oil gathering on the machine 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 i Cable and wiring 1 To avoid electric shock leakage and fire take care not to apply any extra load to the cables in service 2 To avoid possible accidents caused by electric shock leakage and fire never put many loads on one electrical outlet 3 Be sure to securely connect connectors In addition be sure to detach a connector while holding the connector section by hand ii Grounding 1 To avoid possible accidents caused by leakage or electrical st
72. lied with the electrical box for how to adjust the sensor amplifier 4 Detaching the terminal from the applicator Turn cam lever in the direction of arrow B and lift feed finger D in the direction of arrow C Then draw out the terminal in the direction of arrow F 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 Crimping quality standard issued by us 2 When stripping the covering carefully avoid the cable core from breaking being nicked loosening and bending 3 D B e i565 91 X rq 2 C D 3 E Qo 9 c 4 ON
73. 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 wounds 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 Safety instructions CAUTION Basic safety instructions N 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 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 viii for detailed description of the safety device 2 Once the safety device is detached from the machine replace it to its original position and check to be sure that it properly functions
74. nduct repair and maintenance including wiring of electrical parts 3 To avoid possible accidents caused by an abrupt start of the machine in the case of repair and maintenance of any device such as an air cylinder that operates by the pneumatic pressure be sure to detach the compressed air supply pipe to expel the remaining air from the device 4 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 5 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 6 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 Vil SAFETY INSTRUCTIONS TO BE FOLLOWED WHEN USING THE APPLICATOR MODEL AP105 AIR CYLINDER TYPE moving parts of the machine extreme caution has to be taken to keep your hands head and fingers away from the moving parts and the area surrounding them Also do not place any matter that is not necessary in the use of the machine near by 1 To avoid possible accidents resulting in personal injury caused by being caught in the CAUTION Safety device For the machine and the safety device of which configurations are given below the machine is made to spec
75. ng quality standards issued by us 1 How to conduct crimping operation 1 Set wire disk spacer disk adjusting dial and adjusting dial GT as illustrated to the positions same as shown in the sketch on the left A W 1 1 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 Turn on the power switch mounted on the electrical box 4 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 or excessively pressed against it crimping quality deficiencies can result The top end of electric cable is as thin as AWG30 firstly press shoulder portion Q of the electric cable sheath against end face of the terminal then slightly draw the shoulder portion toward you to position the electric cable 5 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 4 3 CE EE ES BE
76. nnne nne n anna nean nnn ann 8 1 Processing the term 4 3 Making preparation for crimping operation esee esee eee eene enn 10 1 How to conduct crimping operation ee 10 2 How to adjust the crimp height 0 12 S CHIMDING QUANEY siseasi A aE aE Naa ap EAE X UN 14 5 1 Crimping conditioNS 14 5 2 Crimping quality standardS EE KY Ki 14 6 Procedure TOF crimpINng cena 16 YNWalmienamee NECI TU 16 EIDIIGSNIO I H n 16 1 1 Sliding section of the ram pp 16 1 2 Sliding section of the terminal feed mechanism pp 16 2 Routine maintenance and inspection II 16 3 Replacing the expendable partS esee eese Leeee e ieeee ee eee eene eene n nnn nnn nnn n nana nns 18 3 1 Replacing the crimper TE DD LEURS 18 09F2 Replacing Ta 18 4 ExpendabDie DNS 18 6 OU SOO UN e tc 20 1 Troubles with respect to functions of the applicator Ln 20 2 Troubles with respect to crimping quality ee 22 3 Adjusting the position of the feed finger sees sees cree creen eene nnns 24 4 Adjusting the mounting position of the scrap guard eere eee eene 24 5 How to adjust the position of the terminal ee eeeeee eere eene nenne nennen nnn 26 9 DDGINOI T
77. nsen City Seoul Phone 02 864 5075 Tele Fax 0345 491 9886 Hirose Electric Co Ltd Phone 2803 5338 2102 Emperor Group Center 288 Hennessy Road Wanchai Tele Fax 2591 6560 Hong Kong Branch 06 07 Printed in Japan
78. rength be sure to have an expert engineer who have the electrical expertise to install an appropriate power plug to the machine In addition be sure to connect the power plug to a grounded receptacle Before operation 1 To avoid possible personal injuries be sure to check to ascertain that connectors and cables are not damaged dropped off or loosened 2 To avoid possible personal injuries keep your hands away from the moving parts of the machine Use oil of the kind designated by us or an equivalent for the machine 5 In the event that oil should get in your eye or contact your skin immediately wash to remove it to protect against irritations and rashes 3 In the event that you should swallow oil by mistake immediately consult a doctor to prevent diarrhea and emesis Mamtenance 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 a 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 2 To avoid possible accidents due to unfamiliarity with the operation of the machine or electric shock hazards be sure to ask an expert engineer who have the electrical expertise or our technical personnel to co
79. ure to remember to put insulation spacer in insulation crimper 1 If not the adjustment using adjusting dial will be rendered ineffective 3 2 Replacing the anvil 1 Remove two anvil mounting bolts 3 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 3 At this time be sure to check that the anvil is closely fitted against base plate 3 Caution 1 When setting the anvil carefully clean the inside of the anvil holder and the anvil so that there is no dust or stain there 2 Set each anvil that the side on which indications are given faces toward the operator 3 Extra caution is needed at the time of attaching the anvil since cut off punch 7 applies a lifting force by means of its spring In addition be sure to place terminal support without fail 4 Expendable parts Parts 1 to 8 have inscribed marks Specify HRS No Product name No Product name code according to the Spare part mounting table insulation crimper Wire anvil supplied with the applicator when ordering Shieldenmper Cut off punch 6 Cut off de Insulation anvil Actuator 5 Shield anvil Terminal reformer 3 3 1 M8 M4 D FHT HARARE 2
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