Page 1/12 mJ.S.T. Mfg. 90., Ltd. annEngineering Center No‘ Date issued: tastes-warmer .210 fifiltlsm" CHM-14103 May 23, 2005 Title of Document: Revision No, Date revised: HANDLING MANUAL Tine Subject: Issued by: XMA Connector (Vlfire-to—Vlfire, Hanging Type) Osaka Engineering Center This handling manual describes points to check for smooth crimping operation of wire-to-wire XMA connector (hanging type), 1‘ Part Name and Model Number 2, Applicable Wire 2-1 Applicable wire 2-2 Precautions 3. Crimping Tool 4‘ CrimpingOperation.. 4—1 Vlfire strip length‘ 4-2 Crimping .......... CONTENTS 4-3 Tensile strength at cn’mped part. 4-4 Crimping appearance.,. 4-5 Precautions for crimping operation #6 Control of crimping operation ..... 4-7 Precautions for storage and handling of crimped contact 5. Harness Assembly Operation,,., 5—2 Inserting retainer into housingm. 6. How to Extract Crimped Contact from Housing in Case of Mis—insem‘on ............. 10 7. Handling Precautions Prepared by: Checked by: Reviewed by: Approved by: TSawano K‘Ezligmatsu KIc/iimi SJCQIama Advanced Connection Systems |AR~4101-1-D
JST Pa e 2/12 Tifle: HANDLING MANUAL No. Rev. No. XMA Connector (\Mre—to-Wire, Hanging Type) CHM-1-2103 1. Part Name and Model Number Part name Model No. Pin contact SXM—OO‘i T-P0.6 Socket contact SXA-001 T-P0.6L Key pattern 1 XWR-~VF-1-S . 2 ~ 3 circuits Key pattern 2 XMAR-tVF-Z-R Rewp‘ade h°”s'"9 Key pattern 2 XMAR—NF—a-E 4 - 6 circuits Without key XMAR-‘VF-S Key pattern 1 XMAP-tV—t-S . 2 - 3 circuits Key pattern 2 XMAP-*V-2-R Plug housrng Key pattern 2 XMAP-tV-3~E 4 ~ 6 circuits Without key XMAP-tV-S . 2 ~ 5 circuits XMASJV—S Reamer e circuits xmsw Note 1: Number of circuits in twodigit figure is indicated by asterisk. 2. Applicable Wire 2-1 Applicable wire of each contact Contact SXM-OO‘lT-Pofi SXA—001T-P0.6L Wire size AWG #26 ~ #22 AWG #26 ~ #22 Insulation outer dia. (mm) (1513 - $1.9 (1)1.3 ~ 411.9 Conductor Annealed copper stranded tin-plated wire 2-2 Precautions Special wires such as solid wire, tin—coated wire, shielded wire, etc. other than above wires cannot be used in principle. When using such special wires, contact JST. 3. Crimping Tool Crimping tool Part name Part name Model No. Semi-automatic press AP-K( ) _ _ Crimping applicator MKS-L SXM 00” P06 Die MKISXAIM-001-06 Applicator and dies set APLMK SXAIM001-06 Semi-automatic press AP-K( ) _ . Crimping applicator MKS-L SXA 001T PO'GL Die MK/SXA-001-06L Applicator and dies set APLMK SXAODt >06L Note 2: The alphabet or figure is indicated in parentheses, Note 3: When crimping operation is conducted by using other than above applicator and die set, JST cannot guarantee the performance of connectori Advanced Connection Systems
.181" Pa e 3/12 Title: HANDLING MANUAL XMA Connector (Wireto-Vtfire, Hanging Type) No. Rev, No. CHM-1-2103 4. Crimping Operation 4-1 Vlfire strip Referring to reference value of wire strip length stated below, conduct wire stripping. As wire strip length differs depending on type of wire and crimping method, decide the best wire strip length considering processing condition. When wire is stripped, do not damage or out off wire conductors, Model No. of contact Strip length (mm) [Ref. value] SXM-001T-P0.G 2.2 SXA-001T-P0.6L 2.2 l l6 4-2 Crimping Strip length Before crimping operation, be sure to check the combination of contact, wire to be used and crimping die are correct. Check the below points for correct crimping at beginning, middle and end of crimping operation. 4-2—1 Crimp height According to wire to be used, adjust dials of applicator at conductor part and insulation part to a proper crimp height, Measur ment of crim hei ht A: Crimp height at wire barrel should be set to pre-determined dimensions, B: Adjust crimp height at wire insulation barrel to the extent that wire insulation is slightly pressed, and set it so that crimping is not excessively. H: Measure crimp height at the center of barrel using specified micrometer. Table of crim hei ht Vlfire Crimp hei ht (mm) Contact . insulation . Type Size 0. D. (mm) Conductor part Insulation part UL1007 AWG #26 1.3 0.65 :t 0.05 1.7 SXM-001T-PO.6 UL1007 AWG #24 1.5 0.70 i 0.05 1.8 UL1007 AWG #22 1.6 0.75 1 0.05 1.9 UL1007 AWG #26 1.3 055 ~ 0.60 1.7 SXA~001T-P0.6L UL1007 AWG #24 1.5 0.60 ~ 0.65 1.8 UL1007 AWG #22 1.6 065 ~ 0.70 1.9 Note: Crimp height at insulation part is a reference value. Be sure to check the crimping condition at insulation part, and conduct operation. 4-2-2 Measurement timing of crimp height Q) When operation starts at morning and afternoon, starts after pausing and finishes. Q When contact reel is exchanged. G) When applicator is adjusted. (after trouble-shooting, etc.) Q) When crimping dies are exchanged. Advanced Connection Systems
JST Pa e 4/12 Title: HANDLING MANUAL No Rev. No, XMA Connector (Wire-to—Wire, Hanging Type) CHM—12103 , @ Crim in oonditi natwir insulation rrel >< e="" ‘="" @1="" insufficient="" crimping="" good="" excessive="" crimping="" (pressed="" weak)="" (pressed="" excessively)="" when="" tension="" is="" applied="" barrel="" bites="" wire="" and="" to="" wire,="" wire="" insulafion="" may="" damage="" wire="" easily="" comes="" off="" contact,="" conductors="" check="" of="" on="" in="" ndition="" a="" wire="" insulati="" n="" barrel="" cutting="" remove="" wire="" insulation.="" check="" no="" flaw.="" 4-3="" tensile="" strength="" at="" crimped="" part="" after="" adjusting="" crimp="" height,="" check="" tensile="" strength="" using="" test="" samples.="" and="" then,="" start="" continuous="" crimping="" operation,="" in="" case="" tensile="" strength="" greatly="" differs="" from="" normal="" tensile="" strength="" (actual="" value),="" check="" if="" there="" is="" a="" defect.="" tensile="" strength="" may="" be="" different="" even="" in="" the="" same="" wire="" size="" due="" to="" different="" strength="" of="" wire="" itself,="" table="" of="" tensile="" strength="" at="" cn‘mged="" git="" unit:="" n="" \mre="" tensile="" strength="" .="" contact="" type="" size="" (actual="" value)="" requirement="" awg="" #26="" 31="" ~="" 38="" 15="" rnin.="" sxm-ool="" t-p0.6="" ul1007="" awg="" #24="" 58="" ~="" 64="" 20="" min.="" awg="" #22="" 80="" ~="" 91="" 35="" mini="" awg="" #26="" 33="" -="" 46="" 15="" min.=""><001t-p0.6l ul1007="" awg="" #24="" 55="" ~="" 64="" 20="" min.="" awg="" #2="" 82="" ~="" 92="" 35="" min="" advanced="" connection="" systems="">
JST p. e m Tine: HANDLING MANUAL No. Rev. No. XMA Connector (Wire-to-ere. Hanging Type) CHM‘1<2103 4—4="" crimping="" appearance="" check="" crimping="" appearance="" visually="" for="" correct="" cn'mping="" with="" equipment="" such="" as="" a="" loupe.="" part="" nam="" f="" rim="" ed="" contact="" bell—mouth="" t="" ,="" .="" wrsting="" é="" ;-="" item="" reference="" value="" ___.="" ._="" _._="" ‘.i_|_ee="" 3?="" bending="" up="" 3°="" max="" —\="" _="" bending="" down="" 3°="" max.="" rolling="" twisting="" 4°="" max.="" mrs="" condumr="" insulation="" rolling="" 5.:="" max.="" bending="" up="" "'"deg="" ”"9“="" [www="" ”"9“="" bell-mouth="" approx.="" 0.1="" ~="" 0.3="" mm="" approx.="" 0="" ~="" 03="" mm="" ‘="" c="" ut—off="" lejgm="" ,="">< ©r-flé—j—="" e="" vw="" re="" conductor="" protruding="" length="" approx,="" 0‘3="" '="" 0'7="" mm="" l__="" bending="" down="" crirnp="" height="" at="" v="" i;="" crimp="" width="" at="" a="" 1="" 4="" rox.="" .="" mm="" conductor="" part="" crimp="" height="" at="" cul—offlengih="" eodectgétfiai:="" pp="" insulation="" arl="" rlmp="" wi="" 3="" p="" wire="" part="" approx.="" 1.8="" mm="" remark:="" mating="" part="" and="" contact="" lance="" must="" be="" free="" from="" deformation.="" note:="" note="" that="" bending="" up,="" bending="" down,="" misting="" and="" rolling="" may="" cause="" deterioration="" of="" operability="" of="" inserting="" contact="" into="" housing,="" deterioration="" of="" contact="" retenfion="" force,="" and="" defective="" mating.="" there="" must="" not="" be="" lame="" burr="" or="" one-sided="" burr.="" examples="" of="" defective="" crimping="" mmm="" vlfire="" conductor="" protruding="" wire="" conductor="" protruding="" vwe="" conductor="" length="" is="" long.="" length="" is="" short.="" comes="" off.="" m="" m="" wire="" barrel="" bites="" wire="" wire="" insulation="" is="" not="" insulation.="" crimped="" sufficiently="" advanced="" connection="" systems="">
”1 Pa e 6/12 Titte: HANDLING MANUAL No. Rev, No. XMA Connector (Wire~to-Vifire, Hanging Type) CHM-1-2103 4-5 Precautions for crimping operation (1) Conduct crimping operation properly and inspect crimping appearance of crimped product with loupe, etc, Note: If conductors are not crimped at the center in barrel, contact may twist slightly but it does not affect the performance (2) Do not conduct empty crimping and crimping twice, because they may cause outstanding burr at crimped part and may lead to abrasion of crimping die quickly. Q) As cutting residue (powder), etc. adhered to crimping die part affects life of dies, clean crimping part occasionally and conduct appropriate crimping. @ Reference number of crimping die life is 300,000 crimping, When chips or excessive roughness are observed on crimping die, replace it without delay. (3) As abrasion of crimping die and insufficient adjustment of applicator may cause defective crimping appearance, do not fail to conduct daily inspection. (6) When crimping operation is conducted with wire hold spring extracted, they may cause that wire conductors come off or wire barrel bites wire insulation, 445 Control of crimping operation To conduct secure crimping operation, record the following items for semi-automatic press and crimping applicator. Model No. or control No. of semi-automafic press and applicator Contact lot No. The number of crimping and cumulative total Crimp height Vifire retention force Crimping appearance and record of adjustment and replacement of crimping die ooeeoe 4-7 Precautions for storage and handling of crimped contact As crimped contact before inserting into housing is subject to deformation by external forces, pay careful attention to the following points for storage and handling. (D The number of crimped contacts for one bundle should be 100 pcs. max. (Preferable quantity is approx. 50 pcs.) Protect contacts by wrapping wim thick paper to prevent from deformation and adhesion of foreign matter, and keep them in an adequate box. (2) Do not place contacts in humid area, under direct sunshine and directly on the floor Store them in a clean room with ordinary temperature and humidity. ® Do not stack too much quantity of crimped contacts nor place anything on them, because weight of themselves may cause defamation of contact and troubles such as defective contacting. Q When a crimped contact is taken out of bundle, do not pull wire but hold wire near rximped section and take it out. (9 Do not stain contact with household goods such as oils, detergent, seasoning. fruitjuice, etc. If stained, never use stained contact, (6) Do not use improperly crimped contact and deformed contact. Advanced Connection Systems
Title: HANDLING MANUAL No. Rev. No. XMA Connector (Wire‘to-Wire, Hanging Type) CHM—1-2103 5. Hamess Assembly Operation Harness assembly operation is a very important process to decide connector performance and hamess quality. Careful operation is required for harness assembly as well as me said crimping operation. 5-1 Inserting crimped contact into housing 5-1-1 Precautions before inserting crimped contact into housing Before inserting contact into housing, check below points. Q) Check that housing is correctly combined with contact (2 Do not place other things on or near working table and do not conduct any other work on same working table to prevent from operation mistake. to Do not stain contact with household goods such as oils, detergent, seasoning, fruit juice. etc. If stained, never use stained contact, 6) Do not use improperly crimped contact and deformed contact such as contact lance and PC board insertion part. 5-1—2 How to insert crimped contact into housing Insert crimped contact into housing aligning backside (lance side) of contact with groove of housing where circuit number indication is viewed as shown below. w: m: \ \ Groove of housing Contact lance Groove 0’ housing Contact lance Receptacle side Plug side 5-1-3 Precautions when inserting crimped contact into housing G) Do not apply any pulling force to crimped part. Insert crimped contact parallel to housing without prying. ® Insert contact into housing without stopping up to backmost. (37 Do not use pin such an insertion jig, etc. because the tip of pin accidentally reach contact mating part and it may cause defective contacting or deformation of contact. 6) Retainer is not an insertion jig for contact. so, do not use it to insert contact into housing. > (5) When insertion is difficult, do not insert forcibly. Check insertion direction and confirm that there is no damage or defamation on contact and housing. 5-1-4 Precautions after inserting crimped contact into housing Do not depend on retainer but check secure locking per each insertion by pulling wire softly with a force of approx. 5N in order to check that contact does not come of! housing. Besides, check whether there is the backlash in the direction of insertion axis (When wire is pulled with too much force, contact lance may be deformed and contact may come off housing.) Advanced Connection Systems
m Pa e 8/12 Title: HANDLING MANUAL No, Rev. No. XMA Connector (Wire-to-Vlfire, Hanging Type) CHM-1-2103 5-2 Inserting retainer into housing 5-2-1 Precautions before inserting retainer into housing Before inserting retainer into housing, check below points. ® Check that housing is correctly combined with retainer. (2) Do not place other things on or near working table and do not conduct any other work on same working table to prevent from operation mistake. (3) Do not stain contact with household goods such as oils, detergent, seasoning, fruit juice, etc. If stained, never use stained contact. @ After inserting all contacts into housing, insert retainer into it. 5-2-2 How to insert retainer into housing Make comb of retainer face to wire and insert it into housing as shown below, In case of 2 ~ 5 cirwits product ? Comb part Wire F In case of 6 circuits product 5-2-3 Precautions when inserting retainer into housing (D As retainer is not an insertion jig of contact. be sure to use it after inserting all contacts into housing. ® Parallel housing and retainer, then insert retainer pushing the both right and left ends of it without stopping till fastening the both looks at the same time. Advanced Connection Systems
.151 Pa 9 9,12 Title: HANDLING MANUAL Noi Rev. No XMA Connector (Wire-lo-ere, Hanging Type) CHM-1-2103 5-2~4 Check after inserting retainer Check visually Ina! relainer is secume locked at bolh surfaces of housing. 0 x EDIE Correct assembly layout Only one side is locked. (In dotted circle) In ca f ~ 5 clrcui roduct O X Correct assembly layout Only one side is locked (In dotted circle) In fig; 9f 6 circuits QMug Advanced Connection Systems
m Page 10/12 Title: HANDLING MANUAL No. Rev. No. XMA Connector (Wire—to—Wire, Hanging Type) CHM‘1—21 03 6. How to Extract Crimped Contact from Housing in Case of Mis-inseition When crimped contact is inserted into improper circuit hole, conduct me following points. (D Q) Do not reuse the housing after the contact is extracted in principle. (Methods of extracting contact and retainer from housing are as below.) When reuse of contact and housing is unavoidably conducted, keep the following points. (1) Only specified person conducts removing retainer and extracting contact. (2) In case such contact is unavoidably reused, the reuse should be once alter checking that the extracted contact is free from deformation, From twice, use a new contact, Besides, do not reuse once used housing and retainer. (3) If abnormality such as defamation is found, replace it with a newly crimped contact. Example: Mating part of pin contact in dotted circle is deformed. (Deformation caused by prying when inserting jig.) (4) After correcfion completes, be sure to check secure locking stated in item 54. When contact comes off housing, use a new housing. How to extrag retainer ® ® (3 Insert the extraction tool into one side of retainer lock part almost in parallel with housing. Lift retainer by extraction tool and unlock it. At this time, do not lift retainer over the height of retainer look of housing, because excessive lifting may break retainer, After unlocking. pull the retainer to extract from the housing / Retainer lock Jig EEEEI Retainerle hooked part Advanced Connection Systems
m Page 11/12 Titie: HANDLING MANUAL No. Rev. No. XMA Connector (Wire-to—Vlfire, Hanging Type) CHM»1-2103 How to e559; Qntgct from housing (D Provide contact extraction tool, EJ-XMP for plug and EJ-XMR for receptacle. <2) insert="" ej-xmp="" for="" plug="" from="" contact="" insertion="" hole="" side="" and="" ej-xmr="" for="" receptacle="" from="" mating="" entrance="" side="" parallel="" between="" contact="" lance="" and="" housing="" (3="" insert="" the="" tool="" up="" to="" the="" innermost="" and="" press="" housing="" lance.="" 69="" in="" the="" condition="" that="" the="" housing="" lance="" has="" been="" pressed,="" pull="" wire="" softly="" and="" extract="" contact="" from="" housing.="" when="" contact="" cannot="" be="" extracted="" even="" by="" pulling="" wire="" softly,="" do="" not="" pull="" it="" forcibly,="" and="" try="" again="" back="" to="" step="" (d.="" do="" not="" conduct="" operation="" by="" using="" other="" than="" jst="" specified="" extraction="" tool,="" because="" they="" may="" cause="" deformation="" of="" mating="" part.="" mating="" .="" receptacle="" contact="" entrance="" “is="" contact="" insertion="" hole="" side="" \="" m\\\\\v="" v;="" a“="" 3-2-7="" extraction="" l="" ._="" i;\\\\\\\\x\\\\="" ’="" 2="" housing="" lanoe="" contact="" extraction="" tool="" (ej-xmp)="" in="" case="" of="" glug="" yfiggoe="" side="" pin="" contact="" contact="" insertion="" hole="" side="" \="" extraction="" insertion="" —=""> ere Contact extraction tool HOUSIHQ lance (EJ-XMR) In case of recegtacle Advanced Connection Systems
m Page 12/12 Tine: HANDLING MANUAL No. Rev. No. XMA Connector (Wire-to-Wire, Hanging Type) CHM-1-2103 7. Handling Precautions (D (D Store contact and housing in a place where temperature is 5°C ~ 35°C and humidity is 45% ~ 85%. Keep them free from damp, dust and direct sunshine. Careful operation is required for storage and transport of housing and harness in a stacking condition to prevent deformation of housing. Stacking allowance in storage and transport are up to 5 stacks of carton box for housing, and up to 300 mm stack height with as little load as possible at housing part for harness. Do not mate pin and socket contacts without inserting them into housing in order to prevent from deformation of contact part. When electrical continuity test for harness is conducted, use counterpart of connector. (Example: receptacle side for plug side) Never use different type of pin like a tester pin, Replace the testing connector periodically for conductivity inspection. Do not always apply external force to harness other than the tension or load generated in normal wire routing operation. Route wire so as not to apply external force to connector except the force, considering an enough length to route and fixing of wire because oontacfing part or crimped part of contact may be damaged, cause defective contacting. Inserting connector shall be conducted on the same axis as much as possible. Insert connector completely until lock of plug housing and receptacle housing clicks (you feel a click). When unmating connector, extract connector straight by pressing releasing lever part of the center lock. Releasing lever Insertion H Vtfithdrawal *— ==—r fig” .334 Advanced Connection Systems