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HRS ZE064W Series Handling Manual

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ZE064W
COUNT
DESCRIPTION OF REVISIONS
0
△
TITLE
ZE064W SERIES HANDLING MANUAL
TECHICAL SPECIFICATION
FORM HC0011-9-1
Handling Manual
Series
DESIGNED
HIROSE ELECTRIC CO.,LTD.
APPROVED
CHECKED
DESIGNED
WRITTEN
ETAD-T0947-00
CHECKED
DATE
HK.UMEHARA
20220209
HH.TSUKUMO
20220209
TY.MOGI
20220209
TY.MOGI
20220209
1 / 32
△
0

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Summary of Contents for HRS ZE064W Series

  • Page 1 ZE064W Series Handling Manual COUNT DESCRIPTION OF REVISIONS DESIGNED CHECKED DATE △ TITLE HIROSE ELECTRIC CO.,LTD. APPROVED ZE064W SERIES HANDLING MANUAL HK.UMEHARA 20220209 CHECKED HH.TSUKUMO 20220209 DESIGNED TY.MOGI 20220209 WRITTEN TY.MOGI 20220209 1 / 32 △ TECHICAL SPECIFICATION ETAD-T0947-00 FORM HC0011-9-1...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SCOPE ..............................3 PARTS DESCRIPTION ......................... 4 DESCRIPTION ............................4 PART NUMBERS ........................... 5 MATERIALS ............................6 PACKAGING ............................7 MECHANICAL PERFORMANCES ...................... 8 STORAGE - HANDLING OF COMPONENTS ................... 9 STORAGE CONDITIONS ........................9 HANDLING OF COMPONENTS ......................9 ASSEMBLY PROCESS ........................

  • Page 3: Scope

    ZE064 terminals. All measurements are in millimeters and Forces in Newtons unless otherwise specified. In addition, photographs and illustrations described are representative products of HRS ZE064W series, so they differ depending on products. Information of this manual is subject to change without notices.

  • Page 4: Parts Description

    PARTS DESCRIPTION DESCRIPTION 【Male connector】 Retainer Collar Panel seal Male housing Male terminal （Crimp terminal） 【Female connector】 Housing seal Female housing Wire seal Seal cover Retainer Female terminal Plug （Crimp terminal） △ HIROSE ELECTRIC CO.,LTD. ETAD-T0947-00 4/32 FORM HC0011-9-2...

  • Page 5: Part Numbers

    PART NUMBERS Description Part Number Male terminal ZE064-2022PCF Female terminal ZE064-2022SCF Female connector X positions (coding A or B) ZE064W-XDS-HU/R(Y) Male connector X positions (coding A or B) ZE064W-XDP-HU/R(Y) Plug ZE064W-WCP(2022) Note 1: please check with Hirose Sales department for the availability of all part numbers. △...

  • Page 6: Materials

    MATERIALS Part Sub part Material Female housing Retainer Female connector Housing seal Silicone Wire seal Silicone Seal cover Housing Retainer Male connector Panel seal Silicone Carbon steel Collar Surface: Nickel plating: 5µm min Metal thickness: 0.2±0.05 mm Copper alloy Female terminal Surface: Tin plating: 1µm min Under: Copper plating: .0.3µm Metal thickness: 0.2±0.05 mm...

  • Page 7: Packaging

    PACKAGING Carton box Type of Quantity of parts Designation HRS P/N dimensions packaging per unit LxWxH (mm) Female 120 pcs/tray ZE064W-8DS-HU/R connector 495 x 315 x 200 Tray x 5 layers (A) or (B) = 600 pcs Female 96 pcs/tray...

  • Page 8: Mechanical Performances

    MECHANICAL PERFORMANCES The main mechanical characteristics are as follow: Test Value AWG20: 70N min Tensile strength of the Wire-Terminal link AWG22: 50N min 4N max for female terminals Terminal insertion force 3N max for male terminals 9N min for female terminals Terminal polarization force 30N min for male terminals Terminal retention force with TPA inactive...

  • Page 9: Storage - Handling Of Components

    STORAGE - HANDLING OF COMPONENTS STORAGE CONDITIONS  Store in a well ventilated environment with the following relative temperature and humidity range: -10° to 60°C ; 85% HR maximum.  Store without contact with the ground, on a pallet or platform, a clean dry surface until the packages are retrieved for production.
  • Page 10  Do not place wire harnesses on the floor.  Refrain from any handling that may result in terminal damage or deformation.  Do not use the housing in case it drops. △ HIROSE ELECTRIC CO.,LTD. ETAD-T0947-00 10/32 FORM HC0011-9-2...

  • Page 11: Assembly Process

    ASSEMBLY PROCESS CRIMPING OF TERMINALS 1 – Cut the cable Set the cable length with reference to the dimensions shown below. Approximate cable cut length = above cable length + 7mm 2 - Strip the cable Please refer to the Crimp Quality Standard (§11) for details on strip length. △...
  • Page 12 3 – Crimp wire in terminal Male terminal: Female terminal: Note 1: Please use the Hirose crimp tool. Note 2: Please refer to the Crimp Quality Standard (§11) to confirm terminal compatibility and check crimp condition. Note 3: Please refer to the Crimp parameters (§12) for the crimp parameters to be used. △...

  • Page 13: Connector Assembly Instructions

    CONNECTOR ASSEMBLY INSTRUCTIONS Male connector: 1 – Pick a connector from the tray. Please hold connectors except panel seal part. And also be careful that the oil of the panel seal not to be touched with other objects except connector housing and retainer. Plastic board PP band Tray...
  • Page 14 2 - Insert the terminal straight to the housing (refer to below direction) until a click by the lance is heard. Retainer wide side The terminal is inserted with the crimping portion facing upward. Supplementary figure of terminal insertion direction Retainer wide side Terminal No.1 Retainer narrow side...
  • Page 15 3 – Push the pre-set retainer from wide side until it clicks. Please don’t touch the panel seal more than necessary. Retainer wide side After setting the retainer, please make sure the retainer is not inclined as seen from the front. If it is tilted, push in an additional retainer to make it set.
  • Page 16 4 – Please protect the panel seal not to be touched with other objects. The protector is required not to be deformed excessively during packaging, shipping and being stored. e.x.) Cover the whole part of connector with plastic cup and tighten the cables to hold. Tighten to hold △...
  • Page 17 Female connector: At both the upper row and the lower, the terminal is inserted with the crimping portion facing upward. The terminal is inserted with crimping portion facing downward. Note: Hold the cable and insert it straight. △ HIROSE ELECTRIC CO.,LTD. ETAD-T0947-00 17/32 FORM HC0011-9-2...
  • Page 18 2 – Push the pre-set retainer until it clicks. Please use a dedicated tool for the set of retainer. Dedicated tool can be substituted as long as the following dimensions (Plastic recommended). Dedicated tool Dedicated tool Retainer Push the dedicated tool in the direction indicated by the arrow.
  • Page 19 Set condition of retainer After setting the retainer, please make sure the retainer is not inclined as seen from the front. *Set condition of retainer *One side of the retainer not installed. (Even in the case of this left-right reversal.) In case of cavities where terminals are not inserted, please use plugs to ensure waterproofness of connectors.

  • Page 20: Wiring Harness Assembly Recommendations

    WIRING HARNESS ASSEMBLY RECOMMENDATIONS  Deformed or damaged parts have to be replaced by a new one.  Apply tape so that every individual wire is subjected to an equal amount of tensile force to avoid any effect on terminals (like disengagement). ...

  • Page 21: Assembly Process To The Panel

    ASSEMBLY PROCESS TO THE PANEL 1 – Pick a harness assembly from packaging. In the harness state, it is recommended to hold the cable and housing. Do not touch the terminals or the male connector panel seal or retainer. Also, make sure that oil is smeared over the entire surface of the panel seal.
  • Page 22 3 – Lightly press the panel seal against the chamfer of the panel frontage to position the male connector. Flange Chamfer of the panel frontage Chamfer of the panel frontage Panel seal Panel seal While in this position, press on the male connector housing or collar and push the male connector straight into the enclosure opening.
  • Page 23 Make sure that the male connector does not rise excessively above the surface of the panel when you take your hand off the male connector. If it floats up excessively, something may have gone wrong. In that case, pull the male connector out of the panel and start the process all over again.

  • Page 24: Mating Operating Process

    MATING OPERATING PROCESS 1 – Prepare a panel with a male connector attached and a female connector harness product. Make sure that the male and female connector key codings are the same. Align the locking direction of the male and female connectors and insert them straight along the mating direction.
  • Page 25 3 – When disconnecting the connector, push down the female connector until the locking lever of the female connector is pushed against it, then grasp the female connector housing and pull it straight against the mating direction. If the female connector is removed while the lock lever is not pushed down enough, it may cause damage to the lock lever.

  • Page 26: Repair Process

    REPAIR PROCESS Male connector: 1 – Release the retainer with your fingers, to return to the pre-set state. Retainer narrow side Make sure that the retainer is in the pre-set state for both left and right. Pre-set Note: Please return to the pre-set state position from retainer wide side when the retainer drops out.
  • Page 27 2 – Insert the repair tool into the terminal hole, and push until it hits. After pushing in, please remove the terminal while maintaining that state. Note: Please refer to the next section (§9) for details on the repair tool. Repair tool Repair tool insertion hole Terminal...
  • Page 28 Female connector: 1 – Using the dedicated tool, release the lock of the retainer and return to the pre-set state. Dedicated tool Cross section of connector Dedicated tool Retainer Insert the dedicated tool Place the tool on the retainer to housing (lock lever side). and push in the direction indicated by the arrow When the tool is pushed into, the retainer returns to the pre-set state.
  • Page 29 2 – Insert the dedicated tool into the terminal hole, and push until it hits. After pushing in, please remove the terminal while maintaining that state. Dedicated tool Note: Insertion into the same terminal hole is limited to 2 times. Please use the new housing after the third time.

  • Page 30: Repair Tools

    REPAIR TOOLS 11.1 REPAIR TOOL FOR RETAINER Part number summary for retainer repair tools: Applicable parts Repair tool name Repair tool part number ZE064W-XDS-HU/R(Y) ZE064W-DS-HU/R/CV-MD 902-5151-0 The following drawing shows definition of tool for retainer release for female connector. Under preparation △...

  • Page 31: Repair Tool For Terminal

    11.2 REPAIR TOOL FOR TERMINAL Part number summary for terminal repair tool: Applicable part Repair tool name Repair tool part number ZE064-2022PCF ZE064-P/RE-MD 902-5150-0 ZE064-2022SCF ZE064-S/RE-MD 902-5149-0 The following drawings show definition of tools for terminal repair. Terminal repair tool for ZE064-2022PCF: △...
  • Page 32 Terminal repair tool for ZE064-2022SCF: △ HIROSE ELECTRIC CO.,LTD. ETAD-T0947-00 32/32 FORM HC0011-9-2...

  • Page 33: Electrical Test

    ELECTRICAL TEST 12.1 CLAMPING AREAS OF CONNECTORS During electrical tests, connectors can be clamped in the following areas: (examples with ZE064W-24DP-HU/R(A) and ZE064W-24DS-HU/R(A)) Male connector: (example with ZE064W-24DP-HU/R(A)) Areas to clamp the male connector Note: Please pay attention to not touch panel seal Female connector: (example with ZE064W-24DS-HU/R(A)) Areas clamp...

  • Page 34: Location Of Test Probes

    12.2 LOCATION OF TEST PROBES The test probes should be located in front face as described below: (Example with the 24P) Male connector: Female connector: △ HIROSE ELECTRIC CO.,LTD. ETAD-T0947-00 34/32 FORM HC0011-9-2...

  • Page 35: Definition Of Test Probes

    12.3 DEFINITION OF TEST PROBES The recommended probe should have the following characteristics:  Diameter: ∅0.60mm maximum  Plating: Gold plated  Spring force: 1N maximum ∅0.6mm max  Stroke: see section below Gold plated Male connector: Female connector: △ HIROSE ELECTRIC CO.,LTD.

  • Page 36: Recommendations For Electrical Tests

    12.4 RECOMMENDATIONS FOR ELECTRICAL TESTS  Perform test after insertion of terminals and closing of retainer.  Avoid any deformation on housing or terminal during electrical test.  Replace any damaged housing or terminal or panel seal with a new one. △...

  • Page 37: Crimp Quality Standard

    CRIMP QUALITY STANDARD 13.1 SCOPE This technical specification prescribes crimp condition of ZE064-2022PCF and ZE064-2022SCF. 13.2 APPLICABLE WIRE  Applicable wire size: 0.3mm² ~ 0.5mm²  Applicable insulation size: ∅1.4mm ~ ∅ 1.7mm 13.3 QUALITY STANDARD Related dimensions for ZE064-2022PCF: N-N (wire barrel cross section image) O-O (insulation barrel...
  • Page 38 Related dimensions for ZE064-2022SCF: N-N (wire barrel cross section image) O-O (insulation barrel cross section image) P enlarged view Cover remaining △ HIROSE ELECTRIC CO.,LTD. ETAD-T0947-00 38/32 FORM HC0011-9-2...
  • Page 39 CHECK POINT MEASURE (mm) Cover location 0.3 ~ 0.8 Location of tip of the core 0.1 ~ 0.6 0.1 ~ 0.5 Bell-mouth 0.5 max Bend-up 2° max Bend-down 3° max Twist ±2° max Rolling ±5° max Strip length 4.0 ~ 4.3 Wire barrel 1.5 max Width...

  • Page 40: Crimp Parameters

    CRIMP PARAMETERS Crimp parameters for terminal ZE064-2022PCF: Tensile SEC AREA strength of CONDUCTOR INSULATION WIRE (mm²) TYPE wire-terminal link (minimum) AESSX0.3f 0.3821 / 22 0.83 ~0.89 1.5 max 1.90 ~ 2.00 1.8 max AESSX0.5f 0.5387 / 20 0.90 ~0.96 1.5 max 2.00 ~ 2.10 1.8 max Crimp parameters for terminal ZE064-2022SCF:...

This manual is also suitable for:

Ze064-2022pcfZe064-2022scf

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