Assembly Procedure for XS2C/XS2G Connector Assemblies
XS2
(1) Connector and Cable External Diameters
• Connectors for 6-, 4-, and 3-mm-diameter Cables (i.e.,
Cables that are 5 to 6, 4 to 5, and 3 to 4 mm in diameter
respectively) are available. When assembling a Connector
used with a cable, make sure that the external diameter of
the Connector is suited to that of the cable.
• Connectors for 6-mm-diameter Cables use white cable
clamps. Connectors for 4- and 3-mm-diameter Cables use
black cable clamps.
A watertight bushing for 6-mm-diameter Cable has no
stripe, that for 4-mm-diameter Cable has a single stripe, and
that for 3-mm-diameter Cable has two stripes.
Note: When connecting a commercially available cable to a connector
assembly, use a cable with an outside diameter of 3 to 6 mm and core
sizes of 0.18 to 0.75 mm2 for crimping connectors and 0.5 mm2 maximum
for soldering connectors.
(2) Component Insertion
Crimping/Soldering Connectors
Straight Connectors
Cover
Watertight Cable
bushing clamp
Cap
(3) Wiring (Processing Cable Ends)
Soldering Connectors
4
6
6±0.5 *A
• Strip 10 mm of the Cable sheath and 4 mm of each core.
• Before soldering cores and solder cup pins together, solder-
coat each of them.
• The following conditions are recommended for soldering
each solder cup pin.
Soldering iron: 30 to 60 W
Soldering temperature: 280°C to 340°C
Soldering period: 3 s max.
• The length marked *A should be 6.5 mm max., otherwise
the proper degree of protection of the connector will not be
maintained.
Crimping Connectors
Crimping
4
10
−0
4
L-shaped Connectors
Cover
Ring (L-shaped models only) *
Watertight Cable clamp Cap
bushing
*A ring is not required for Screw-on Connectors.
• As shown in the above illustration, connect the above
components to the Cable with its end processed.
Screw-on Connectors
Confirm that you have all of the required parts.
Cover
Cover
Watertight
bushing
Cable clamp
Cap
*2
Ring *1
Watertight bushing
Cable clamp
Cap
Insulation caps and insulation tubes are included with
5-pole Connectors (XS2C-D5S@ and XS2G-D5S@).
*1.Rings are not required with 7-mm and 8-mm cables.
*2.Insert the waterproof bushing for 7-mm and 8-mm
cables in the direction shown in the diagram.
• Strip 14 mm of the Cable sheath and 4 mm of each core.
• Make sure that each core is not damaged and its end
strands are not spread out.
• Mount the XY2F-0003 Locator to DMC's AFM8 (M25520/2-
01) Crimping Tool, both of which are sold separately, and
set the selector dial of the Crimping Tool to 6 for the XS2U-
@@21 and to 7 for the XS2U-@@22.
• After mounting the crimping pins to the Locator, fully insert
the cores to the crimping pins.
• Squeeze the handle of the Crimp Tool to press-fit the cores
to the crimping pins.
(Squeeze the handle firmly until the handle automatically
returns to the release position.)
Wiring
Pin clamp
Press
1 to 1.5
• After press-fitting the cores to the pins, insert the pins into
the pin clamp as shown in the illustration. Then make sure
that the lead colors correspond to the pin clamp numbers
that are identical to the connector pin numbers.
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