CMK-R
INDUSTRY STANDARD APPLICATOR
OPERATION
MANUAL
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CMK-R INDUSTRY STANDARD APPLICATOR
For safe use
• Always switch of the Press at the mains and remove the applicator from the
Press before making any adjustments or fitting new parts.
• Always refer to this manual before making any adjustments to JST
Applicators
• All JST Applicators are supplied with a Die-construction sheet, please refer
to this document when ordering spare parts.
• All JST Industry standard Applicators have been designed to operate in
Industry standard presses with a shut height of 135.78mm. If you have any
doubt to whether our applicator is compatible with your Press please do not
hesitate to call our Technical Services Department where one of our
Engineers will be pleased to advise.
• Do not modify or adapt the applicator without prior consent of JST.
• Always ensure that safety guards are fitted to the Press when using your
JST applicator.
• To prevent damage to the dies, always ensure that a protective rubber collar
is fitted between the dials and casting of the applicator when it is removed
from the press.
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CONTENTS
Page
1.
Ram Slide Section..............................................................................
4
2.
Shear Blade........................................................................................
5
3.
Stripper...............................................................................................
5
4.
Upper Die Parts..................................................................................
6
5.
Lower Die Parts..................................................................................
7
6.
Alignment Of Shear Blade, Anvil (A) and (B)..................................
8
7.
Guide Plates, Feed Plate.....................................................................
9
8.
Terminal Feed Pitch...........................................................................
10
9.
Pressure Pad Adjustment.................................................................... 11
10.
Terminal Feed Position......................................................................
11.
Additional Information....................................................................... 12
12.
Crimp Height...................................................................................... 14
13.
CMK-R Parts List..............................................................................
15
14.
CMK-R Exploded Diagram...............................................................
16
15.
Preventive maintenance.....................................................................
17
16.
Crimping specifications.....................................................................
18
11
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1. APPLICATOR RAM SLIDE
1-1 SLIDE ASSEMBLY
The conductor dial (108) and the insulation dial (111) are fixed by the shank (112).
To remove the two disks you must first loosen the 4mm grub screw positioned in the
main body of the slide, now by loosening the shank you can remove both wire disks.
Positioned in the rear of the slide is the cam (119), there are two different cams
available for this applicator, the first we call an upstroke cam, with this cam fitted
the terminal is present over the anvil when the press is at top dead centre, this type of
cam is commonly used when the applicator is located in a bench press. The other is
called a downstroke cam, this operates in the opposite manner, which means the
terminal feeds forward as the press travels to bottom dead centre, this type of cam is
commonly used when the applicator is located in a fully automatic machine.
1-2 TROUBLE SHOOTING
The dials are difficult to turn!
1. Dismantle slide assembly as described above and check for any foreign bodies.
2. Ensure 3mm grub screw located in the insulation dial is not excessively
tightened.
3. Check condition of the positioning Pin (109).
The dials turn freely but do not locate in position correctly!
1. Check the condition of the positioning spring (110) and the positioning pin
(109), The Spring may be broken.
2. Ensure 3mm-grub screw located in the insulation dial is adjusted correctly.
(112)
(108)
(111)
(146)
(119)
(109)
(110)
(148)
(107)
No.
107
108
109
110
111
112
113
119
146
148
DESCRIPTION
Ram
Conductor dial
Positioning pin
Positioning spring
Insulation dial
Shank
Block ring
Cam
Conductor spacer
Insulation spacer
(113)
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2. SHEAR BLADE
2-1 ASSEMBLING THE SHEAR BLADE
Place spacer (149) onto the rear of the ram, making sure that the chamfered edge is
facing in, and the etched part number is facing out. Place shear blade (150) into
position and secure with 2 x M4 hexagon screws.
Note:
Make sure that the M4 screws holding the blade and spacer DO NOT protrude
through to the front of the ram, This will result in the punches not being able to
float freely, and almost certainly cause punch damage.
(150) Shear
blade
(149) Spacer
(107) Ram
3. TERMINAL STRIPPER
3.1 PURPOSE
After the terminal has been successfully crimped on the wire, the terminal may
adhere to the punches, the stripper assumes the role of removing the terminal from
the punches.
3.2 ASSEMBLY
Firstly, attach the stripper (155) to the stripper bracket (142) using 2 x M4 screws,
next attach the bracket (142) to the slot on the side of the main casting using 1 x M6
screw. The stripper is usually positioned between the Conductor punch and the
Insulation punch, ensuring there is no contact with either part.
Depending on the kind of terminal, the stripper may be fitted to the rear of the
conductor punch.
(142) Stripper
Bracket
(155) Stripper
Insulation punch
Conductor punch
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4. UPPER DIE PARTS
4-1 ASSEMBLING UPPER DIE PARTS
To ensure the upper die parts are assembled in the correct orientation the engraved
part numbers must always be facing outwards.
The parts must be fitted in the correct order as detailed below:
1. Conductor spacer (146)
2. Insulation spacer (148)
3. Block ring (113)
After you have fitted these parts tighten them down with a 5mm-hexagon screw and
check that they are not clamped and do move up and down freely.
4. Conductor punch (144)
5. Insulation punch (145)
6. A Spacer & wire spring are sometimes fitted between the two punches.
7. Punch Spacer (147)
After you have fitted these parts, tighten down with a 6mm-hexagon screw and
again check that they are not clamped and punches do move up and down freely.
4-2 TROUBLE SHOOTING
The punches or spacers do not move freely!
1. Dismantle and check for any foreign bodies.
2. Check the sides of the punches for wear / damage or burrs.
3. Check the parts that are fitted, against the relevant die construction sheet.
(107) Ram
(144) Conductor punch
(147) Punch Spacer
(145) Insulation Punch
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5. LOWER DIE PARTS
5-1 ASSEMBLING LOWER DIE PARTS
To ensure the lower die parts are assembled in the correct orientation the engraved
part numbers must always be facing outwards.
The parts must be fitted in the correct order as detailed below:
1.
2.
3.
4.
Shear blade anvil (A)
Shear blade anvil (B)
Conductor anvil
Insulation anvil
When all the above are in place, using 2 x 5mm hexagon screws gently tighten the
die parts into position.
IMPORTANT
When these parts are positioned it is essential that they are knocked down flat
against the Die plate, preferably using a piece of soft metal (brass) to avoid
damaging the anvil parts.
(105) Die block
(151) Shear blade Anvil A
(152) Shear blade Anvil B
(153) Conductor Anvil
(154) Insulation Anvil
(104) Die Plate
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6. SHEAR BLADE
6-1 POSITIONING OF THE SHEAR BLADE
The Die block is correctly located when the Shear blade passes through the 2 Shear
blade anvils freely without touching either side. To set this position correctly, follow
the procedure below.
Remove the applicator from the Press and loosen the 4 x 5mm hexagon screws that
attach the Die block to the Die Plate.
Bring the Ram down slowly to align the Shear Blade, with the slot in the Shear blade
Anvil. When the Shear blade passes through the slot in the Shear blade anvil freely,
carefully re-tighten the screws.
To ensure that you have set this part correctly you can mark both sides of the Shear
blade with a pen, then slowly move the Ram up and down. If the Shear blade is
positioned correctly the ink will still be present on the Blade, if the ink has been
removed this indicates that the setting is incorrect.
Shear Blade
Shear Blade Anvil B
Conductor Anvil
Shear Blade Anvil A
Insulation Anvil
Die Block
Die Plate
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7. GUIDE PLATE
7-1 POSITIONING OF THE GUIDE PLATES
To ensure the correct alignment of the Guide Plates, firstly mount the Feed Plate
onto the Die Block and secure tightly using 2 x 5mm hexagon screws. Next fit the
Anvil parts as described in section 5.
Now you can fit the 2 guide plates using 4 x 4mm hexagon screws (do not tighten).
Take a strip of the terminals that are compatible with the die set in the applicator and
align the strip with the centre of the anvil parts ensuring that everything is parallel
(see below), now you can carefully tighten the 4 x 4mm hexagon screws.
Guide Plate (R)
Guide Plate (L)
Feed Plate
Die Block
Die Plate
Centre Line of Anvil
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8. TERMINAL FEED PITCH
8-1 When you receive the applicator the pitch will be factory set, however if you do
need to make an adjustment, please ensure that the press is switched off and the
applicator is removed from the Press.
Note: The function of this nut is to achieve the correct pitch of the feed finger as shown
in 8-3 (not to set the final position over the Anvil).
8-2 The pitch of the Feed Finger is adjusted by loosening the Stroke adjustment bearing
nut (117) and sliding it either up, to make the stroke longer, or down, to shorten the
stroke.
After you make this adjustment you will have to adjust the terminal position as
described in section 10.
8-3 When adjusting the pitch always try to feed the terminal on the Insulation bucket as
shown in the item 2 below, if this cannot be achieved then using the Conductor bucket
is acceptable.
(1)
(2)
Recommended
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9. PRESSURE PAD
9-1 The purpose of the Pressure pad is to insure that the Terminal stays in the correct
position over the anvil when the Feed finger is moving backwards, the pressure on the
terminal can be adjusted by either tightening or loosening the 2 x M5 adjustment
screws as shown below.
M5 adjustment Screw
M5 Locking nut
M5 Spring Block
Spring
Pressure Pad
10. Terminal Feed Position
10-1 When you receive the applicator the feed will be factory set, however if you do
need to make an adjustment, please ensure that the press is switched off and the
applicator is removed from the Press.
Note: The function of this adjustment is to ensure that the terminal is in the correct
position when crimped. See section 16.
10-2 To adjust the position of the Feed finger loosen the M5 screw in the lever block
(124), then carefully loosen the Ring nut (125). Once these 2 parts have been loosened
you can adjust the position of the Feed finger by rotating the Adjusting bolt (123),
clockwise to take the terminal forward and anti-clockwise to bring the Terminal back.
When you have assumed the correct position carefully tighten the Ring nut (125) then
the M5 screw.
Now you can place the applicator back into the press and carefully rotate the Press by
manual operation to see if the correct position has been achieved (See section 15).
If the crimped terminal is not correct then repeat this process.
10-3 The terminal position will vary if the Pitch screw is adjusted (section 8).
Please see the following page for the exploded view of this section.
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CMK-R INDUSTRY STANDARD APPLICATOR
Exploded view
M5 Screw
Adjusting Bolt (123)
Lever Block (124)
Ring nut (125)
Feed Finger
11. ADDITIONAL INFORMATION
11-1 Terminal Holder
Depending on which terminal you are processing, a Terminal holder is sometimes fitted
to the Shear blade Anvil (A). The purpose of this part is to stop the terminal from
lifting up with the Shear blade prior to being positioned over the Anvil.
Shear blade Anvil (A)
Shear blade Anvil (B)
Terminal Holder
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11-2 Cam Roller and Cam Roller shaft
The Cam roller’s function is to move a long the Cam which in turn will move the Feed
finger into position, therefore, if there is any wear in this part or this part becomes
damaged then it will result in the terminal being positioned incorrectly.
Cam roller
Cam roller shaft
11-3 Springs
•
Feed Finger Spring – The function of the Feed Finger Spring is to keep downward
pressure on the feed finger to ensure consistent feeding of the Terminal.
•
Return Spring – The function of the Return Spring is to ensure that the Feed finger
pitches correctly every time, if this spring becomes stretched then inconsistent
feeding may occur.
•
Pressure Spring – The function of this spring is to keep constant pressure onto the
terminal strip if this part is worn or damaged then the crimping will become
inconsistent.
Feed finger spring
Return spring
Pressure spring
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12. CRIMP HEIGHT
12-1 The 2 dials on the top of the Ram are used to adjust the conductor and Insulation
crimp heights.
NOTE: The numbers and letters around these dials should not be used as a reference
for a correct crimp, as this will vary depending on the shut height of the press the
applicator is used in.
If for any reason you cannot achieve the correct crimp height, please contact our
Technical services department.
12-2 Conductor crimp height
The top dial, which has the letters from A-H around it, is for adjusting the Conductor
crimp height. To adjust the crimp height of the conductor, carefully rotate this dial, the
lower the letter (A) the harder the crimp.
When making any adjustment it is recommended that you start with the higher letter
(H) to avoid any damaged being caused by over crimping.
To ensure that you have the correct crimp height, there is a silver label fixed to the side
of the applicator, this will have all the crimp heights, for the different gauge wires used
with that terminal on it.
The steps between each dial setting are 0.05mm increments.
For information regarding how to measure the crimp heights please see section 16.
12-3 Insulation crimp height
The Lower dial, which has the numbers from 1-8 around it, is for adjusting the
Insulation crimp height. To adjust the crimp height of the Insulation, carefully rotate
this dial, the lower the number (1) the harder the crimp.
When making any adjustment it is recommended that you start with the higher number
(8) to avoid any damaged being caused by over crimping.
The steps between each dial setting are 0.10mm increments.
For information regarding how to ensure that you are using the correct setting please
see section 16.
Conductor crimp adjustment
Insulation crimp adjustment
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13. Parts list for the applicator CMK-R
No.
101
Body
Part Name
Part No.
4007-2001
No.
133
Part Name
Spring anchor
Part No.
4007-4011
102
Plate (L)
4007-4002
133A
Return spring
MA01-349
103
Plate (R)
104
4007-4003
134
Pressure pad
4007-4012
Die plate
4007-3004
135
Pressure pad block
4007-4013
105
Die block
4007-4005
136
Pressure pad pin
MA01-472
106
Feed plate
4007-4006
137
Release lever
4007-4014
107
Ram
4007-4007
138
Release lever pin
MA01-474
108
Conductor dial
4006-4008
139
Hook
4007-4015
109
Positioning pin
MA01-213
140
Hook pin
MA01-476
110
Positioning spring
MA01-214
141
Spring block
4007-4016
111
Insulation dial
4006-4009
142
Stripper bracket
4007-4017
112
Shank
4006-4010
143
Identification plate
4007-4018
113
Block ring
MA01-225
114
Stroke adjustment plate
4007-4008
144
Conductor punch
115
Stroke adjustment shaft
MA01-331
145
Insulation punch
116
Stroke adjustment bearing
MA01-332
146
Conductor spacer
117
Stroke adjustment bearing nut
MA01-333
147
Punch spacer
118
Stroke adjustment screw
MA01-334
148
Insulation spacer
119
Cam
4007-4009
149
Shear blade spacer
120
Cam roller
MA01-308A
150
Shear blade
121
Cam roller shaft
MA01-337A
151
Shear blade anvil (A)
122
Feed shaft
MA01-338
152
Shear blade anvil (B)
123
Adjustment bolt
MA01-339
153
Conductor anvil
124
Lever block
MA01-340
154
Insulation anvil
125
Ring nut
MA01-341
155
Stripper
126
Feed lever (A)
MA01-342M
156
Terminal holder
127
Feed lever support pin
MA01-343
157
Guide plate (R)
128
Feed lever pin
MA01-344
158
Guide plate (L)
129
Feed lever (B)
4007-4010M
130
Feed finger
MA01-346
131
Feed finger pin
MA01-347
132
Feed finger Spring
MA01-348
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14. CMK-R Applicator exploded view
112
108
111
119
109
107
110
146
148
123
113
124
141
125
147
122
149
133A
150
145
140
144
137
120
121
102
128
142
138
139
127
129
143
101
103
126
136
131
132
158
155
135
134
118
157
151
130
105
106
133
152
115
116
153
154
114
104
156
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15. Preventive maintenance
Quality Statement
The quality of a finished crimp is dependent on the use of the manufacturers specified application
tooling that has been cleaned and maintained in accordance with the following schedule.
Daily Care
1.1 Turn off the crimping press and isolate from the electricity supply. Remove the safety covers
from the crimping press.
1.2 Clean all wire and terminal scrap from the tooling with the aid of a small paint brush.
Caution
The use of a pneumatic airline to clean the tooling should be avoided. Any debris on the tool will be
blown away under great force and could either cause injury to persons nearby or be forced into
moving parts of the tooling.
1.3 Visually check the crimping dies, shear section and stripper blade for evidence of wear or
damage. If any parts are damaged, please contact JST to order replacement parts.
1.4 Check that there is a thin film of grease on the bearing surface of the ram, if necessary apply
general-purpose grease to restore the lubrication. Do not over grease the ram, because the excess
grease will either drip onto the tooling or will attract debris.
1.5 Check that the dial settings are aligned correctly over the crimping punches and that they are
correctly set to the pre-determined reference position.
1.6 Check that the safety covers are in a good serviceable condition and replace on the tooling.
Clean the polycarbonate safety cover with a general-purpose aerosol spray cleaner to restore
good visibility.
Weekly care, or when removing the applicator from the press for storage.
In addition to the daily checks, the following maintenance should also be carried out on the tooling.
2.1 Remove the crimping punches from the ram (part numbers are affixed 63*** or 64***),
please note the sequence of dis-assembly so that the parts can be replaced in the correct
order. Refer to the Dies Construction Sheet supplied with the tooling for the assembly
order.
2.2 Hold each crimping punch in a vice and with the aid of a piece of waste cloth apply a
small amount of a good quality metal polish into the crimp form of the punch.
2.3 Using a sawing motion, polish the form until a brilliant mirror-like finish is restored.
2.4 Replace the crimping punches in the ram ensuring that the punches are free to move in a
lateral axis when the retaining screw is fully tightened.
Continued overleaf
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2.5 Remove the applicator from the crimping press (check the press operation manual for
instructions if you are unsure of how to remove the applicator from the press.)
2.6 Check the security of the fastenings. If any part is loose, tighten with the appropriate
hexagon key or spanner supplied with the crimping press.
2.7 Remove the ram from the main body of the applicator and clean off all the old grease
from the ram, feed cam and the mating surface of the applicator.
Caution
If an aerosol degreaser is used to clean the tooling, ensure that all traces of the solvent are removed
prior to reassembly.
2.8 Apply a thin smear of general-purpose grease to the bearing surfaces of the ram, feed
cam and cam-roller assembly and replace in the body of the applicator.
2.9 Apply a few drops of light machine oil to each of the pivot points on the feed-arm
mechanism.
2.10 Replace the applicator in the press.
2.11 Replace the safety covers.
2.12 If it is not intended to replace the applicator in the press, please ensure that the rubber collar
supplied with the tooling is placed between the dials and the applicator body. This action will avoid
any damage occurring to the crimping dies due to percussive shock when the crimping punches
make contact with the crimping anvils.
Notes
Recommended materials for maintenance:
Recommended grease should be of the general purpose ‘LM’ type.
Recommended oil is general-purpose machine oil, i.e. ‘3-In-One’ oil
Recommended metal polish is of the paste type, i.e. ‘Solvol Autosol’
J.S.T MFG. CO., LTD. 2002
The contents of this document are subject to revision from time to time. For the latest issue of this leaflet,
please contact J.S.T.
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16. Crimping specifications
CONTENTS
1.
Checks Before Crimping..................................................................20
2.
Stripping Wire Insulation.................................................................20
3.
Crimping...........................................................................................21
3.1 Precautions regarding crimping........................................................21
3.2 Adjusting the crimp height (CH)......................................................22
3.3 Adjusting the crimp height of the insulation barrel..........................23
3.4 Tensile tests at the crimped section..................................................25
4. Correctly Crimped Conditions................................................................25
4.1 Crimped Appearance........................................................................25
4.2 The crimped cross-section must be correctly finished
as shown to the right.........................................................................25
4.3 All conductors must be crimped.......................................................26
4.4 The lance must not be deformed.......................................................26
4.5 The terminal tip and mating part must not be deformed...................26
4.6 The terminal must not be bent or deflected excessively...................26
4.7 The terminal barrel must be properly bell-mouthed.........................27
4.8 The terminal must be cut at the correct position..............................27
4.9 The wire must be crimped at the correct position............................28
5. Check-points for correct Crimping.........................................................29
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Preface
Since the chain terminals and electric wires to be connected vary greatly in type and usage,
it is difficult to provide instructions for all possible crimping combinations and conditions.
This manual, therefore, provides one general guideline for your reference.
Please contact us if you have any questions regarding the use of special wires, the correct
combinations of terminals and wires etc.
1. Checks Before Crimping
Check that all wires, terminals and dies to be used are correct.
(1) Use stranded wire or cord. (Check the wire size and the insulation colour).
(2) Refer to the applicable wires in the catalogue to determine which terminal
type is necessary to match the wires to be used. (Check the model number
and appearance).
(3) Determine which dies match the terminal. (Check that the dies are free from
damage).
Note: Contact us first if you wish to use solid wires, solder-plated wires, wires not
listed as applicable or other special wires.
2. Stripping Wire Insulation
The wire insulation strip length is determined by referring to the figure
over. Set the correct length depending on the terminal used and strip the
insulation with a wire stripper, taking care not to damage the wire conductors.
Bundle the stripped wires in paper to protect the wire strands from bending or
fraying when transported.
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The wire insulation stripping length is determined by the following equation:
1 = E + A/2 + a
The correct value of a is between 0.5 and 1.0 mm.
Precautions:
(1) Take care to prevent damage to the wire strands, uneven strip lengths and
Insufficient cutting of the insulation.
(2) Strip the shielding cable as shown below:
The end of the outer wire becomes uneven
as the wire is twisted. Trim the wire
approximately 2 to 3 mm to make it even
(3) Do not excessively twist the conductors.
3. Crimping
3.1 Precautions regarding crimping
At first glance, crimping terminals appears to be very easy.
However, crimping involves the use of a press employing 1000 kg (1 ton) of
pressure. Sufficient care must be taken to prevent accidents.
Please instruct beginners to work safely regardless of how much time such
training requires. Always use safety guards so that an operator’s fingers cannot
enter the crimping die area.
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Precautions:
(1) Turn off the crimping machine whenever the Press is not in use.
(2) Turn off the machine at the mains before adjusting the dies and feeder unit.
(3) Do not touch the dies unless the machine is switched off.
(4) Position the foot switch where it will not be operated by other people or
falling objects.
(5) Always concentrate on what you are doing.
(6) Work in a stable posture.
(7) Do not place any unnecessary objects on the die unit.
(8) To make sure that the operating conditions are correct, manually cycle the press
before going to automatic operation. After the handle is used, be sure to remove
it from the crimping machine.
(9)Always ensure that the safety guard is replaced after adjustment.
3.2 Adjusting the crimp height (CH)
After crimping, measure the crimp heights of the crimped terminal with a
micrometer (Contact JST for information on suitable tools) at the centre of the wire
barrel and at the centre of the insulation barrel.
Sectional view of the crimped terminal:
Cross Sections
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* Set the crimp height of the wire barrel to the specified dimension.
* Determine the crimp height of the insulation barrel in relation to the outer diameter
of the wire insulation. (Refer to item 3.3)
Notes:
1. After adjusting the crimp height, use a trial sample to conduct a tensile test
(refer to item 3.4) in order to examine the strength of the crimped section
before going to automatic crimping operation. Occasionally examine the
strength of the crimped section not only at the beginning but also during
automatic operation to check for any abnormality in crimp height.
2. After the dies are replaced or the crimp height is changed and before trial
crimping, rotate the manual handle to make sure that the dies do not
interfere with each other. (Even when the crimp height is high, the dies may
interfere with each other if the dies are incorrectly aligned. Be sure to place
the dies at the correct positions).
3. When the adjustment is completed, check again that all screws are tight.
3.3 Adjusting the height of the insulation barrel
Crimping the insulation barrel is not as important as the wire crimp , but it performs
an important strain-relief function.
However, excessive crimping may cause the conductor to break on the inside.
Such breakage cannot be seen. Care must therefore be taken to prevent such
damage.
Adjust the crimp height of the insulation section as shown in the
example below.
Insufficient Crimping
- The wire insulation is loose
and can be moved.
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Correct
- The barrel edges firmly grip the insulation.
Excessive crimping
- The barrel edges cut into the strands.
999
Checking for correct crimping:
Following the items described below to check that the insulation barrel is correctly
crimped.
(1) Check that the wire insulation does not slip when the wire is bent in the order (1, 2
and 3) shown the right.
(2) Cut off the insulation barrel at the (a) portion and cut off the wire at the (b)
portion. Remove the wire insulation and check the wire conductors for damage.
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3.4 Tensile tests at the crimped section
Test a sample crimped in the normal crimping manner using a tensile tester or
push-pull gauge.
A simple method of suspending a predetermined weight can also be used.
Slowly pull the sample so that it receives no abrupt shock.
Example: Tensile test with a push-pull gauge
4. Correct Crimped Conditions
Crimp the terminal so that it is correctly finished as follows:
4.1 Crimped appearance:
4.2 The crimped cross-section must be correctly finished as shown on the right:
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4.3 All conductors must be crimped. Uncrimped conductors are not acceptable.
Uncrimped conductors.
4.4 The lance must not be deformed.
4.5 The terminal tip and mating part must not be deformed.
4.6 The terminal must not be bent or deflected excessively.
Bend
Bend
Deflection
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4.7 The terminal barrel must be correctly bell-mouthed.
The (A) portion of the barrel must be bell-mouthed.
The (B) portion of the barrel is not necessarily to be bell-mouthed.
The (C) portion must be free of cracks.
4.8 The terminal must be cut at the correct position.
The projection is too long.
The insulation barrel of the subsequent terminal is deformed.
The projection should be 0.2 to 0.5 mm.
Excessive Cutting
The mating part is deformed.
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4.9 The wire must be crimped at the correct position.
The conductors do not protrude enough. (The wire easily comes off due to
incomplete crimping).
The conductors protrude excessively. (The conductors interfere with the tightening
nut, preventing the terminal from being installed).
The wire insulation is crimped at the wire barrel. (Poor conduction or breakage due
to excessive crimping will occur).
The wire insulation is not completely crimped at the insulation barrel. (The wire
insulation easily comes out from the insulation barrel).
The conductors and wire insulation are visible.
The conductors must protrude 0.5 to 1.0 mm.
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5. Check-points for correct Crimping
Be sure to check the following points before beginning work each day.
Check Item
Wire barrel
Check that the crimp heights and tensile
Strength is correct.
Insulation barrel
Check that the crimped shape and the crimp
Heights are correct.
Appearance
- Check that the wire barrel is correctly
bell-mouthed
- Check that the wire is crimped at the correct
position
- Check that the crimped shape is correct
- Check that all conductors are crimped
- Check that the terminal lance is not deformed
- Check that the mating part of the terminal is
not deformed
- Check that the terminal is not bent or
deflected
- Check that there is no conspicuous burr.
- Check that the terminal is cut at the correct
position
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[Reference]
It is best to make up the Crimping CheckList as shown below for convenient
Checking.
CRIMPING CHECK LIST
Example Form
Date
Product
Name
Terminal Wire
CH(A) CH(B) Tensile Appearance Worker
Strength
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