AP-K2N CRIMPING
MACHINE
OPERATION
MANUAL
1
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
PREFACE
The AP-K2N semi-automatic crimping machine is easy to operate, and is suitable for
mass production of crimped harnesses with chain terminals.
Before using the AP-K2N please read this manual to ensure that you are familiar with
the features of the machine and the layout of the operating controls.
We recommend that you always keep this manual near the machine to use for
reference when required. This manual also contains information on maintenance,
fault-finding and adjustment of the crimping machine and its associated tooling.
For safe operation
• THIS MACHINE IS A POWER PRESS AND SHOULD NEVER BE USED
WITHOUT THE SAFETY GUARDS FITTED.
• If you think that something is wrong with the machine, immediately turn OFF the
machine and disconnect the lead from the power supply. Guards must only be
removed by an authorised person during setting, adjustment and maintenance.
• The maximum measured sound output generated by the Crimping Press is 86 dB.
It is recommended that ear defenders are worn whilst operating the machine.
• Do not modify or adapt the machine without prior consent of JST.
• This crimping machine complies with the CE directive for machinery and has the
CE mark affixed to indicate its compliance.
• This crimping machine must not be incorporated into other machinery without the
consent of JST (ref. The Supply of Machinery (safety) Regulations 1992,
S.I 1992/3073).
2
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Table of Contents
1. SPECIFICATIONS................................................................................................4
1 - 1 Crimping Machine Specifications......................................................................4
1 - 2 Applicator Specifications...................................................................................4
2. INSTALLING AND TRANSPORTING THE MACHINE..........................................5
2 - 1 Installation........................................................................................................5
2 - 2 Transporting.....................................................................................................5
3. PREPARATION FOR OPERATION......................................................................6
3 - 1 Mounting the Reel Hanger................................................................................6
3 - 2 Mounting the Applicator....................................................................................6
3 - 3 Mounting the Terminal Reel..............................................................................7
3 - 4 Mounting the Safety Guard...............................................................................8
4. CONTROL BOX CONFIGURATION……………………………………………...…..12
5. OPERATION.......................................................................................................13
5 - 1 Manual Operation...........................................................................................13
5 - 2 Operation under Power...................................................................................14
6. APPLICATOR.....................................................................................................15
6 - 1 Terminal Feed Position Adjustment................................................................15
6 - 2 Bell Mouth Adjustment....................................................................................16
6 - 3 Feed-finger Travel Adjustment........................................................................17
6 - 4 Crimp Adjustment...........................................................................................17
6 - 5 Die Part Replacement.....................................................................................18
6 - 6 Lubrication of Applicator.................................................................................18
7. CRIMPING MACHINE MAINTENANCE..............................................................19
7 - 1 Lubrication......................................................................................................19
7 - 2 Inspection and Repair.....................................................................................21
8. FAULT FINDING.................................................................................................22
9. EXPLODED VIEWS AND PARTS LISTS............................................................26
AP-K2N Crimping Machine Exploded Diagram..... ……….......................................26
MK-L Applicator..........................................................................………...................28
MKS-L Applicator……………....................................................……….....................30
MKF-L Applicator..............................................................................……….............32
MKS-LS Applicator.................................................................................……….......34
3
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
1. SPECIFICATIONS
Models MK-L and MKF-L for end feeding
terminals, and models MKS-L and MKS-LS for
side feeding terminals. The crimping machine
utilizes a quick change system thus allowing quick
change-over times.
The crimping machine is composed of the
crimping press and an applicator.
There are two basic types of applicators
(a total of four models).
1.1 Crimping Machine Specifications
Model no: AP-K2N
º External dimensions: 280mm Wide x
480mm Long x 560mm High
º Weight: 90 Kg
º Power supply: 220/240V AC single phase
50/60 Hz
º Power consumption: 680VA
º Crimping force: 1500 Kg
º Ram stroke: 30mm
º Ram speed: 260 strokes per minute
(60 Hz), and 220 strokes per minute
(50 Hz)
º Closed height: 160.0 mm ± 0.01 at B.D.C
1.2 Applicator specifications
Model no. MKS-L (for side-feeding terminals)
º Weight 6.4 Kg
º Feed pitch 30mm max.
º Crimp height adjustment: Dial type
Model no. MK-L (for-end feeding terminals)
º Weight 6.8 Kg
º Feed pitch 30mm max.
º Crimp height adjustment: Dial type
Model no. MKF-L (for-end feeding flag terminals)
º Weight 6.8 Kg
º Feed pitch 30mm max.
º Crimp height adjustment: Dial type
Model no. MKS-LS (for side feeding terminals)
º Weight 4.5 Kg
º Feed pitch 30mm max.
º Crimp height adjustment: Dial type
4
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
2 INSTALLING AND TRANSPORTING
THE MACHINE
2.1 Installation
Mount the crimping machine on a solid foundation, place
a rubber mat between the machine and foundation to
reduce vibration and stabilize the machine.
The diagram to the left illustrates the footprint
dimensions of the machine. Secure the machine to the
foundation with four M8 bolts.
The machine should be mounted so that the crimping
dies are at the approximate eye level of a seated
operator.
CAUTION
Ensure that the belt cover of the crimping machine does
not overhang the edge of the mounting surface.
2.2 Transporting
Always mount the handles supplied with the toolbox to
move the machine (as shown in the photograph on the
left).
The machine should always be transported by placing
the lifting handles onto the arms of a fork-lift truck.
DO NOT ATTEMPT TO LIFT MANUALLY.
5
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Step 3
3. PREPARING FOR OPERATION
Place the applicator on the base-plate of the crimping
machine. Pull up the applicator ram whilst simultaneously pushing the feed lever in the direction of the
arrow shown in the photograph below, so that the collar
on the shank slides into the groove on the press ram.
Then push the applicator fully back into the press.
3.1 Mounting the Reel Hanger
Due to packing considerations, when you receive the
machine the reel hanger is not mounted on the machine.
Assemble the reel hanger then mount it on the machine
as illustrated below.
CAUTION
ENSURE THAT THE SHANK IS CORRECTLY
LOCATED IN THE RAM. THERE IS A DANGER OF
MAJOR TOOLING DAMAGE IF THE TOOLING IS NOT
LOCATED CORRECTLY (AS IN THE PHOTOGRAPH
BELOW).
3.2 Mounting the applicator (All types)
Step 1
Loosen bolts A & B with a 5mm hexagon wrench
supplied with the tool-kit.
Step 4
Step 2
Securely fasten the clamps with the 5 mm hexagon key,
and visually check that the tooling is mounted correctly.
Remove the protective rubber collar from under the dials
on the applicator ram.
6
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
3.3 Mounting the Terminal Reel
Mounting the MKS-L or MKS-LS
Applicator
Mount the terminal reel to the reel hanger so that the
terminal barrels are facing the reel guide, then feed the
terminals through the terminal guide to the applicator.
Step 1
Rotate the wing bolt clockwise to raise the pressure
plate. Feed the terminal strip between the guide rails.
Mounting the MK-L Applicator
Step 2
Step 1
Place the first terminal in position so that the terminal is
centralised over the anvil. Rotate the wing bolt counterclockwise to lower the pressure plate so that pressure is
applied to the terminal.
Push down the tension lever and engage the hook with
the feed plate so that the pressure pad rises. Feed the
terminal strip between the guide rails.
Step 2
Place the first terminal at the correct crimping position.
Release the hook from the feed plate to allow the
pressure pad to apply pressure on the strip.
7
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Illustration of Terminal reels mounted on the AP-K2N Crimping Machine
MK-L
MKS-L
Step 3
Select the appropriate side guard (JST UK-4), and mount
onto the side guard support bracket (JST UK-9), using
the countersunk screws supplied.
3.4 Mounting the safety guard
For reasons of safety and to comply with legislation,
safety guards must always be mounted to the crimping
machine. The above photographs illustrate the AP-K2N
crimping machine with the safety guards fitted.
The following photographs illustrate the different types of
guards available for the range of JST applicators.
WARNING
AN AUTHORISED COMPETENT PERSON
MUST ONLY CARRY OUT THE
FOLLOWING OPERATIONS.
When using the MK-L Applicator.
Step 1
Secure the fabricated steel guard (JST UK-7), onto the
Applicator using the cap head socket screws supplied.
Step 4
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilising
these screws.
Step 2
Secure the die guard (JST UK-1), onto the applicator
using the cap head socket screws supplied.
Step 5
Adjust the side guard support to achieve the best
relationship between guard and applicator.
8
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Step 6
Tighten the screws and check that the guards are
correctly and securely fitted.
Step 4
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilizing
these screws.
When using the MKS-L Applicator
Step 5
Adjust the side guard support to achieve the best
relationship between guard and applicator.
Step 1
Secure the fabricated steel guard (JST UK-7), to the
applicator using the cap head socket screws supplied.
Step 2
Secure the die guard (JST UK-6), onto the applicator
using the cap head socket screws supplied.
Step 6
Tighten the screws and check that the guards are
correctly and securely fitted.
Step 3
Select the appropriate side guard (JST UK-3), and mount
onto the side guard support bracket (JST UK-9), using
the countersunk screws provided.
9
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
When using the MKS-L Applicator for SPC or
PSL splices
Step 4
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilizing
these screws.
Step 2
Secure the fabricated steel guard (JST UK-135), onto the
side face of the applicator using the cap head screws
supplied.
Step 5
Adjust the side guard support bracket to achieve the best
relationship between guard and applicator.
Step 3
Select the appropriate side guard (JST UK-3), and mount
onto the side guard support bracket (JST UK-9), using
the countersunk screws supplied..
Step 6
Tighten the screws and check that the guards are
correctly and securely fitted.
Step 1
Secure the fabricated steel guard (JST UK-17), to the
applicator using the cap head screws supplied.
10
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
When using the MKF-L Applicator
Step 4
Adjust the side guard support bracket to achieve the best
relationship between guard and applicator.
Step 1
Secure the fabricated steel guard (JST UK-35), to the
applicator using the cap head screw supplied.
Step 2
Select the appropriate side guard (JST UK-95), and
mount onto the side guard support bracket (JST UK-9),
using the countersunk screws supplied.
Step 5
Tighten the screws and check that the guards are
correctly and securely fitted.
IMPORTANT
If the safety guards become damaged or worn
they must be replaced immediately.
Please contact the JST Technical Department
for replacement guards.
Step 3
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilizing
these screws.
11
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
4. CONTROL BOX CONFIGURATION
7. Operation Light Switch (Ope. Light)
This switch controls the Worklamp. Press it to the right to
turn the light on, and to the left to turn it off.
The lamp-bulb is rated at 40 Watts and is of the ‘Rough
Service’ type. Do not exceed 40 Watts because the
surface temperature of the worklamp exceeds the
maximum recommended temperature.
1. Counter
Counts the number of crimped terminations. Reset the
counter to 0 to begin counting operations.
2. Reset Push-button
Press this button to reset the counter (resets the counter
to 0)
1. COUNTER
3. Function Indicator Lamps
2. RESET
• Rear Cover
The rear cover indicator lamp is lit when the belt-cover
is open. Whilst this lamp is lit, the motor does not
operate even if the Power On push-button is pushed.
3. FUNCTION
INDICATOR LAMPS
CAUTION
DO NOT OPEN THE BELT COVER WHILST MOTOR IS
RUNNING, BECAUSE THE FLYWHEEL CONTINUES
TO ROTATE FOR A FEW SECONDS AFTER THE
MOTOR IS TURNED OFF DUE TO INERTIA STORED
IN THE FLYWHEEL.
4. POWER ON
PUSH-BUTTON (GREEN)
• Auto Power-Off
When the crimping operation stops for a period of
approximately 3 minutes or more, for example when
you unintentionally leave the motor running after
finishing work or temporarily stop the operation,
the motor automatically stops and the Auto Poweroff indicator lamp illuminates.
6. CIRCUIT PROTECTOR
PUSH-BUTTON
5. POWER OFF
PUSH-BUTTON (RED)
7. OPERATION LAMP
SWITCH
If the Rear Cover indicator illuminates, close the cover
and press the Power On push-button to restart. If the
Auto Power Off indicator illuminates, just press the
Power On push-button to restart.
4. Power On Push-button (green Indicator
Lamp)
Press this button to turn on the motor. The green
indicator lamp illuminates and stays lit whilst the motor is
running.
5. Power Off Push-button (Red Indicator
Lamp)
Press this button to turn off the motor. The red Power Off
indicator lamp illuminates.
6. Circuit Protector Push-button (Thermal
Overload device)
When the crimping machine is overloaded, the Circuit
Protector push-button ‘pops out’, and the motor stops.
Wait for at least one minute, press the Circuit Protector
Push-button in, then press the Power On push-button.
Contact the JST Service Department if you think that the
Circuit Protector is activated too often because the press
may require attention.
12
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Step 3
Place the hand-crank supplied in the press tool-kit on the
end of the main shaft and rotate in a counter-clockwise
direction to manually cycle the press through one
revolution. The ram moves up and down one stroke and
crimps the terminal.
5. OPERATION
WARNING
Disconnect the press from the power supply
before operating by hand. Operations by hand
whilst guards are removed must only be
performed by authorized competent persons.
5.1 Manual Operation
CAUTION
When using an applicator for the first time after fitting it in
the press, or whenever a die-part is replaced or the
applicator is adjusted, ensure that the press is manually
cycled at least one revolution. This is a very important
operation to ensure that the terminals are crimped
correctly and it also allows a degree of ‘feel’ through the
crank handle which prevents major tooling damage from
occurring if the die-parts have been installed incorrectly.
Step 1
Remove the cap head socket screws from the ram cover
using the hexagon key supplied with the tool-kit, and
open the belt cover.
Step 4
Remove the hand-crank, close the belt cover and
replace the cap head socket screw in the catch and
tighten with the hexagon key.
Step 2
Manually operate the solenoid by pushing the clutch
lever in a downward direction until the clutch ‘clicks’.
CAUTION Ensure that hand-crank is rotated through one complete revolution (until it physically stops).
If the press is left part-way through a cycle it will try to complete the cycle when the motor is turned on
and this action could result in damage being caused to the tooling.
13
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
5.2 OPERATION
Step 1
Connect the power supply cable and the foot-switch
cable to the control box using the screw in connectors.
Connect the power supply cable to the mains supply and
switch on the press.
Step 4
Check that neither of the function indicators is
illuminated, then press the Power On push-button
(green). The motor starts running.
NOTE: If a malfunction indicator is illuminated the motor
will not start even if you press the Power On push-button.
CAUTION
Ensure that the power supply cable is routed from the
press safely and does not become trapped or chafed by
any part of the crimping machine.
ON
Step 5
Position a wire over the terminal and press the footswitch once to activate it. The terminal is crimped and
the next terminal is indexed along over the anvils ready
for the next operation.
Step 2
Press the Ope. Light to the right to turn on the Operation
Light.
Step 6
When you finish using the press, turn off the Work-lamp
and press the Power Off push-button.
Step 3
To count the number of crimped terminations, press the
Reset push-button to set the counter display to 0.
OFF
CAUTION
If any problems occur during operations, immediately press the Power Off push-button and investigate the reason
If the problem requires the removal of safety guards, contact a person authorised to remove the guards. ON NO
ACCOUNT REMOVE SAFETY GUARDS IF YOU ARE NOT AUTHORISED TO DO SO.
14
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
6. APPLICATOR ADJUSTMENT
6.1 Terminal Feed Position Adjustment.
CAUTION
The following adjustments require the removal
of the safety guards and must only be carried
out by authorized competent persons.
There is a risk of serious crushing injury in
tooling exposed by the removal of the safety
guards . Ensure that fingers are kept away
from the moving parts of the applicator.
SCREW
COLLAR
When using the MK-L Applicator
Adjust the terminal feed position to adjust the terminal
crimping position. Before making this adjustment be sure
that the applicator is mounted in the crimping machine
correctly and the press ram is at Top Dead Centre.
Loosen the 5mm cap head socket screw and the knurled
collar using a small length of silver steel or similar, as
indicated on the photograph.
With the aid of the silver steel or a flat ended screwdriver rotate the adjustment shaft so that the feed-finger
places the terminal in the correct position for crimping.
Rotate the shaft counter-clockwise to move the terminal
forward, and clock-wise to move it backwards.
When the adjustments are completed, tighten the
knurled collar first followed by the cap screw.
Rotate the press through one revolution manually (see
page 10), and check the resultant crimped terminal. If the
appearance of the terminal is not correct repeat the
above adjustment operation and check again.
When a satisfactory result is achieved, replace the
guards, connect the crimping machine to the power
supply and recommence the crimping operation.
When using the MKS-L Applicator
Adjust the terminal feed position to adjust the terminal
crimping position. Before making this adjustment be sure
that the applicator is mounted in the crimping machine
correctly and the press ram is at Top Dead Centre.
SCREW
COLLAR
To position a terminal at the centre of the die, follow the
procedure below.
Loosen the 5mm cap head socket screw and the knurled
collar using a small length of silver steel or similar, as
indicated on the photograph.
With the aid of the silver steel or a flat ended screwdriver rotate the adjustment shaft so that the feed-finger
places the terminal in the correct position for crimping.
Rotate the shaft counter-clockwise to move the terminal
to the right (forwards), and clock-wise to move it to the
left (backwards).
When the adjustments are completed, tighten the
knurled collar first followed by the cap screw.
Rotate the press through one revolution manually (see
page 10), and check the resultant crimped terminal. If the
appearance of the terminal is not correct repeat the
above adjustment operation and check again.
When a satisfactory result is achieved, replace the
guards, connect the crimping machine to the power
supply and recommence the crimping operation.
15
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Slot-head adjustment screws
6.2 Bell Mouth Adjustment
When using the MK-L Applicator
Adjust the terminal feed position with reference to the
bell-mouth position. Refer to section 6.1
When using the MKS-L Applicator (old type)
Move the entire feed-plate to obtain the desired bellmouth crimp. First, loosen the feed-finger retaining screw
in the feed-finger holder. Next, loosen the two cap head
socket screws in the slots on the base of the applicator
(see photograph).
With the aid of a flat ended screwdriver, rotate the
adjusting screw in the front of the adjustment carriage,
turn the screw clockwise to increase the bell-mouth
(move the guide rails towards the front of the press), and
counter-clockwise to decrease the bell-mouth (move the
guide rails towards the back of the press).
Re-tighten the adjustment screws on the base of the
applicator, centralize the feed-finger in the slot in the
guide rail and tighten the screw.
Feed-finger screw
Adjustment screw
Check the bell-mouth on the resultant crimp and readjust if necessary.
When using the MKS-L Applicator (new type)
Move the entire feed-plate to obtain the desired bellmouth crimp. First, loosen the feed-finger retaining
screw in the feed-finger holder. Next, loosen the two
hexagon-headed bolts situated on the front of the
adjustment carriage just above the top surface of the
applicator base-plate.
With the aid of a 5mm hexagon key, rotate the screw in
the front of the adjustment carriage, turn the screw clockwise to decrease the bell-mouth (move the guide rails
towards the back of the press), and counter-clockwise to
increase the bell-mouth (move the guide rails towards
the front of the press).
Hexagon nuts
Re-tighten the adjustment bolts, centralize the feedfinger in the slot in the guide rail and tighten the screw.
Check the resultant crimp and re-adjust if necessary.
There is a crimping manual available from the JST
Technical Department detailing the points to inspect on a
crimped terminal to achieve results as per our
specifications.
A copy is issued with every AP-K2N Crimping machine
supplied to a customer but please contact JST if you
require further copies.
Adjustment screw
16
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
6.3 Feed-finger travel adjustment
INSULATION CRIMP ADJUSTING DIAL
Applicators are assembled and adjusted prior to
despatch from JST and will not require adjustment by
customers. Please contact JST Technical Services
Department if you consider there is a problem with the
Pitch setting adjustment.
CONDUCTOR CRIMP ADJUSTING DIAL
6.4 Crimp Height adjustment
The applicator has two dials to adjust the insulation and
wire crimp-height. The upper dial, marked with letters
A - H, is for the wire (conductor), crimp-height.
The lower dial, marked with numbers 1 - 8, is for the
insulation crimp height.
JST do not advise pad settings for wire sizes, as is the
practice of some manufacturers.
We believe that the best method to adopt is to specify
crimp-heights and adjust the dials until the desired crimpheight is achieved.
º Wire crimp-height (conductor) adjustment.
Setting the upper dial to graduation A produces the
tightest crimp-height (lowest), and graduation H the
least tight (highest). The crimp height alters by
approximately 0.05mm per graduation, so a total
range of adjustment of 0.40mm is attainable.
º Insulation crimp-height adjustment.
Setting the lower dial to graduation 1 produces the
tightest crimp-height (lowest), and graduation 8
the least tight (highest). The crimp-height alters by
approximately 0.10mm per graduation, so a total
range of 0.80mm is attainable.
We do not state insulation crimp-heights due to the
large variation of insulation types available. The
insulation should be set as per instructed in the JST
Crimping Manual supplied with the AP-K2N crimping
machine. If you require further copies, please contact
the JST Technical Services Department.
MK-L
MK-L
INSULATION CRIMP ADJUSTING DIAL
CONDUCTOR CRIMP ADJUSTING DIAL
CAUTION
When initially installing the applicator in the
press, ensure that the dials are set at H - 8 to
avoid the possibility of tooling damage.
Always check the crimp-height of the terminal by use of a
Crimp-height Micrometer because they are designed
specifically for the purpose and indicate the true crimpheight. If you require details for the supply of a crimpheight micrometer please contact JST Technical
Services Department.
If the applicator is not capable of achieving the desired
crimp-height by adjusting the dials, please contact the
JST Technical Services Department, because there is a
range of blocks available to alter the range of crimp
heights available. If you specify the blocks currently
installed in your applicator (see ‘Exploded view’ supplied
with applicator), we can advise you of the part no of the
replacement blocks necessary to achieve the desired
crimp-height.
Do not adjust the crimp-height by altering the shut-height
of the AP-K2N press, because it is factory set and should
only require occasional adjustment when serviced by the
JST Service Engineer.
MKS-L
17
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
.5 Die Part Replacement
The crimping dies are consumable parts. When a die
part becomes worn and requires replacement, check the
part number engraved on the die part, or consult the
‘exploded view’ drawing supplied with every applicator
and order a new part from JST technical Services
Department.
CAM
If you consider that the replacement process is too
difficult, or the tooling has sustained damage, please
contact JST to either send back the tooling for repair or
alternatively a JST Service Engineer can visit your
company to repair the tool on site.
6.6 Lubrication of Applicator
Periodically lubricate the surfaces indicated on the
photographs with grease. A general purpose grease
obtainable from Garages or car accessory shops is
suitable.
Remove the ram from the applicator body and apply the
grease to the cam surface.
CAM-ROLLER
Apply grease to the surface of the cam-roller.
APPLY GREASE HERE
Apply grease to the four faces of the applicator ram.
CAUTION
Apply grease sparingly because excess grease
attracts dirt and scrap insulation etc.
18
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
MAIN SHAFT BEARING GREASING LOCATION
7. CRIMPING MACHINE
MAINTENANCE
CAUTION
Disconnect the Power Cable from the mains
supply before carrying out any maintenance
operations on the Crimping Press.
7.1 Lubrication
MAIN SHAFT BEARING
Lightly grease the main-shaft bearing once a year using
a general purpose grease, eg Castrol LM.
RAM SECTION
Remove the cap head socket screws from the ram cover
and add a few drops of machine oil to the felt pads in the
three oiling holes once a week.
RAM SECTION OILING LOCATIONS
CLUTCH SECTION
Remove the cap head socket screws from the belt-cover
catch and open the cover.
Add a few drops of oil to the oiling points indicated on the
photograph.
CLUTCH SECTION OILING LOCATIONS
NOTE: The frequency of lubrication is dependant on the
use of the machine. Do not apply excessive lubrication
because the oil may drip through onto the applicator
and contaminate the terminals.
ROLLER CLUTCH
Step 1
Slowly rotate the fly-wheel whilst pulling the V-belts to
the side to remove them.
CAUTION
ENSURE THAT FINGERS DO NOT BECOME
TRAPPED BETWEEN THE V-BELT AND THE
FLY-WHEEL
Step 2
With the aid of a pair of internal circlip pliers, remove the
circlip retaining the fly-wheel.
19
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Step 3
Firmly grip the fly-wheel on both sides and pull off the
end of the shaft. There are seven ‘stick rollers’ inside the
clutch and they may fall out when the fly-wheel is pulled
off the shaft, so take care not to lose any.
Step 4
Remove any traces of old grease from all components of
the clutch mechanism and sparingly lubricate all the
clutch components with fresh grease.
Specified Grease: Multemp PS no.1 manufactured by Kyodo Yushi Co Ltd.
Do not use general purpose grease because
the clutch will not function correctly.
Contact JST Technical Services Department
for details of grease stockists.
Step 5
Assemble the clutch ensuring that the clutch lever is
engaged correctly with the clutch cam, as in photo A.
PHOTO A
If the clutch is assembled as in photo B, it will not be
possible to re-mount the flywheel onto the shaft.
PHOTO B
`
20
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
7.2 Inspection and Repair
RAM STABILITY
Approximately every six months physically check that the
ram is not loose.
To check the ram, remove the screws from the catch and
open the cover.
Grip the ram firmly and try to move the ram from side to
side. It is also possible to detect whether the ram is loose
by the noise it makes when crimping, and also the
measured crimp height of the terminal may become
unstable.
º Adjustment Procedure
Step 1
Remove the two dome-nuts from the side wall of the
ram.
Step 2
Loosen the three cap head screws on the right hand
side of the adjustable ram guide.
Step 3
Fasten the grub screws on the ram guide finger-tight
so that you can manually move the ram up and down
by hand, but it does not drop under its own weight.
Next, check that the ram does not wobble and that it
moves smoothly.
Make a final check check that the ram is stable and the
screws are secure. Replace cap head screws in ram
cover.
21
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
º Positioning of the Solenoid Bracket
Once a year remove the cap head screws from the
catch on the belt cover and open the cover.
Check that the clearance is correct as shown on the
photograph.
The clearance should be 6 - 7mm, if it varies from this
dimension adjust the bracket in the following manner:-
Clearance
6 - 7mm
Loosen the two cap head screws holding the bracket
to the press casting and move the solenoid up or down
until the correct clearance is obtained.
Tighten the cap head screws on the retaining bracket,
close the belt cover and replace the socket screws in
the bracket.
8. FAULT-FINDING
→
The Motor
runs
→
Press the FootSwitch once
→
→
→
1. The Power Cord
is disconnected
1.The Ram moves 1
cycle (up and down)
2. The Ram does
not move
→
→
2. The power cord is
broken
→
Press the
Power On
push-button
3. A solder joint on
the Power Cord
metal plug is bad
→
4. The Thermal
Trip is activated
→
The Motor
does not run
3. The Ram ‘clunks’
several times
5. The Clutch is
engaged
6. Emergency Stop
switch is activated
→
4. The Ram ‘clunks’
many times
→
7. Belt Cover is open
→
22
5. The Ram moves
too slowly, or
stops at Bottom
Dead Centre
→
OK
1. The connecting pin
is broken
2. A solder joint on the
foot-switch metal plug
is bad
3. The foot-switch cord
is damaged
4. The clutch spring
has become slack
or has broken
5. control box is faulty
1. A spring has become
slack
2. The clutch lever or
stopper is worn out
3. The solenoid is
defective
4. The control box is
defective
1. The solenoid is
defective
2. A spring has become
slack
3. The control box is
defective
1. A stick roller is worn
2. Grease is applied
incorrectly, or the
wrong grease is
applied to the roller
clutch
3. The applicator is
seized
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
1. The Motor does not run
(1) The Power cord is disconnected
reconnect the power cord.
(2) The Power cord is damaged
replace the power cord
(3) A solder joint on the Power Cord metal plug is
bad
Resolder the joint
(4) The Thermal Trip is activated
Press in the thermal trip push-button. If the thermal
trip has activated, wait one minute or more before
resetting. Consult the JST Technical Department if
the thermal trip activates frequently.
(5) The Emergency Stop switch is activated
Reset by turning the switch clockwise
(6) The Belt Cover is open
Close the belt cover and re-secure the catch with
the cap head socket screws.
2. The Ram does not move
(1) The Connecting Pin is broken
Replace the connecting pin with a new one.
Connecting pin
AP-K2N CRIMPING MACHINE
JST
23
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
(2) A solder joint on the Foot-Switch metal plug is
bad
Resolder the joint
(3) The Foot-Switch cord is damaged
Replace the Foot-Switch cord with a new one.
Connect the micro-switch to the plug as per the
illustration.
(4) The Clutch Spring has become slack or has
broken
Replace the spring with a new one.
(5) The Control Box is faulty
The Control Box requires repair. Contact the JST
Technical Services Department for assistance.
3. The Ram ‘clunks’ several times
(1) A Spring has become slack
Replace the spring with a new one.
(2) The Clutch Lever or Stopper is worn out
Replace parts with new ones.
24
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
(3) The Solenoid is defective
Adjust the relationship between the solenoid piston
and cylinder by moving the solenoid cylinder back
or forth on the solenoid bracket.
(4) The Control Box is defective
The control box requires repair. Contact the JST
Technical Services Department for assistance.
4. The Ram ‘clunks’ many times
(1) The Solenoid is defective
Refer to 3-(3) above.
(2) A Spring has become slack
Replace the spring with a new one, see 3-(1).
(3) The Control Box is defective
The control requires repair. Contact JST Technical
Services Department for assistance.
5. The Ram moves too slowly, or stops at
Bottom Dead Centre
(1) A Stick Roller is worn out
Replace the stick rollers with new ones. Always
replace the rollers as a set of seven.
Oversize rollers are available from JST to extend
the service life of the clutch. Please contact the
Technical Services Department for details.
(2) Grease is applied incorrectly, or the wrong
grade of grease has been used
Clean the clutch and reapply the correct grade of
grease. See section 7 for details of grease specification.
(3) The Applicator is seized
Contact the JST Technical Services Department for
assistance.
(4) Part of the Clutch assembly is missing
Check that all the Stick Rollers are assembled.
25
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
9. EXPLODED VIEWS AND PARTS LISTS
AP-K2N Crimping Machine
26
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
27
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
28
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Parts list for the applicator MK-L
No.
101
102
Part Name
Part No.
No.
Part Name
Part No.
Body
MA02-101
133
Hex. Nut M4 type-1
Slider
MA02-210
134
Stroke adj. Shaft
MA01-331
MA01-332
103
Copper bar (3.8 x2mm)
135
Stroke adj. Bearing
104
Positioning spring
MA01-214
136
Stroke adj. Plate
MA02-330
105
Positioning pin
MA01-213
137
Hex. Nut
MA01-333
106
Insulation disk
MA01-215
138
Stroke adj. Screw
MA01-334
107
Spring
MA01-216
139
Hook
MA01-475
108
Steel ball
140
Hook pin
MA01-476
109
Wire disk
141
Release lever
MA01-473
110
Shank
MA01-217
142
Release lever pin
MA01-474
111
Cam
MA02-335
143
Pressure pad pin
MA01-472
112
Spring cap
MA01-477
144
Pressure pad
MA01-470
113
Spring block
MA01-479
145
Feed plate
114
Spring
MA01-480
146
Spring anchor
MA01-350
115
Support pin
MA01-343
147
Die block
MA01-105
116
Stripper hanger
MA02-481
148
Die plate
MA02-104
117
Plate (L)
MA02-102
149
Side block
MA02-107
118
Plate (R)
MA02-103
150
Wire block
119
Feed shaft
MA01-338
151
Insulation block
120
Ring nut
MA01-341
152
Block ring
121
E-shaped ret. ring (6 )
153
Crimper (A)
122
Lever block
MA01-340
154
Crimper (B)
123
Adj. Bolt
MA01-339
155
Die holder ring
124
Cam roller
MA01-308A
156
Stripper
125
Cam roller shaft
MA01-337A
157
Guide plate (R)
126
Feed lever (A)
MA01-342
158
Guide plate (L)
127
Feed lever pin
MA01-344
159
Shear blade anvil (A)
128
Feed lever (B)
MA01-345
160
Shear blade anvil (B)
129
Feed finger pin
MA01-347
161
Crimper anvil (A)
130
Feed finger spring
MA01-348
162
Crimper anvil (B)
131
Feed finger
163
Shear blade
132
Returning spring
164
Spacer
MA01-211
MA01-349
29
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
MA01-225
30
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Parts list for the applicator MKS-L
Part No.
No.
Body
MA03-101
135
Stroke adj. Bearing
MA01-332
102
Slider
MA03-210
136
Stroke adj. Plate
MA03-330
103
Copper bar (3.8 x2mm)
137
Hex. Nut
MA01-333
104
Positioning spring
138
Stroke adj. Screw
MA01-334
105
Positioning pin
MA01-213
139
Spring anchor pin
MA03-352
106
Insulation disk
MA01-215
140
Spring anchor
MA03-350
107
Spring
MA01-216
141
Pressure plate
108
Steel ball (3 )
142
Pressure spring
109
Wire disk
MA01-211
143
Returning spring
110
Shank
MA01-217
144
Feed finger
111
Cam
MA03-335
145
Feed finger holder
112
Die block
MA03-105
146
Stripper bracket
113
Die plate
MA03-104
147
Stripper
114
Side block
MA03-107
148
Stripper screw
115
Support pin
MA01-343
116
Feed plate base
MA03-106
150
Guide plate (R)
117
Adj. Plate
MA03-108
151
Guide plate (L)
118
Adj. Screw
MA03-109
152
Feed plate
119
Feed shaft
MA01-338
153
Spacer
120
Ring nut
MA01-341
154
Crimper (A)
121
E-shaped ret ring (6 )
155
Spacer
122
Lever block
MA01-340
156
Crimper (B)
123
Adj. Screw
MA03-339
157
Punch
124
Cam roller
MA01-308A
158
Shear blade
125
Cam roller shaft
MA01-337A
159
Shear blade spring
126
Feed lever (A)
MA01-342
160
Shear blade supporter
127
Feed lever pin
MA01-344
161
Shear blade base
128
Feed lever (B)
MA01-345
162
Crimper anvil (B)
129
Feed finger pin
MA01-347
163
Crimper anvil (A)
130
Feed finger spring
MA01-348
164
Spacer
131
Plate (L)
MA03-102
165
Scrap cover
132
Plate (R)
MA03-103
166
Wire block
133
Hex. Nut (M4, type-1)
167
Insulation block
134
Stroke adj. shaft
168
Block ring
No.
101
Part Name
MA01-214
MA01-331
31
Part Name
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Part No.
MA03-349
MA01-225
32
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Parts list for the applicator MKF-L
Part Name
Part No.
No.
No.
101
Body
NF-2101
138
102
Slider
NF-3118
Part Name
Part No.
Stroke adj. Screw
MA01-334
139
Punch
NF-4122
NF-3149
103
Copper bar (3.8 x2mm)
140
Die plate
104
Positioning spring
MA01-214
141
Bracket
NF-4133
105
Positioning pin
MA01-213
142
Spring post
NF-4159
106
Insulation disk
NF-4121
143
Returning spring
MA03-349
107
Spring
MA01-216
144
Spring
NF-4126N
108
Steel ball (3 )
109
Wire disk
MA01-211
146
Keep plate
NF-4125
110
Shank
MA01-217
147
Crimper anvil base
NF-4105
111
Cam
NF-4168
148
Feed plate
NF-2129*
112
Guide shoe
NF-4140
149
Support pin
NF-4163
113
Tension spring
NF-4117
150
Needle bearing K12x15x13
NF-B164
114
Fulcrum bolt
NF-4115
151
Collar
NF-4154
115
Support pin
MA01-343
152
E-shaped ret.ring (9 )
116
Spring post
NF-4116
153
Guide block
NF-4165
117
Plate (L)
NF-4114
154
Holder block
NF-4147
118
Plate (R)
MA02-103
155
Pressure plate
119
Feed shaft
MA01-338
156
Guide plate (R)
120
Ring nut
MA01-341
157
Guide plate (L)
121
E-shaped ret.ring (6 )
158
Pin
122
Lever block
MA01-340
159
Feed finger
123
Adj. Bolt
MA01-339
160
Shear blade
124
Cam roller
MA01-308A
161
Shear blade anvil (A)
125
Cam roller shaft
MA01-337A
162
Shear blade anvil (B)
126
Feed lever (A)
MA01-342
163
Tension spring
NF-4110
127
Feed lever pin
MA01-344
164
Spring post
NF-4108
128
Feed lever (B)
NF-4138
165
Spring post
NF-4111
129
Feed finger pin
MA01-347
166
Wire block
130
Feed finger spring
MA01-348
167
Insulation block
131
Feed adj. Plate
NF-4137
168
Block ring
132
Spring post
NF-4139
169
Crimper (A)
133
Hex. Nut (m4,type-1)
170
Crimper (B)
134
Stroke adj. Shaft
MA01-331
171
Die holder ring
135
Stroke adj. Bearing
MA01-332
172
Crimper anvil (A)
136
Hook
NF-4113
173
Crimper anvil (B)
137
Hex. Nut
MA01-333
174
Finger holder
33
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
NF-4109
MA01-225
34
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Parts list for the applicator MKS-LS
Part No.
No.
Part Name
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
Body
Plate
Slider
Positioning spring
Positioning pin
Block ring
Cam
Shank
Wire disk
Insulation disk
Die plate
Feed plate base
Die block
Retaining bolt
Feed shaft
Cam roller
Pin
Feed lever
Feed lever pin
Adj. Screw
Feed finger spring
Feed finger pin
Hook
Name plate
Protection rubber
Hex. Socket head bolt (M6x18)
Key (6x6x25 round ends)
Spring washer (5)
Button head screw (M5x12)
Hex. Socket head bolt (M5x18)
Hex. Socket head bolt (M5x10)
Hex. Socket head bolt (M4x8)
Pin (2x4)
Hex. Socket head bolt (M3x6)
Hex. Socket head bolt (M5x50)
Rivet (1.5 x5)
Hex. Nut (M6, type-1)
Spring washer (6)
Compressed coil spring
Tension spring
Ball plunger
Hex. Socket head screw (M4x10)
35
LS-2301
LS-4302
LS-3303
MA01-214
MA01-213
MA01-223
LS-4307
LS-4308
LS-4309
LS-4310
LS-3311
LS-4312
LS-4313
LS-4314
LS-4315
LS-4316
LS-4317
LS-4318
LS-4319
112-223
MA01-348
LS-4322
LS-4323
LS-4324
LS-4325
LS-B331
LS-B343
LS-B344
LS-B345
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Notes:
36
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
Offices World-Wide
HEAD OFFICE: J.S.T. MFG. CO., LTD.
2-6-8, Shigino-nishi, Joto-ku, Osaka, 536-0014 JAPAN.
Phone: (06) 6968-6855 / Int'
l 81-6-6968-6855Fax: (06) 6964-2085 / Int'
l 81-6-6964-2085
Tel:
U.K.
44 \ 0 \ 1986 87 4131
Tel:
32 \ 0 \ 1660 0525
Fax:
32 \ 0 \ 1660 5877
Tel:
49 \ 0 \ 7181 4007 0
Fax:
49 \ 0 \ 7181 4007 21
Belgium
Fax:
44 \ 0 \ 1986 87 4276
Tel:
33 \ 3 \ 2672 4503
France
Germany
Fax:
33 \ 3 \ 2672 1088
Italy
Tel:
Fax:
39 \ 02 \ 9390 0418
39 \ 02 \ 9390 0421
Spain
Tel:
Fax:
34 \ 93 \ 564 2120
34 \ 93 \ 564 8266
Singapore
Tel:
Fax:
65 \ 743 0405
65 \ 746 1787 [G4]
Thailand
Tel:
Fax:
66 \ 2 \ 693 2905
66 \ 2 \ 693 2906
Tel:
Fax:
Tel:
Fax:
60 \ 0 \ 3 755 4620
60 \ 0 \ 3 758 3802
60 \ 0 \ 4 226 7258
60 \ 0 \ 4 226 7269
Indonesia
#1
Indonesia
#2
Tel:
Fax:
Tel:
Fax:
62 \ 0 \ 7 7061 1685
62 \ 0 \ 7 7061 1684
62 \ 0 \ 21 575 0816
62 \ 0 \ 21 575 0803
Honk Kong
Tel:
Fax:
85 2 \ 2413 7979
85 2 \ 2411 1193
China
Tel:
Fax:
86 \ 21 5866 3418
86 \ 21 5866 3421
Korea
Tel:
Fax:
8 \ 0 \ 2 2527 3334/3335
8 \ 0 \ 2 2527 3336
Taiwan
Tel:
Fax:
886 \ 0 \ 2 2531 8500
886 \ 0 \ 2 2531 8485
U.S.A.
Tel:
Tel:
Fax:
1 \ 847 \ 473 1957
1 \ 800 947 1110 (toll free)
1 \ 847 \ 473 0144 [G4]
Australia
Tel:
Fax:
61 \ 0 \ 3 9877 6444
61 \ 0 \ 3 9877 6395
Malaysia
#1
Malaysia
#2
For full up to date address details go to: www.jst-mfg.com/e00com/e31com.html
In line with a policy of continual development JST reserves the right to change the specifications of the goods described
in this manual at any time and without prior notice.
37
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc