JST CMKS-L Operation Manual
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JST CMKS-L Operation Manual

Industry standard applicator
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CMKS-L
INDUSTRY STANDARD APPLICATOR
OPERATION
MANUAL
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS174-00
CMKS-L Manual.doc

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Summary of Contents for JST CMKS-L

  • Page 1 CMKS-L INDUSTRY STANDARD APPLICATOR OPERATION MANUAL H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS174-00 CMKS-L Manual.doc...
  • Page 2 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.

  • Page 3: Table Of Contents

    CMKS-L INDUSTRY STANDARD APPLICATOR CONTENTS Page Ram Slide Section................Ejector....................Upper Die Parts.................. Lower Die Parts.................. Feed Plate Base, Anvil (A) and (B)........Guide Plates, Feed Plate..............Terminal Feed Pitch................Pressure Pad Adjustment..............11 Terminal Feed Position..............Additional Information............... 13 Crimp Height..................

  • Page 4: Ejector

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 5: Upper Die Parts

    CMKS-L INDUSTRY STANDARD APPLICATOR 3. UPPER DIE PARTS 3.1 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.
  • Page 6 CMKS-L INDUSTRY STANDARD APPLICATOR (112) (108) (111) (109) (146) (148) (110) (113) (160) (119) (163) (107) (147) (159) (145) (144) H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS174-00 CMKS-L Manual.doc...

  • Page 7: Lower Die Parts

    CMKS-L INDUSTRY STANDARD APPLICATOR 4. LOWER DIE PARTS 4.1 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.
  • Page 8 CMKS-L INDUSTRY STANDARD APPLICATOR 5. Feed Plate Base 5.1 Assembling feed plate base. Feed plate base (106) Die Plate (104) IMPORTANT Ensure feed plate base moves freely back and forth within the relevant slot of the die plate. Feed plate base should be screwed into the main casting with relevant M5 screw surrounded by adjustment spring.
  • Page 9 CMKS-L INDUSTRY STANDARD APPLICATOR 6. GUIDE PLATE 6.1 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 the 2 x 5mm hexagon screws.

  • Page 10: Terminal Feed Pitch

    CMKS-L INDUSTRY STANDARD APPLICATOR 7. TERMINAL FEED PITCH 7.1 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.

  • Page 11: Pressure Pad Adjustment

    CMKS-L INDUSTRY STANDARD APPLICATOR 8. PRESSURE PAD 8.1 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 loosening the 2 x M5 locking nuts and either tightening or loosening the 2 x M5 adjustment screws as shown below.

  • Page 12: Terminal Feed Position

    CMKS-L INDUSTRY STANDARD APPLICATOR 9. TERMINAL FEED POSITION 9.1 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.

  • Page 13: Additional Information

    CMKS-L INDUSTRY STANDARD APPLICATOR 10. ADDITIONAL INFORMATION 10.1 Wire Stop / Stripper Depending on which terminal you are processing, a wire stop / stripper is sometimes fitted to the die spacer The purpose of this part is to position the wire correctly prior to crimping and remove the terminal from the crimp punches after the crimping process.

  • Page 14: Crimp Height

    CMKS-L INDUSTRY STANDARD APPLICATOR 11. CRIMP HEIGHT 11.1 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 only 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.
  • Page 15 CMKS-L INDUSTRY STANDARD APPLICATOR 12. Parts list for the applicator CMKS-L Part Name Part No. Part Name Part No. Body 4006-2001 132A Return spring 4006-P025 Plate (L) 4006-4002 Plate (R) 4006-4003 Die plate 4006-3004 Die block 4006-4005 Conductor punch Feed plate base...
  • Page 16 CMKS-L INDUSTRY STANDARD APPLICATOR 13. CMKS-L Applicator exploded view 132A H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS174-00 CMKS-L Manual.doc...
  • Page 17 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.
  • Page 18 CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 19: Crimping Specifications

    CMKS-L INDUSTRY STANDARD APPLICATOR 15. Crimping specifications CONTENTS Checks Before Crimping..............Stripping Wire Insulation..............Crimping................... 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.

  • Page 20: Checks Before Crimping

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 21: Stripping Wire Insulation

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 22: Crimping

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 23: Adjusting The Crimp Height (Ch)

    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.
  • Page 24 CMKS-L INDUSTRY STANDARD APPLICATOR 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.
  • Page 25 CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 26: Tensile Tests At The Crimped Section

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 27: All Conductors Must Be Crimped

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 28: The Terminal Must Be Cut At The Correct Position

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.

  • Page 29: The Wire Must Be Crimped At The Correct Position

    CMKS-L INDUSTRY STANDARD APPLICATOR 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).

  • Page 30: Check-Points For Correct Crimping

    CMKS-L INDUSTRY STANDARD APPLICATOR 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.
  • Page 31 CMKS-L INDUSTRY STANDARD APPLICATOR [Reference] It is best to make up the Crimping CheckList as shown below for convenient Checking. CRIMPING CHECK LIST Example Form Date Product Terminal Wire CH(A) CH(B) Tensile Appearance Worker Name Strength H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS174-00...

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