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Summary of Contents for JST CMK-R
- Page 1 CMK-R INDUSTRY STANDARD APPLICATOR OPERATION MANUAL H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS142-01 CMK-R 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.
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Page 3: Table Of Contents
CMK-R INDUSTRY STANDARD APPLICATOR CONTENTS Page Ram Slide Section................Shear Blade..................Stripper....................Upper Die Parts.................. Lower Die Parts.................. Alignment Of Shear Blade, Anvil (A) and (B)........Guide Plates, Feed Plate..............Terminal Feed Pitch................Pressure Pad Adjustment..............11 Terminal Feed Position.............. -
Page 4: Ram Slide Section
CMK-R 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: Shear Blade
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 6: Upper Die Parts
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 7: Lower Die Parts
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 8: Alignment Of Shear Blade, Anvil (A) And (B)
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 9: Guide Plates, Feed Plate
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 10: Terminal Feed Pitch
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 11: Pressure Pad Adjustment
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 12: Additional Information
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. - Page 13 CMK-R INDUSTRY STANDARD APPLICATOR 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.
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Page 14: Crimp Height
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 15: Cmk-R Parts List
CMK-R INDUSTRY STANDARD APPLICATOR 13. Parts list for the applicator CMK-R Part Name Part No. Part Name Part No. Body 4007-2001 Spring anchor 4007-4011 Plate (L) 4007-4002 133A Return spring MA01-349 Plate (R) 4007-4003 Pressure pad 4007-4012 Die plate 4007-3004... -
Page 16: Cmk-R Exploded Diagram
CMK-R INDUSTRY STANDARD APPLICATOR 14. CMK-R Applicator exploded view 133A H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Applicators and Die sets\TS142-01 CMK-R Manual.doc... -
Page 17: Preventive Maintenance
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 CMK-R INDUSTRY STANDARD APPLICATOR 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.
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Page 19: Crimping Specifications
CMK-R INDUSTRY STANDARD APPLICATOR 16. 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
CMK-R 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: Crimping
CMK-R INDUSTRY STANDARD APPLICATOR 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. -
Page 22: 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 23: Adjusting The Crimp Height Of The Insulation Barrel
CMK-R INDUSTRY STANDARD APPLICATOR * 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. - Page 24 CMK-R INDUSTRY STANDARD APPLICATOR Correct - The barrel edges firmly grip the insulation. Excessive crimping - The barrel edges cut into the strands. Checking for correct crimping: Following the items described below to check that the insulation barrel is correctly crimped.
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Page 25: Tensile Tests At The Crimped Section
CMK-R 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 26: All Conductors Must Be Crimped
CMK-R 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 27: The Terminal Barrel Must Be Properly Bell-Mouthed
CMK-R 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 28: The Wire Must Be Crimped At The Correct Position
CMK-R 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 29: Check-Points For Correct Crimping
CMK-R 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 30 CMK-R 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\TS142-01...
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