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CMKS-L Manual.doc

CMKS-L

INDUSTRY STANDARD APPLICATOR

OPERATION

MANUAL

Summary of Contents for CMKS-L

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

Page 2: ...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...

Page 3: ...Ram Slide Section 4 3 Ejector 4 4 Upper Die Parts 5 5 Lower Die Parts 7 6 Feed Plate Base 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 12 11 Additional Information 13 12 Crimp Height 14 13 CMKS L Parts List 15 14 CMKS L Exploded Diagram 16 15 Preventive maintenance 17 16 Crimping specifications 19 ...

Page 4: ... 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 P...

Page 5: ... these parts tighten them down with a 5mm hexagon screw and check that they are not clamped and move up and down freely 4 Punch spacer 147 5 Conductor punch 144 6 Insulation punch 145 7 A Spacer wire spring are sometimes fitted between the two punches 8 Punch ring spacer 163 9 Ejector 159 160 After you have fitted these parts tighten down with a 6mm hexagon screw and again check that they are not ...

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

Page 7: ... in the correct order as detailed below 1 Die Block 105 2 Die spacer 149 3 Conductor anvil 153 4 Insulation anvil 154 5 Shear Blade 150 151 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 ofnon ferrous metal...

Page 8: ...8 5 Feed Plate Base 5 1 Assembling feed plate base 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 Base should then be held lightly in place with two M5 screws Die Plate 104 Feed plate base 106 ...

Page 9: ...Block and secure tightly using the 2 x 5mm hexagon screws Now you can fit the 2 guide plates using the 4 x 4mm hexagon screws do not fully tighten the large guide plate screws Insert a strip of the terminals that are compatible with the die set in the applicator and ensure that the strip moves smoothly between the two guide rails Now the 2 x 4mm hexagon screws can be carefully tightened on the lar...

Page 10: ...f 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 7 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...

Page 11: ... 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 M5 adjustment Screws M5 Locking nuts Pressure Pad 161 Thumb Screw ...

Page 12: ...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 achieved the correct position carefully tighten the Ring nut 125 then the M5 screw Now you can place the applicator back into the press and careful...

Page 13: ...ove the terminal from the crimp punches after the crimping process CAUTION you must ensure that the stripper is set in a position behind the crimp anvils and punches so that they will not come into contact and cause damage to the tool 10 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 ...

Page 14: ...p 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 increment...

Page 15: ...Shear blade anvil 113 Block ring MA01 225 152 Scrap chute 114 Stroke adjustment plate MA03 330 153 Conductor anvil 115 Stroke adjustment shaft MA01 331 154 Insulation anvil 116 Stroke adjustment bearing MA01 332 155 Wire stop stripper 117 Stroke adjustment bearing nut MA01 333 156 Wire stop stripper bracket 118 Stroke adjustment screw MA01 334 157 Small Guide plate 119 Cam 4006 4011 158 Large Guid...

Page 16: ...plicators and Die sets TS174 00 CMKS L Manual doc 16 13 CMKS L Applicator exploded view 145 144 163 153 154 146 148 113 112 108 111 109 110 118 123 124 125 122 121 120 114 117 116 115 101 107 119 126 129 132A 132 130 164 128 103 102 106 105 104 157 158 166 127 155 156 149 150 151 152 159 160 161 162 147 165 ...

Page 17: ... 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 t...

Page 18: ...ling 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 cove...

Page 19: ...el 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 t...

Page 20: ...f 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 C...

Page 21: ...ge the wire conductors Bundle the stripped wires in paper to protect the wire strands from bending or fraying when transported 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...

Page 22: ...r s fingers cannot enter the crimping die area 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 Wo...

Page 23: ...ion 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 t...

Page 24: ...e 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 examples below Insufficient Crimping The wire insulation is loose and can be moved Correct The barrel edges firmly grip...

Page 25: ... 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 ...

Page 26: ...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...

Page 27: ...ors and Die sets TS174 00 CMKS L Manual doc 27 4 3 All conductors must be crimped Uncrimped conductors are not acceptable 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 Uncrimped conductors Bend Bend Deflection ...

Page 28: ...rectly 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 The mating part is deformed Excessive Cutting ...

Page 29: ...complete 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 Th...

Page 30: ... 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...

Page 31: ...erv Application tooling Applicators and Die sets TS174 00 CMKS L Manual doc 31 Reference It is best to make up the Crimping CheckList as shown below for convenient Checking CRIMPING CHECK LIST Date Product Name Terminal Wire CH A CH B Tensile Strength Appearance Worker Example Form ...

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