JST AP-K2 User manual

AP-K2 CRIMPING
MACHINE
OPERATION
MANUAL

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PREFACE
The AP-K2 semi-automatic crimping machine is easy to operate, and is suitable
for mass production of crimped harnesses with chain terminals.
Before using the AP-K2 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.

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CONTENTS
1.
Specifications
Page 4
1-1. Crimping machine specifications
Page 4
1-2. Applicator Specifications
Page 4
2.
Installing the machine
Page 5
2-1. Machine Installation
Page 5
3.
Machine preparation
Page 6
3-1. Mounting of the Reel hanger
Page 6
3-2. Mounting of the Applicator
Page 6
Prevention of tooling damage
Page 7
Prevention of terminal damage
Page 8
3-3. Mounting the Terminal reel
Page 9
3-4. Setting the counter
Page 10
3-5. Mounting the Safety guard
Page 10
4.
Operation
Page 11
4-1. Manual operation
Page 11
4-2. Inspection before operation
Page 12
4-3. Operation under power
Page 12
5.
Applicator
Page 13
5-1. Terminal feed position adjustment
Page 13
5-2. Bell mouth adjustment
Page 14
5-3. Feed-finger travel adjustment
Page 15
5-4. Crimp height adjustment
Page 15
5-5. Die part replacement
Page 16
5-6. Lubrication of Applicator
Page 16
6.
Maintenance
Page 17
6-1. Lubrication
Page 17
6-2. Inspection and repair
Page 19
6-3. Positioning the solenoid bracket
Page 20
7.
Fault finding
Page 21
Electrical circuit diagram
Page 25
8.
Exploded views and parts list
AP-K2 Crimping machine exploded view
Page 26
MK-L Applicator
Page 28
MKS-L Applicator
Page 30
MKF-L Applicator
Page 32
MKS-LS Applicator
Page 34

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1. SPECIFICATIONS
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
1.2 Applicator specifications
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
Models MK-L and MKF-L for end feeding
terminals, and models MKS-L and MKS-LS for
side feeding terminals. The crimping machine
utilises a quick-change system thus allowing quick
changeover times.
Model no: AP-K2
º External dimensions: 280mm Wide x
480mm Long x 560mm High
º Weight: 95 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
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. MKS-LS (for side feeding terminals)
º Weight 4.5 Kg
º Feed pitch 30mm max.
º Crimp height adjustment: Dial type

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2. INSTALLING 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 stabilise 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.

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3. MACHINE PREPARATION
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.
Step 1
Assemble the Reel hanger as shown in the photo
below.
Step 2
Mount the Reel hanger on the Crimping machine.
3.2 Mounting the Applicator
Step 1
Loosen bolts A and B with a 5mm hexagon
wrench supplied with the tool-kit.
Step 2
Remove the protective rubber collar from under the
dials on the applicator ram.
Step 3
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).
Step 4
Securely fasten the clamps with the 5mm hexagon
key, and visually check that the tooling is mounted
correctly.

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PREVENTION OF TOOLING DAMAGE.
1.
Place the rubber collar under the
ram head as shown in picture 1.
IMPORTANT.
Repeat this procedure every time
you remove an applicator from
the press.
Picture 1.
2.
DO NOT leave the applicator
without the rubber collar attached,
as shown in picture 2.
Picture 3.
Picture 2
.
3.
Picture 3, is a zoomed in view of
the punch and anvil when the
rubber collar is left off.
The two circled points are the
points of contact where the
damage will be caused.
Picture 3.

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PREVENTION OF TERMINAL DAMAGE.
1. Mount reel on reel holder attached to the
side of the press, as shown.
2. Adjust the collar; ensure that the collar is
adjusted so there is a light drag on the reel
prior to untying the reel.
3. Terminals are tied with wire, do not untie
before collar is fitted as the windings will
become loose, always re-tie after each
production run.
4. Make sure the reels are stored up on end in
the original box, do not lay the terminals on their
side as they can drop and get tangled.
CORRECT.
INCORRECT.

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3.3 Mounting the Terminal reel
Step 1
Mount the terminal reel to the reel hanger so
that the terminal barrels are facing the reel
guide.
Step 2
Feed the terminals through the terminal guide.
Mounting the MK-L applicator
Step 3
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 4
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.
Mounting the MKS-L applicator
Step 3
Rotate the wing bolt clockwise to raise the
pressure plate. Feed the terminal strip between
the guide rails.
Step 4
Place the first terminal in position so that the
terminal is centralised over the anvil. Rotate the
wing bolt counter- clockwise to lower the pressure
plate so that pressure is applied to the terminal.

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3-4. Setting the counter
The counter (5 digits) helps you to count the
number of crimped terminals processed.
Press the reset button to reset the counter to
zero.
3-5. Mounting the safety guard
There are many types of safety guards available, please consult JST for details.
A RELEVANT SET OF SAFETY GUARDS IS ALWAYS DESPATCHED WITH THE MACHINE