JST AP-K2N User manual

1
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
AP-K2N CRIMPING
MACHINE
OPERATION
MANUAL
This datasheet has been downloaded fromhttp://www.digchip.com at this page

2
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).

3
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

4
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
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
utilizes a quick change system thus allowing quick
change-over times.
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
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

5
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
2.2 Transporting
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.
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.

6
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
3. PREPARING FOR OPERATION
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.
3.2 Mounting the applicator (All types)
Step 1
Loosen bolts A & 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
Place the applicator on the base-plate of the crimping
machine. Pull up the applicator ram whilst simultan-
eously 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.
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 5 mm hexagon key,
and visually check that the tooling is mounted correctly.

7
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
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.
Mounting the MK-L Applicator
Step 1
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.
Mounting the MKS-L or MKS-LS
Applicator
Step 1
Rotate the wing bolt clockwise to raise the pressure
plate. Feed the terminal strip between the guide rails.
Step 2
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.

8
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
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 2
Secure the die guard (JST UK-1), onto the applicator
using the cap head socket screws supplied.
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.
Step 4
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilising
these screws.
Step 5
Adjust the side guard support to achieve the best
relationship between guard and applicator.

9
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.
When using the MKS-L 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 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.
Step 4
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilizing
these screws.
Step 5
Adjust the side guard support to achieve the best
relationship between guard and applicator.
Step 6
Tighten the screws and check that the guards are
correctly and securely fitted.

10
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 1
Secure the fabricated steel guard (JST UK-17), to the
applicator using the cap head screws supplied.
Step 2
Secure the fabricated steel guard (JST UK-135), onto the
side face of the applicator using the cap head screws
supplied.
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 4
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilizing
these screws.
Step 5
Adjust the side guard support bracket to achieve the best
relationship between guard and applicator.
Step 6
Tighten the screws and check that the guards are
correctly and securely fitted.

11
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 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 3
Remove the two upper motor fixing screws and clamp
the side guard support bracket onto the press utilizing
these screws.
Step 4
Adjust the side guard support bracket to achieve the best
relationship between guard and applicator.
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.

12
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
4. CONTROL BOX CONFIGURATION
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)
3. Function Indicator Lamps
•
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.
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.
• 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 Power-
off indicator lamp illuminates.
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.
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
2. RESET
3. FUNCTION
INDICATOR LAMPS
4. POWER ON
PUSH-BUTTON (GREEN)
5. POWER OFF
PUSH-BUTTON (RED)
6. CIRCUIT PROTECTOR
PUSH-BUTTON
7. OPERATION LAMP
SWITCH

13
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
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 2
Manually operate the solenoid by pushing the clutch
lever in a downward direction until the clutch ‘clicks’.
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.
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.
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.

14
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.
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.
Step 2
Press the Ope. Light to the right to turn on the Operation
Light.
Step 3
To count the number of crimped terminations, press the
Reset push-button to set the counter display to 0.
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.
ON
Step 5
Position a wire over the terminal and press the foot-
switch once to activate it. The terminal is crimped and
the next terminal is indexed along over the anvils ready
for the next operation.
Step 6
When you finish using the press, turn off the Work-lamp
and press the Power Off push-button.
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.

15
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.
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 screw-
driver 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.
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 screw-
driver 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.
SCREW COLLAR
SCREW COLLAR

16
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
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 bell-
mouth 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.
Check the bell-mouth on the resultant crimp and re-
adjust if necessary.
When using the MKS-L Applicator (new type)
Move the entire feed-plate to obtain the desired bell-
mouth 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 clock-
wise 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).
Re-tighten the adjustment bolts, centralize the feed-
finger 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.
Slot-head adjustment screws
Feed-finger screw Adjustment screw
Hexagon nuts
Adjustment screw

17
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
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.
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 crimp-
height 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.
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 crimp-
height. If you require details for the supply of a crimp-
height 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.
INSULATION CRIMP ADJUSTING DIAL
CONDUCTOR CRIMP ADJUSTING DIAL
MK-L
MK-L
INSULATION CRIMP ADJUSTING DIAL
CONDUCTOR CRIMP ADJUSTING DIAL
MKS-L

18
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.
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.
Apply grease to the surface of the cam-roller.
Apply grease to the four faces of the applicator ram.
CAUTION
Apply grease sparingly because excess grease
attracts dirt and scrap insulation etc.
CAM
CAM-ROLLER
APPLY GREASE HERE

19
H:\0 - Quality Documents\2 Department\Tech Serv\Application tooling\Presses\AP-K2N\TS010-00 AP-K2N Operation
Manual.doc
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.
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.
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.
MAIN SHAFT BEARING GREASING LOCATION
RAM SECTION OILING LOCATIONS
CLUTCH SECTION OILING LOCATIONS

20
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 manufac-
tured 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.
If the clutch is assembled as in photo B, it will not be
possible to re-mount the flywheel onto the shaft.
PHOTO A
PHOTO B
`