JST CMK-R User manual

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CMK-R Manual.doc
CMK-R
INDUSTRY STANDARD APPLICATOR
OPERATION
MANUAL

JST CMK-R INDUSTRY STANDARD APPLICATOR
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CMK-R Manual.doc
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For safe use
• Always switch of the Press at the mains and remove the applicator from the
Press before making any adjustments or fitting new parts.
• Always refer to this manual before making any adjustments to JST
Applicators
• All JST Applicators are supplied with a Die-construction sheet, please refer
to this document when ordering spare parts.
• All JST Industry standard Applicators have been designed to operate in
Industry standard 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 damage to the dies, always ensure that a protective rubber collar
is fitted between the dials and casting of the applicator when it is removed
from the press.

JST CMK-R INDUSTRY STANDARD APPLICATOR
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CONTENTS
Page
1. Ram Slide Section.............................................................................. 4
2. Shear Blade........................................................................................ 5
3. Stripper............................................................................................... 5
4. Upper Die Parts.................................................................................. 6
5. Lower Die Parts.................................................................................. 7
6. Alignment Of Shear Blade, 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...................................................................... 11
11. Additional Information....................................................................... 12
12. Crimp Height...................................................................................... 14
13. CMK-R Parts List.............................................................................. 15
14. CMK-R Exploded Diagram............................................................... 16
15. Preventive maintenance..................................................................... 17
16. Crimping specifications..................................................................... 18

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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.
Positioned in the rear of the slide is the cam (119), there are two different cams
available for this applicator, the first we call an upstroke cam, with this cam fitted
the terminal is present over the anvil when the press is at top dead centre, this type of
cam is commonly used when the applicator is located in a bench press. The other is
called a downstroke cam, this operates in the opposite manner, which means the
terminal feeds 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 Pin (109).
The dials turn freely but do not locate in position correctly!
1. Check the condition of the positioning spring (110) and the positioning pin
(109), The Spring may be broken.
2. Ensure 3mm-grub screw located in the insulation dial is adjusted correctly.
No. DESCRIPTION
107 Ram
108 Conductor dial
109 Positioning pin
110 Positioning spring
111 Insulation dial
112 Shank
113 Block ring
119 Cam
146 Conductor spacer
148 Insulation spacer
(112)
(108)
(146)
(111)
(113)
(109)
(110)
(107)
(119)
(148)

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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.
Note: Make sure that the M4 screws holding the blade and spacer DO NOT protrude
through to the front of the ram, This will result in the punches not being able to
float freely, and almost certainly cause punch damage.
3. TERMINAL STRIPPER
3.1 PURPOSE
After the terminal has been successfully crimped on the wire, the terminal may adhere to the punches, the stripper assumes the role of removing the terminal from
the punches.
3.2 ASSEMBLY
Firstly, attach the stripper (155) to the stripper bracket (142) using 2 x M4 screws,
next attach the bracket (142) to the slot on the side of the main casting using 1 x M6
screw. The stripper is usually positioned between the Conductor punch and the
Insulation punch, ensuring there is no contact with either part.
Depending on the kind of terminal, the stripper may be fitted to the rear of the
conductor punch.
(107) Ram
(149) Spacer
(150) Shear
blade
(142) Stripper
Bracket
(155) Stripper
Conductor punch
Insulation punch

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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. Conductor spacer (146)
2. Insulation spacer (148)
3.
Block ring (113)
After you have fitted these parts tighten them down with a 5mm-hexagon screw and
check that they are not clamped and do move up and down freely.
4. Conductor punch (144)
5. Insulation punch (145)
6. A Spacer & wire spring are sometimes fitted between the two punches.
7. Punch Spacer (147)
After you have fitted these parts, tighten down with a 6mm-hexagon screw and
again check that they are not clamped and punches do move up and down freely.
4-2 TROUBLE SHOOTING
The punches or spacers do not move freely!
1. Dismantle and check for any foreign bodies.
2. Check the sides of the punches for wear / damage or burrs.
3. Check the parts that are fitted, against the relevant die construction sheet.
(107) Ram
(144) Conductor punch
(145) Insulation Punch
(147) Punch Spacer

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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. Shear blade anvil (A)
2. Shear blade anvil (B)
3. Conductor anvil
4. Insulation anvil
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 of soft metal (brass) to avoid
damaging the anvil parts.
(105) Die block
(151) Shear blade Anvil A
(152) Shear blade Anvil B
(153) Conductor Anvil
(154) Insulation Anvil
(104) Die Plate

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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.
Remove the applicator from the Press and loosen the 4 x 5mm hexagon screws that
attach the Die block to the Die Plate.
Bring the Ram down slowly to align the Shear Blade, with the slot in the Shear blade
Anvil. When the Shear blade passes through the slot in the Shear blade anvil freely,
carefully re-tighten the screws.
To ensure that you have set this part correctly you can mark both sides of the Shear
blade with a pen, then slowly move the Ram up and down. If the Shear blade is
positioned correctly the ink will still be present on the Blade, if the ink has been
removed this indicates that the setting is incorrect.
Shear Blade Anvil A
Shear Blade Anvil B
Insulation Anvil
Conductor Anvil
Shear Blade
Die Plate
Die Block

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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.
Now you can fit the 2 guide plates using 4 x 4mm hexagon screws (do not tighten).
Take a strip of the terminals that are compatible with the die set in the applicator and
align the strip with the centre of the anvil parts ensuring that everything is parallel
(see below), now you can carefully tighten the 4 x 4mm hexagon screws.
Centre Line of Anvil
Guide Plate (L)
Guide Plate (R)
Die Plate
Die Block
Feed Plate

JST CMK-R INDUSTRY STANDARD APPLICATOR
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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.
Note: The function of 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).
8-2 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 10.
8-3 When adjusting the pitch always try to feed the terminal on the Insulation bucket as
shown in the item 2 below, if this cannot be achieved then using the Conductor bucket
is acceptable.
(1) (2)
Recommended