JST CMK-R User manual

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

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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.

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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

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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)

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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

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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

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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

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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

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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

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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

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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.
10. Terminal Feed Position
10-1 When you receive the applicator the feed 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 adjustment is to ensure that the terminal is in the correct
position when crimped. See section 16.
10-2 To adjust the position of the Feed finger loosen the M5 screw in the lever block
(124), then 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 assumed the correct position carefully tighten the Ring nut (125) then
the M5 screw.
Now you can place the applicator back into the press and carefully rotate the Press by
manual operation to see if the correct position has been achieved (See section 15).
If the crimped terminal is not correct then repeat this process.
10-3 The terminal position will vary if the Pitch screw is adjusted (section 8).
Please see the following page for the exploded view of this section.
M5 adjustment Screw
M5 Locking nut
Spring
Pressure Pad
M5 Spring Block

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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.
Feed Finger
Adjusting Bolt (123)
Lever Block (124)
M5 Screw
Ring nut (125)
Exploded view
Shear blade Anvil (A) Shear blade Anvil (B)
Terminal Holder

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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.
11-3 Springs
• Feed Finger Spring – The function of the Feed Finger Spring is to keep downward
pressure on the feed finger to ensure consistent feeding of the Terminal.
• Return Spring – The function of the Return Spring is to ensure that the Feed finger
pitches correctly every time, if this spring becomes stretched then inconsistent
feeding may occur.
• Pressure Spring – The function of this spring is to keep constant pressure onto the
terminal strip if this part is worn or damaged then the crimping will become
inconsistent.
Cam roller
Cam roller shaft
Return spring
Pressure spring
Feed finger spring

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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.
If for any reason you cannot achieve the correct crimp height, please contact our
Technical services department.
12-2 Conductor crimp height
The top dial, which has the letters from A-H around it, is for adjusting the Conductor
crimp height. To adjust the crimp height of the conductor, carefully rotate this dial, the
lower the letter (A) the harder the crimp.
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 increments.
For information regarding how to measure the crimp heights please see section 16.
12-3 Insulation crimp height
The Lower dial, which has the numbers from 1-8 around it, is for adjusting the
Insulation crimp height. To adjust the crimp height of the Insulation, carefully rotate
this dial, the lower the number (1) the harder the crimp.
When making any adjustment it is recommended that you start with the higher number
(8) to avoid any damaged being caused by over crimping.
The steps between each dial setting are 0.10mm increments.
For information regarding how to ensure that you are using the correct setting please
see section 16.
Conductor crimp adjustment
Insulation crimp adjustment

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13. Parts list for the applicator CMK-R
No. Part Name Part No.
No. Part Name Part No.
101 Body 4007-2001 133 Spring anchor 4007-4011
102 Plate (L) 4007-4002 133A Return spring MA01-349
103 Plate (R) 4007-4003 134 Pressure pad 4007-4012
104 Die plate 4007-3004 135 Pressure pad block 4007-4013
105 Die block 4007-4005 136 Pressure pad pin MA01-472
106 Feed plate 4007-4006 137 Release lever 4007-4014
107 Ram 4007-4007 138 Release lever pin MA01-474
108 Conductor dial 4006-4008 139 Hook 4007-4015
109 Positioning pin MA01-213 140 Hook pin MA01-476
110 Positioning spring MA01-214 141 Spring block 4007-4016
111 Insulation dial 4006-4009 142 Stripper bracket 4007-4017
112 Shank 4006-4010 143 Identification plate 4007-4018
113 Block ring MA01-225
114 Stroke adjustment plate 4007-4008 144 Conductor punch
115 Stroke adjustment shaft MA01-331 145 Insulation punch
116 Stroke adjustment bearing MA01-332 146 Conductor spacer
117 Stroke adjustment bearing nut MA01-333 147 Punch spacer
118 Stroke adjustment screw MA01-334 148 Insulation spacer
119 Cam 4007-4009 149 Shear blade spacer
120 Cam roller MA01-308A 150 Shear blade
121 Cam roller shaft MA01-337A 151 Shear blade anvil (A)
122 Feed shaft MA01-338 152 Shear blade anvil (B)
123 Adjustment bolt MA01-339 153 Conductor anvil
124 Lever block MA01-340 154 Insulation anvil
125 Ring nut MA01-341 155 Stripper
126 Feed lever (A) MA01-342M 156 Terminal holder
127 Feed lever support pin MA01-343 157 Guide plate (R)
128 Feed lever pin MA01-344 158 Guide plate (L)
129 Feed lever (B) 4007-4010M
130 Feed finger MA01-346
131 Feed finger pin MA01-347
132 Feed finger Spring MA01-348

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14. CMK-R Applicator exploded view
156
151
152
153
154
105
104
106
133
130
117114
116
118
134
144 137
139
132
143
115
120
122
129
131
125
158
146
112
108
111
138
109
110
107
119
148
113
147
145
102
142
103
155
157
149
150
127
101
141
121
126
128
123
124
140
133A
136
135

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15. Preventive maintenance
Quality Statement
The quality of a finished crimp is dependent on the use of the manufacturers specified application
tooling that has been cleaned and maintained in accordance with the following schedule.
Daily Care
1.1 Turn off the crimping press and isolate from the electricity supply. Remove the safety covers
from the crimping press.
1.2 Clean all wire and terminal scrap from the tooling with the aid of a small paint brush.
Caution
The use of a pneumatic airline to clean the tooling should be avoided. Any debris on the tool will be
blown away under great force and could either cause injury to persons nearby or be forced into
moving parts of the tooling.
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. 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 that they are
correctly set to the pre-determined reference position.
1.6 Check that the safety covers are in a good serviceable condition and replace on the tooling.
Clean the polycarbonate safety cover with a general-purpose aerosol spray cleaner to restore
good visibility.
Weekly care, or when removing the applicator from the press for storage.
In addition to the daily checks, the following maintenance should also be carried out on the tooling.
2.1 Remove the crimping punches from the ram (part numbers are affixed 63*** or 64***),
please note the sequence of dis-assembly so that the parts can be replaced in the correct
order. Refer to the Dies Construction Sheet supplied with the tooling for the assembly
order.
2.2 Hold each crimping punch in a vice and with the aid of a piece of waste cloth apply a
small amount of a good quality metal polish into the crimp form of the punch.
2.3 Using a sawing motion, polish the form until a brilliant mirror-like finish is restored.
2.4 Replace the crimping punches in the ram ensuring that the punches are free to move in a
lateral axis when the retaining screw is fully tightened.
Continued overleaf

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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.
2.7 Remove the ram from the main body of the applicator and clean off all the old grease
from the ram, feed cam and the mating surface of the applicator.
Caution
If an aerosol degreaser is used to clean the tooling, 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 covers.
2.12 If it is not intended to replace the applicator in the press, please ensure that the rubber collar
supplied with the tooling is placed between the dials and the applicator body. This action will avoid
any damage occurring to the crimping dies due to percussive shock when the crimping punches
make contact with the crimping anvils.
Notes
Recommended materials for maintenance:
Recommended grease should be of the general purpose ‘LM’ type.
Recommended oil is general-purpose machine oil, i.e. ‘3-In-One’ oil
Recommended metal polish is of the paste type, i.e. ‘Solvol Autosol’
 J.S.T MFG. CO., LTD. 2002
The contents of this document are subject to revision from time to time. For the latest issue of this leaflet,
please contact J.S.T.

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16. Crimping specifications
CONTENTS
1. Checks Before Crimping.................................................................. 20
2. Stripping Wire Insulation................................................................. 20
3. Crimping........................................................................................... 21
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. 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 terminal barrel must be properly bell-mouthed.........................27
4.8 The terminal must be cut at the correct position..............................27
4.9 The wire must be crimped at the correct position............................28
5. Check-points for correct Crimping......................................................... 29

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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.
Please contact us if 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. (Check the model number
and appearance).
(3) Determine which dies match the terminal. (Check that the dies are free from
damage).
Note: Contact us first if you wish to use solid wires, solder-plated wires, wires not
listed as applicable or other special wires.
2. Stripping Wire Insulation
The wire insulation strip length is determined by referring to the figure
over. Set the correct length depending on the terminal used and strip the
insulation with a wire stripper, taking care not to damage the wire conductors.
Bundle the stripped wires in paper to protect the wire strands from bending or
fraying when transported.