JST CMKS-L User manual

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CMKS-L Manual.doc
CMKS-L
INDUSTRY STANDARD APPLICATOR
OPERATION
MANUAL

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For safe use
• Always switch off 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.
• Do not make adjustments to the tooling unless qualified to do so.
• When replacement parts are required, use only genuine JST supplied parts.
Die parts that are manufactured using an incorrect heat treatment process
can shatter during use.

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CONTENTS
Page
1. 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

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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 type is an pre-feed 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
type is a post-feed 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.
2. EJECTOR
2.1 PURPOSE
After the terminal has been successfully crimped on the wire, the terminal may
adhere to the punches; the ejector assures the function of stripping the terminal
from the punches.
2.2 ASSEMBLY
Place the ejector punch with relevant spring (159) into the corresponding slot of
ejector holder (160) ensuring the ejector slides freely up and down when fixed into
position on the front of the crimping punches.

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3. UPPER DIE PARTS
3.1 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 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 clamped and punches move up and down freely.
3.2 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.

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(112) (108)
(111)
(110)
(109)
(119)
(146)
(107)
(147)
(148)
(163)
(113)
(160)
(159)
(144) (145)

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4. LOWER DIE PARTS
4.1 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. 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 (brass) to avoid
damaging the anvil parts.
(105) Die block
(150) Shear blade
(151) Shear blade Anvil
(153) Conductor Anvil
(154) Insulation Anvil
(104) Die Plate
Die Spacer (149)

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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)

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6. GUIDE PLATE
6.1 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 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 large guide rail.
Die Plate (104)
Feed plate base (106)
Feed plate (166)
Large Guide Rail (158)
Small Guide Rail (157)

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7. TERMINAL FEED PITCH
7.1 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).
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 10.
7.3 When adjusting the pitch always feed the terminal on the rectangle hole and not the
round hole that can be viewed through the slot on the top of the small guide rail. (See
below)
Small Guide Rail (157)
✔
✔
✔

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8. PRESSURE PAD
8.1 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

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9. TERMINAL FEED POSITION
9.1 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.
9.2 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 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 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.
9.3 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.
Feed Finger (164) (165)
Adjusting Bolt (123)
Lever Block (124)
M5 Screw
Ring nut (125)
Exploded view

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10. ADDITIONAL INFORMATION
10.1 Wire Stop / Stripper
Depending on which terminal you are processing, a wire stop / stripper is sometimes
fitted to the die spacer The purpose of this part is to position the wire correctly prior to
crimping and remove 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 any wear in this part or this part becomes
damaged then it will result in the terminal being positioned incorrectly.
Cam roller
Cam roller shaft
Stripper bracket (156)
Wire stop / Stripper
(155)
Die spacer (149)

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11. CRIMP HEIGHT
11.1 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 only 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. The crimp height should be measured with a crimp micrometer.
If for any reason you cannot achieve the correct crimp height, please contact our
Technical services department.
11.2 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.
11.3 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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12. Parts list for the applicator CMKS-L
No. Part Name Part No.
No. Part Name Part No.
101 Body 4006-2001 132A Return spring 4006-P025
102 Plate (L) 4006-4002
103 Plate (R) 4006-4003
104 Die plate 4006-3004
105 Die block 4006-4005 144 Conductor punch
106 Feed plate base 4006-4006 145 Insulation punch
107 Ram 4006-3007 146 Conductor spacer
108 Conductor dial 4006-4008 147 Punch spacer
109 Positioning pin MA01-213 148 Insulation spacer
110 Positioning spring MA01-214 149 Die spacer
111 Insulation dial 4006-4009 150 Shear blade
112 Shank 4006-4010 151 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 Guide plate
120 Cam roller MA01-308A 159 Stripper
121 Cam roller shaft MA01-337A 160 Stripper holder
122 Feed shaft MA03-338 161 Pressure plate
123 Adjustment bolt MA03-339 162 Pressure plate springs x 2
124 Lever block MA01-340 163 Punch ring spacer
125 Ring nut MA01-341 164 Feed finger holder
126 Feed lever (A) 4006-4015 165 Feed finger
127 Feed lever support pin MA01-343 166 Feed plate
128 Feed lever pin MA01-344
129 Feed lever (B) 4006-4016-1
130 Feed finger pin AMA03-347
132 Return spring bracket 4006-4012

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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

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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 (the ‘weekly care’ checks listed from 2.1 – 2.4 below, should also be applied
on a daily basis when using terminals manufactured from steel)
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 paintbrush.
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.

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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.
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. 2005
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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15. 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.