JST CMKS-L User manual

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

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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CMKS-L Manual.doc
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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.

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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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

JST CMKS-L 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 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.

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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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.

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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CMKS-L Manual.doc
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(112) (108)
(111)
(110)
(109)
(119)
(146)
(107)
(147)
(148)
(163)
(113)
(160)
(159)
(144) (145)

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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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)

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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CMKS-L Manual.doc
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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)

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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CMKS-L Manual.doc
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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)

JST CMKS-L INDUSTRY STANDARD APPLICATOR
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CMKS-L Manual.doc
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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)
✔
✔
✔