JST MKS-L User manual

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The Quality Connection
MKS-L
SIDE FEED APPLICATOR
Instruction Manual

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The Quality Connection
Table of Contents
1. Introduction………………………………………………………………………. 3
2. Specifications……………………………………………………………………. 3
3. Installation and Removal……………………………………………………….. 4
4. Load and Unload Terminals……………………………………………………. 8
5. Crimp Height Adjustment………………………………………………………. 11
6. Assembly and Adjustments……………………………………………………. 12
7. Trouble Shooting…………………………………………………………………21
8. Parts List…………………………………………………………………………. 24
9. Exploded View drawing………………………………………………………… 25
10. Preventative Maintenance………………..…………..……………………….. 26

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1. Introduction
The JST MKS-L applicator applies side feed terminals to prestripped wires. A silver nameplate has
been affixed to the side of the applicator indicating the die set that has been attached to the
applicator to crimp the specified contact. The applicator has been preset and tested for this specific
contact and samples crimped with the applicator at the time of assembly are included. In addition to
this manual a copy of the Die Construction Sheet has been included with the applicator. The Die
Construction Sheet includes crimp height and width information, die set parts list, and an exploded
view drawing of the die set.
2. Specifications
The JST MKS-L side feed applicator was designed to operate in a JST AP-K2N crimping press and
is fitted with a pre feed cam. Before installing this applicator in any other crimping press it is very
important to check that the press can accept the following specifications.
•Weight………………………………………………………………14.1lbs (6.4kgs)
•Feed Distance……………………………………………………...1.18” (30mm) max.
•Crimp Height Adjustment………………………………………….Dial Type
•Shut Height………………………………………………………….6.299” (160mm)
•Applicator Speed……………………………………………………4000 Cycles Per Hour**
**As a bench top operation the speed of the applicator is dependent upon the skill level of the
operator. If mounted in an automated machine the applicator is reliable up to a speed of 4000
cycles per hour. In this case the optimum speed is dependent upon the characteristics of the
machine and the rigidity of the wire insulation.
When installing the applicator to a press other than the JST Model AP-K2N it is extremely important
to check that the shut height of the press is 6.299” (160mm). Installation in a press with the incorrect shut
height can cause severe damage to the tooling. When the applicator has been newly installed to a press
always hand cycle the press to confirm that it will cycle freely. If it will not cycle freely the press shut
height will need to be adjusted.

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The Quality Connection
3. Installation and Removal
3-1 Installation into AP-K2N press
3-1-1 Turn presses power off and disconnect from the receptacle.
3-1-2 Loosen two bolts, A and B, on the applicator hold down guide with a 5mm hex wrench.
Base Plate
Bolt A
Bolt B
3-1-3 Remove the rubber-tooling protector from the applicator. Retain the rubber-tooling
protector, as it must be replaced any time the applicator is removed from the press.
Tooling Protector

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3-1-4 Place the applicator on the applicator base plate of the crimping press. Pull up on the slide
while pushing back on the lever in the direction of the arrow shown in photo below so the
collar on the top shank slides into the ram groove of the machine. Then push the applicator
until it stops.
Lever
Push
3-1-5 Snugly tighten bolts A and B on the applicator hold down guide with a 5mm hex wrench.
Bolts A &B
3-1-6 Replace all safety equipment per the instructions in the crimping machine manual.

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3-2 Removal from AP-K2N press
3-2-1 Turn presses power off and disconnect from the receptacle.
3-2-2 Replace the rubber-tooling protector around the slide of the applicator.
Tooling Protector
3-2-3 Loosen two bolts, A and B, on the applicator hold down guide.
Bolts A &B

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3-2-4 Remove the applicator from the press while holding the slide so that it does not drop.
3-2-5 Lower the slide until it is closed on the protective tooling rubber.
Tooling Protector

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4. Loading and Unloading Terminals
4-1 Loading Terminals Into The Applicator
4-1-1 Turn presses power off and disconnect from receptacle.
4-1-2 Rotate the wing bolt on the pressure plate clockwise to raise the pressure plate.
Wing Bolt
4-1-3 Feed the terminal strip under the pressure plate and through the guide plates until the first
terminal is centered over the crimp anvils.
Centered over anvil

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The Quality Connection
4-1-4 Rotate the wing bolt counterclockwise to lower the pressure plate so that pressure is
applied to the terminal strip.
Wing Bolt
4-2 Unloading Terminals From The Applicator
4-2-1 Turn presses power off and disconnect from receptacle.
4-2-2 Rotate the wing bolt on the pressure plate clockwise to raise the pressure plate.
Wing Bolt

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4-2-3 Lift the feed finger so that it is no longer engaging the terminal strip.
4-2-4 Remove the terminal strip from the applicator.
Feed Finger

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5. Crimp Height Adjustment
The applicator has two dials that are used to adjust crimp heights. The top dial is marked with letters
A through H and is used to adjust the crimp height of the conductor barrel. The lower dial is marked
with the number 1 through 8 and is used to adjust the crimp height of the insulation barrel.
Conductor Adjustment
Insulation Adjustment
CAUTION
1. To avoid damage to the dies from excessive crimping set the dials to H-8 to begin crimp height
adjustment.
2. The proper dial settings may differ depending on the wire. Always measure the crimp height with a
micrometer to be sure the crimp height meets the desired value.
3. If the applicator does not provide the desired by adjusting the dials, replace the wire block of
insulation block. Various sizes are available from JST. Tell JST the numbers on the blocks you are
using and how far out of spec the crimp height is and we will be able to assist with the appropriate
blocks. Do not adjust the shut height of the AP-K2N press to adjust crimp height.
5-1 Conductor Crimp Height Adjustment
5-1-1 Turn the power to the press off and be sure the motor has come to a complete stop.
5-1-2 Set the top dial in the H position. This is the highest crimp height and is always the
correct starting position.
5-1-3 Measure the crimp height and check to see if it is within the specification found on the
Die Construction Sheet. If it is not within the specification lower the letter setting on
the dial. The crimp height will decrease approximately .002” (0.05mm) per graduation.
Continue the process until the correct crimp height is achieved.
5-2 Insulation Crimp Height Adjustment
5-2-1 Turn the power to the press off and be sure the motor has come to a complete stop.
5-2-2 Set the bottom dial in the 8 position. This is the highest position and is always the
correct starting position.
5-2-3 Crimp a sample. If the desired crimp height is not attained lower the dial number.
Continue the process until the desired crimp height is attained.

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6. Assembly and Adjustments
6-1. Slide part
6-1-1 Assembly of slide part
Install each part so that the part number faces outward and can be seen. Wire disk
(No.109) and insulation disk (No.106) are attached by the shank (No.110). When
removing them, loosen the set bolt on the right side of slide (No. 102), and then
loosen shank (No.110). Tighten wire block (No.166), insulation block (No.167) and
block ring (No.168) with fitting bolt. Wire block and insulation block should have
movement in up and down directions.
6-1-2 Trouble cases
(1) Dial does not turn smooth or not at all,
•Caused by wire disk (No.109)
Positioning pin (No.105) and spring (No.104) do not work well due to rust, etc.
Wire block (No.166) and crimper (A) (No.154) are not assembled correctly due to
slanting, adhesion of foreign matters, etc.
•Insulation disk (No.106)
Steel ball (No.108) and spring (No.107) are defective or excessively tightened.
Incorrect fitting of insulation block (No.167) and crimper (B) (No.156) due to
slanting, adhesion of foreign matters, etc.
(2) Dial does not stop,
•Wire disk (No.109)
Broken spring (No.104) or broken positioning pin (No.105).
•Insulation disk (No.106)
Steel ball (No.108) is missing; spring (No.107) is missing or damaged, etc.

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6-2. Upper die part
6-2-1 Install die parts so that part numbers face outward. Install spacer (A) (No.153) to the
slide (No.102). Some die sets may not have a spacer (A). Install crimper (A) (No.154)
and crimper (B) (No.156). Spacer (B) may be used between crimpers (A) and (B) for
some die sets. Install punch (No.157) and tighten with bolt. Spacer (C) may be used
between punch and crimper (B) for some die sets.
6-2-2 After tightening, crimpers (A) and (B) should have movement in the up and down
directions. If the crimpers will not move check that the die parts have been installed
flat, there is no foreign matter, all die parts are correct, etc.
6-2-3 Accessories
In cases where a wire hold spring, die hold ring, tongue hold punch, tongue hold
punch holder and spring are included, pay attention to the length of fitting bolt so that
it does not extrude to the front. This will prevent movement of crimpers (A) and (B).

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6-3. Lower Die Part
6-3-1 Do not move die block (No.112) and side block (No.114) that have been preset on the
die plate (N0. 114) by JST. These blocks properly set the position of the crimper
anvils in the side-to-side and front to back directions. Install spacer (No.164), crimper
anvil (A) (No.163), crimper anvil (B) (No.162), shear blade supporter (No.160), shear
blade base (No.161), shear blade spring (No.159), shear blade (No.158) in order and
tighten with two bolts from the back of die block (No.112).
6-3-2 When tightening the two bolts, do so slowly alternating between the two bolts until
they are snug. Be sure all parts are pushed against the side block (No. 114) and
finish tightening.

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6-4 Centering of crimper and crimper anvil
6-4-1 Lower slide (No.102) little by little and check the gaps on both right and left sides of
crimper and crimper anvil with loupe, etc. A white paper can be used in back to check
the gaps more easily.
6-4-2 When the gaps are not even on the right and left sides, loosen bolt on side block
(No.114) and adjust the gaps evenly on both the right and left sides and tighten the bolt
securely.
6-5 Gap between crimper (B) and shear blade
6-5-1 Check the gap between crimper (B) (No.156) and shear blade (No.158) lowering slide
(No.102) little by little. (Reference the die construction sheet for value of gap).
6-5-2 When the gap is not within reference value, loosen the bolt on the die block (No.112).
Move die block little by little to adjust the gap, and tighten bolt securely. The value of
gap will vary depending on terminal to be used.

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-6. Guide plate part
usted the terminals will move freely
from left to right, but will have no movement front to back.
6
Install feed plate (No.152) on feed plate base (No.116), which is mounted on die plate (No.113).
Feed plate (No.152) is to be installed on feed plate base (No.116) in parallel. Install guide plate
(L) (No.151) on feed plate (No.152) pushing to the back. Then, install guide plate (R) (No.150)
on feed plate (No.152). Feed a strip of terminals between guide plate (R) (No.150) and guide
plate (L) (No. 151). Adjust guide plate (R) (No.150) so that the terminals are held straight, yet
still move freely and tighten the screws. When properly adj
6-7 Pressure plate
oes not move back as the feed finger moves. After adjusting, lock securely with
hexagon nut.
Tighten pressure plate (No.141) with two bolts that have been placed through the pressure
springs (No. 142) from under the left side of feed plate (No.152). Adjust pressure strength so
that terminal d
(151)
(
152
)
(150)
(116)
(151)
(
152
)
151)
(141)
(142)
(150)
(
(
152
)

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6-8 Terminal Feed Pitch
6-8-1
ring up will make the stroke pitch longer. Moving it down will shorten
the stroke pitch.
Adjustment of terminal feed pitch by stroke adjustment
Feed the terminals so that the contact is centered over crimper anvil (A) (No.163).
Hold the terminal with pressure plate (No.141). To adjust the stroke pitch of feed
finger (No.144) loosen the stroke adjust bearing nut (No.137) fitted to stroke adjust
plate (No.136). Remove stroke adjust screw (No.138) and hexagon nut (No.133), and
move the stroke adjust bearing (No.135) and stroke adjust shaft (No.134). Moving the
stroke adjust bea
6-8-3
e the
rovided on the terminal strip
carrier, use the protrusion to adjust terminal feed.
Adjust the stroke pitch from one square hole on the terminal carrier strip to the next
square hole. When a square hole is not provided on the terminal carrier strip, us
round hole instead. When triangular protrusion is p

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6Terminal feed position-9.
6-9 position.
6-9-2
s the
rd. Adjust the terminal position so that it is centered over the
6-9-3 ting applicator on crimping machine and
checking that ram is upper dead center.
-1 The relative position of terminal and crimping die is determined by the feed
Adjust the feed position so that terminal is centered over the crimper anvil.
Loosen ring nut (No.120) and the screw on the lever block (No.122), turn adjusting
bolt (No.123) to move feed finger (No.144) back and forth together with the terminal,
and terminal position is adjusted. When adjusting bolt (No.123) is turned in the up (L
direction), the feed finger moves forward. Turning in the down (R direction) move
feed finger backwa
crimper anvil.
Adjust terminal feed positions after moun
(123) 122) 121) (120)
( (
6-9-4 After adjustment, securely tighten the loosened bolt and ring nut (No.120).
6-10. B
6-10-1 a
ctor by providing a transition area from the
6-10-2
s. When the terminal
position is moved back the size of the bell-mouth decreases.
ell-mouth (Adjustment of crimping position)
The bell-mouth is the area of the conductor barrel that is not hit by the crimper on
crimped terminal. The area that was not hit by the crimper slightly bulges and is
called the bell-mouth. The proper bell-mouth on the insulation side of the conductor
barrel will prevent breakage of wire condu
insulation barrel to the conductor barrel.
Reference value of the bell-mouth is the material thickness of the terminal.
When the terminal position is moved forward along with guide plate (L) (No.151)
and guide plate (R) (No.150) the size of the bell-mouth increase
(119)
4)
(125)
(12
(
144
)
(130)
(129)
(128)
(127)
(126) (115)
(145)

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6-11. Bell-mouth Size
6-11-1
djusting bolt is turned to left (counterclockwise), quantity of the
bell-mouth increases.
6-11-2
d finger (No.144) in the slot part of guide plate
•Between crimper (B) (No.156) and punch (No.157). In this case,
Always check the explode view of the Die Construction Sheet before assembling this
section.
When adjusting bolt (No.118) is turned to right (clockwise) after loosening the two
bolts on feed plate base (No.116), feed plate (No.152) moves to back decreasing the
bell-mouth. When the a
Before feed plate (No.152) is moved to adjust the bell-mouth; the screw that holds
feed finger (No.144) must be loosened. Failure to loosen the feed finger screw will
either prevent the feed plate from moving or break the feed finger. After adjusting
quantity of bell-mouth, center the fee
(151)
(150)
(116)
(L) (No.151) and tighten the screw.
6-12 Accessories
6-12-1 Wire hold spring can be mounted in two areas.
•Between crimper (A) (No.154) and crimper (B) (No.156).
Note that configuration and part number of shear blade (No.158) change.
(152)
(118) (117)
(113)
(157)
(156) (155)
(154)
(153)

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6-12-2
g on the wire strip length. Note that moving the stripper
too far forward will place it under crimper (A) (No.154) causing all the parts to be
damaged, while moving the stripper too far backward may cause deformation and
bending of the terminal.
6-12-3
Scrap cover (No.165) is to collect the cut off terminal carrier strip pieces away from
the working area. Note that dislocation of position may cause clogging of terminals or
damage to dies.
6-12-4
r (No.124) rotates as it moves along
the cam (No.111). Abnormal abrasion of the
cam roller may cause dispersion in terminal
feeding.
Stripper
Stripper (No.147) is available in two types. A stationary type (left below) that is
mounted to the spacer (No.164) or a moving type (right below) that is mounted to
guide plate (R) (No.150). To adjust stripper position, move the stripper bracket (No.
146) back or forth dependin
(147)
Scrap cover
(146)
(147)
(146)
(165)
Cam roller and cam roller shaft
Cam rolle