JST AP-F6 User manual

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AP-F6
PNEUMATIC TAPE-ON-REEL
CRIMPING MACHINE
OPERATION
MANUAL

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
PREFACE
The AP-F6 semi-automatic terminal-on-tape crimping machine is easy to operate, and is suitable
for mass production of crimped harnesses with closed-barrel insulated and uninsulated T.O.R
(Tape-on Reel) terminals.
Before using the AP-F6, please read this manual to ensure that you are familiar with the features
of the machine and the layout of the operating controls.
We recommend that you always keep this manual near the machine to use for reference when
required. This manual also contains information on maintenance, faultfinding and adjustment of
the crimping machine and its associated tooling.
For safe operation
• THIS MACHINE HAS THE POTENTIAL TO CAUSE SERIOUS INJURY AND SHOULD
NEVER BE USED WITHOUT THE SAFETY GUARDS FITTED.
• If you think that something is wrong with the machine, immediately turn OFF the
machine, disconnect the lead from the power supply, and the hose from the air supply. Guards
must only be removed by an authorised person during setting, adjustment and maintenance.
• The maximum measured sound output generated by the Crimping Press is 81dB.
• Do not modify or adapt the machine without prior consent of JST.
• This crimping machine complies with the CE directive for machinery and has the
CE mark affixed to indicate its compliance.
• This crimping machine must not be incorporated into other machinery without the
consent of JST (ref. The Supply of Machinery (safety) Regulations 1992,
S.I 1992/3073).

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Table of Contents
1. SPECIFICATIONS………………………………………………………………………
1 - 1 Crimping Machine Specifications………………………………………………
1 - 2 Crimping dies……………………………………………………………………..
2. INSTALLING AND TRANSPORTING THE MACHINE……………………………..
2 - 1 Installation.................................................................................……………
2 - 2 Transporting...................................................................................…………
3. CONTROL BOX CONFIGURATION.....................................................................
3 - 1 Control Panel and Functions.......................................................................
4. PREPARATION FOR OPERATION......................................................................
4 - 1 Mounting the Reel Hanger………………………………………………………
4 - 2 Mounting the Dies………………………………………………………………..
4 - 3 Mounting the Terminal Reel…………………………………………………….
4 - 4 Touch Sensor Adjustment………………………………………………………
4 - 5 Foot Switch Operation...............................................................................…
4 - 6 Mounting the Safety Guard..........................................................................
4 - 7 Air Supply Connection..................................................................................
4 - 8 Preparing the Machine for Operation...........................................................
5. OPERATION……………………………………………………………………………
5 - 1 Touch Sensor Operation..............................................................................
5 - 2 Foot Switch Operation..................................................................................
6. INSPECTION OF CRIMPED WIRE...................................................................…
6 - 1 Checking and Adjustment of Crimp Position................................................
6 - 2 Adjustment of Insulation Support………………………………………………
7. CRIMPING MACHINE MAINTENANCE..........................................................……
7 - 1 Lubrication....................................................................................................
7 - 2 Cleaning.............................................................………………………………
7 - 3 Shut Height Adjustment.............................................................................…
7 - 4 Filter Regulator Adjustment..........................................................................
8. FAULT FINDING................................................................................................….
8 - 1 Diagramatic Flow Chart................................................................................
8 - 2 Flow Chart Definitions...................................................................................
9. EXPLODED VIEW AND PARTS LIST...............................................................…
9 - 1 Exploded View.............................................................................................
9 - 2 Parts List......................................................................................................

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
1. SPECIFICATIONS
The crimping machine consists of the
crimping press and a die-set.
There are two basic types of die-set,
1.1 Crimping Machine Specifications
1.2 Crimping Dies
Various types of crimping dies are available.
Select according to the type and size of the
terminals to be crimped, by referring to the table
on page 2.
Dies assembly drawing for non-insulated
terminals.
One is designed for use with Pre-insulated
terminals, and one for use with non-
insulated terminals.
Model no: AP-F6
º External dimensions: 264 wide x 415 long x
385mm high (not including reel hanger).
º Weight: 40 Kg.
º Power supply: 220/240V AC single phase
50/60 Hz.
º Air pressure: 490 - 686 Kpa (5 - 7 Kg/Cm²)
º Air consumption: 490 Kpa Hr. 3NL/cycle
º Applicable terminals: Insulated and non-
insulated terminals 0.50 - 5.5 mm².
Dies assembly drawing for insulated terminals.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
SELECTION TABLE FOR AP-F6 CRIMPING DIES.
Type Of Terminal:
Terminal Part No: Part Number:
Die Part Number Die Set Number
0.5 - ( ) 3101 L
3102 U3H-2622
3841 E x 2 (see note ii)
3941 EH (see note ii)
1.25 - ( ) 3111 L
3112 U3H-2216
3841 E x 2 (see note ii)
Non-Insulated 3941 EH (see note ii)
Terminal 2 - ( ) 3121 L
3122 U3H-1614
3841 E x 2 (see note ii)
3941 EH (see note ii)
5.5 - ( ) 3131 L
3132 U3H-1210
3841 E x 2 (see note ii)
3941 EH (see note ii)
V0.5 - ( ), FV0.5 - ( ) 3201N C, U
N0.5 - ( ), NV0.5 - ( ) 3301N I, U 3V-2622N
3202N C, L
3302N I, L
V1.25 - ( ), FV1.25 - ( ) 3211N C, U
N1.25 - ( ), FN1.25 - ( ) 3311N I, U 3V-2216N
3212N C, L
3312N I, L
Insulated Terminal V2 - ( ), FV2 - ( ) 3221N C, U
N2 - ( ), FN2 - ( ) 3321N I, U 3V-1614N
3222N C, L
3322N I, L
V5.5 - ( ), FV5.5 - ( ) 3231N C, U
N5.5 - ( ), FN5.5 - ( ) 3331N I, U 3V - 1210N
3232N C, L
3332N I, L
VD0.5 - ( ) 3201N C, U
FVD0.5 - ( ) 3301N I, U 3V - 2622N
3202N C, L
3302N I, L
VD1.25 - ( ) 3211D C, U
FVD1.25 - ( ) 3311D I, U 3V - 2216D
VDDF1.25-( ) 3212D C, L
Insulated Terminal FVDDF1.25-( ) 3312D I, L
With Copper Sleeve VD2 - ( ) 3221D C, U
FVD2 - ( ) 3321D I, U 3V - 1614D
VDDF2-( ) 3222D C, L
FVDDF2-( ) 3322D I, L
VD5.5 - ( ) 3231N C, U
FVD5.5 - ( ) 3331N I, U 3V - 1210N
VDDF5.5 – ( ) 3232N C, L
FVDDF5.5 – ( ) 3332N I, L
NOTE: ( i ) When ordering the dies, the appropriate size should be given between the
Brackets.
( ii ) Parts for the ejector (part no's 3841 and 3941) are optional.
( iii ) If you require a die not listed above, please contact the J.S.T. Technical
Services Department.
( iv ) The single letter code given after the part no refers to the following:-
I = Insulator, C = Conductor, U = Upper, L = Lower, E = Ejector, EH = Ejector Holder Plate

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
2. INSTALLING AND
TRANSPORTING THE MACHINE
2.1 Installation
The crimping machine should be
mounted on a flat, stable surface.
There should be a single phase power
supply, and a compressed air outlet
available.
The rubber feet should be screwed
into the holes provided in the base,
and adjusted to the desired angle to
allow the most comfort-able working
position. The lock-nuts must be
tightened after the desired position is
achieved to ensure that they do not
become loosened with use.
2.2 Transporting
The machine must only be lifted by
the base, by two persons.
The press weighs 40 kilos, and should
not be lifted by one person under any
circumstances, because serious back
injury could result.
There is a handle attached to the front
of the machine to aid lifting.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
3. CONTROL BOX CONFIGURATION
3.1 Control Panel and functions
FRONT FACE
1. Main Switch
This rocker switch controls the power
supply to the AP-F6. When the machine
is turned on the pilot lamp illuminates.
Always ensure that the machine is
turned off when it is left unattended for
any reason.
2. Total Counter
This counter displays the total cycles
performed by the AP-F6.
3. Reset Button
This button is depressed to zero the
Total Counter display.
4. ' Fault ' Display (red LED)
This LED illuminates when the air
pressure falls below a pre-set level, or
the Safety Guard is not fitted to the
machine.
5. Input display (red LED)
This LED illuminates whenever the
Touch Sensor or Foot switch are
actuated.
6. Tape Feed Switch
The Tape Feed switch illuminates when
the main switch pilot lamp is on.
The Tape feed switch can only be
operated when the Adjust Switch is in
the UP position.
If an operational error occurs, the Tape
Feed switch will flash on and off.
7. Adjust Switch
This switch is used to move the ram up
or down.
8. Touch Sensor Switch
The Touch Sensor switch should be in
the 'ON' position when the Touch
Sensor is in use.
9. Touch Sensor Input Socket
This is the socket into which the Touch
Sensor plug is connected.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
REAR FACE
10. Buzzer
If the air pressure drops below a pre-
set level, the Safety Guard is not
fitted, or there is an operational error,
then the buzzer will be operated.
11. D-Sub Input Socket
This socket is not required during
everyday use, and so it should be kept
covered at all times.
12. Circuit Protector
The electronic circuits are protected
by an overload device, and should a
fault occur, the trip will operate and
turn the machine off.
CAUTION !
Be sure to discover the cause of
the fault before turning the
machine back on.
Help should be sought from an
authorised person , and under no
circumstances should the Safety
Guard or Cover be removed by
unauthorised persons.
To re-set the machine, the button
should be pushed in after
approximately one minute.
13. Foot Switch Socket
This input socket is used when, for
reasons of wire size or terminal type, it
is not possible to use the Touch
Sensor.
14. Mains Input Socket
This socket is for the Input of the
240V, single phase power supply.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
4. PREPARATION FOR OPERATION
4.1 Mounting the Reel Hanger
Assemble the reel hanger, as per the
parts list, and mount onto the crimping
press with the two cap head screws
provided, as illustrated.
4.2 Mounting the Crimping Dies
CAUTION !
Ensure that the press is
disconnected from the electricity
and air supplies before mounting
the die-set.
When the machine is shipped, the
ram of the crimping press is in the
open position. Sometimes the ram
falls down under its own weight during
transit, and as a result the dies cannot
be fitted.
If the above condition is experienced,
please consult the instructions in
section 4.8 before continuing.
Insulated Terminals
Step 1, Upper crimping die mounting
procedure.
Position the conductor punch in the
ram
and place insulation punch on top.
Secure them both in the ram with the
cap head screw supplied, whilst
simultaneously pushing the punches
in an upward direction, to ensure they
are tightly pressed on the ram.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Step 2, Lower crimping die mounting
procedure.
Position the conductor anvil in the
lower crimping die holder, mount the
insulation anvil in front of conductor
anvil, and secure with the cap screw
provided, whilst simultaneously
pushing down on the anvils to ensure
that they are correctly seated in the
holder.
Step 3, Stripper mounting
A stripping blade is required to ensure
that the terminal is removed from the
crimping punches after the completion
of the crimping operation. The
Stripping blade works by ' wiping ' the
terminal from between the blades.
The stripper is mounted on a backing
plate, part no F3-4132, which is in turn
mounted on a bracket, part no 2108-
4117-1, and is positioned equally
distant between the conductor and
insulation punches, ensuring that it
does not touch either of the punches.
The stripper, backing plate and
bracket are all secured by cap head
screws which should be securely
fastened upon completion of the
adjustment.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Uninsulated Terminals
Step 1, Upper crimping die mounting
procedure.
Position the conductor punch in the
ram and secure with the cap head
screw provided, whilst simultaneously
pushing the punch upwards to ensure
that it is seated correctly in the ram.
Step 2, Lower crimping die mounting
procedure.
Position the ejector in the lower die
holder, followed by the conductor
anvil, the second ejector and finally
the keep plate.
Secure the assembly with the cap
screw supplied, whilst simultaneously
pushing down upon the anvil to
ensure that it is seated correctly.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
4.3 Mounting the Terminal Reel
Step 1, Terminal reel set-up
Mount the terminal reel on the reel-
hanger and tighten the securing screw
so that the reel does not rotate under
its own weight.
Step 2, Feeding tape capstan set-up
Raise the tape holder by pressing in
the button, part no F3-4128.
Step 3, Engaging the feeding tape on
the teeth of the feeding capstan
Hook the slot of the feeding tape onto
the teeth of the feeding capstan,
push down the tape holder, part no
2108-4134, until the pusher button '
pops out ' and retains the lever.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
4.4 Touch Sensor Adjustment
The touch sensor is fitted to the press
to allow semi-automatic operation
when using suitable types of wire.
It is always preferable to use the
touch sensor, if possible, because the
action of touching the sensor to
operate the press ensures that
conductors of the wire protrude
sufficiently through the crimp terminal
to produce a correctly terminated wire.
Note
The touch sensor cannot be used with
wires of 26 AWG or less, and certain
types of terminal. If you cannot
achieve satisfactory results using the
sensor, it will be necessary to use the
foot-switch to operate the crimping
press.
The touch sensor is mounted on the
same bracket as the stripper (see
section 3.2), and should be adjusted
so that it is placed approximately 1mm
behind the conductor crimp barrel.
The position is secured by tightening
the cap head screw onto the mounting
bracket.
4.5 Foot Switch Operation
When it is not possible to use the
touch sensor, due to incompatible wire
or terminals, it is necessary to use the
foot switch supplied with the AP-F6.
The foot switch plugs into the rear of
the control box (see section 4).
CAUTION !
Do not plug the Foot Switch into
the AP-F6 whilst the machine is
connected to the power supply,
because the machine may be
operated by accident.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
4.6 Mounting the Safety Guard
There is a safety guard supplied with
the AP-F6, and because it is fitted
with an opto-electronic switch, the
press will not operate without the
guard fitted.
The safety guard is secured to the
press with two cap head screws
mounted either side of the guard.
WARNING !
Do not attempt to operate the AP-
F6 without the Safety Guard fitted,
because major injury could result if
a finger or hand is caught between
the dies.
4.7 Air supply connection
CAUTION !
Ensure that the power switch is
turned off before connecting the air
hose.
The air connection consists of a
female socket to be fitted to the end of
a suitable length of air hose. The
socket is a push fit onto a male
tailpiece fitted onto the air pressure
regulator mounted on the rear face of
the press.
To disconnect the hose, the ring on
the female socket must be pushed
away from the press, which then
allows the connection to be broken.
4.8 Preparing the machine for
operation
Step 1.
Connect the air and electricity
supplies and press the power ON
switch.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Step 2.
Set the Adjust Switch to the UP
position.
Step 3.
Press the Tape-Feed button to
advance the tape until the first
terminal on the tape is located at the
crimping position.
Step 4, Temporary holding of terminal.
Set the adjust switch to the DOWN
position.
The ram moves down and rests on
top of the terminal, and holds it firmly
in position.
The terminal is now ready for
crimping.
5. OPERATION
5.1 Touch Sensor operation.
Step 1.
Turn the Touch Sensor ON.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Step 2.
Insert a stripped wire into the terminal
barrel, ensuring that the strip length is
as per specification.
(If the strip length is too short, the
conductor will not protrude sufficiently
to operate the sensor.)
Step 3.
The press will now perform one
crimping cycle, and feed the next
terminal over the anvils ready for the
next operation.
Remove the crimped wire from the
tape by pulling firmly and withdrawing
through the Safety Guard.
5.2 Foot Switch operation
Step 1.
Turn the Touch Sensor switch OFF.
Step 2.
Insert a stripped wire into the terminal
barrel, ensuring that the strip length is
as per specification.
Step 3.
Step on the Foot switch, the press will
now perform one crimping cycle, and
feed the next terminal over the anvils
ready for the next operation.
Remove the crimped wire from the
tape by pulling firmly and withdrawing
through the Safety Guard.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
6. INSPECTION OF CRIMPED WIRE
6.1 Checking and adjustment of
crimp position
CAUTION !
Before opening the fabricated
cover to adjust the crimp position,
ensure that the air and electricity
supplies are disconnected.
If the crimp position is not centred
correctly, adjustments are required to
be made to the index wheel position
(part no. 2108-4115-1).
In the case of an insulated terminal,
the insulation should be removed from
the terminal with the aid of a pair of
cutters, to enable the indentation to be
assessed.
The drawings opposite illustrate the
visual appearance of both correctly
and incorrectly crimped terminals.
The adjustment procedure is as
follows:-
Step 1.
Set the Adjust switch to the UP
position.
The ram rises to Top Dead Centre,
and the terminal is free to move
relative to the anvil.
Step 2.
Disconnect both the air and electricity
supplies.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Step 3.
Remove the M4 screw securing the
door on the left hand side of the main
Body Cover fabrication, and swing the
cover open against the hinges.
Step 4.
Loosen the lock-nut on the rear of the
belt pulley, and turn the bolt with the
aid of a spanner, either clock-wise or
counter-clockwise depending on which
direction the terminal needs to be
adjusted.
Repeat this adjustment until the correct
condition is obtained.
Note
Each complete revolution of the
adjuster moves the terminal
approximately 0.8mm in either
direction. Adjusting the bolt in a clock-
wise direction moves the terminal
towards the front of the press.
Step 5.
Close the access door, replace the cap
head screw, and reconnect the air and
electricity supplies.
6.2 Adjustment of the insulation
support
CAUTION !
Before removing the Safety Guard to
adjust the insulation support,
ensure that the air and electricity
supplies are disconnected.
Step1.
Set the Adjust Switch to the UP
position.
The ram rises to Top Dead Centre, and
the terminal is free to move relative to
the anvil.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Step 2.
Disconnect both the air and
electricity supplies.
Step 3.
Remove the safety Guard by undoing
the two cap head screws. Remove the
terminal tape from the capstan wheel.
Step 4.
Insulation crimp adjustment.
Release the crimping punches in the
ram, by loosening the cap head
retaining screw.
The insulation crimp height can be
adjusted to three different positions, by
turning the adjusting cam (part
no.2108-4109).
The position is dependant on the wire
insulation outside diameter. The
settings are marked as follows:- S =
Small insulation diameter, M = Medium
insulation diameter, L = Large
insulation diameter.
Select the appropriate setting for the
wire insulation size, and tighten the
retaining cap screw, whilst
simultaneously pushing the crimping
punches in an upward direction to
ensure that they are correctly seated in
the ram.

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JST AP-F6 PNEUMATIC CRIMPING MACHINE
Step 5.
Replace the terminals in the Index wheel,
re-connect the air and electricity supplies,
and refit the Safety Guard.
7. CRIMPING MACHINE MAINTENANCE
7.1 Lubrication
Ensure that the ram is regularly lubricated
with a general purpose machine oil
(approximately once every week).
7.2 Cleaning
The crimping dies are chrome plated, and
as a result they require polishing at regular
intervals with a good quality metal polish to
ensure that the terminals do not become
stuck in the punches due to a build-up of
deposits. If the deposits are not removed,
the terminals may become bent during the
stripping operation.
7.4 Filter Regulator adjustment
The air pressure on the Filter Regulator is
factory set to 0.6 MPa before despatch.
If the pressure is not set to this figure, the
regulator will require adjustment using the
following method:-
Pull the knob on top of the regulator in an
upward direction and rotate in either a
clockwise or counter-clockwise direction
until the gauge reads the correct pressure.
Push the knob down to lock it in position
once the correct pressure is achieved.
7.3 Shut Height Adjustment
The shut height of the press is factory set so
that when the ram is at Bottom Dead Centre,
the conductor crimp dies are closely touching to
ensure that the correct crimp height is
achieved.
If the linkage becomes worn it is possible that
the shut height will not be correct and the crimp
height will fluctuate.
If this problem occurs, contact the J.S.T.
Technical Services Department, because the
setting of the crimp height requires special
tooling.