JST AP-K2 Manuel utilisateur

AP-K2 CRIMPING

MACHINE

OPERATION

MANUAL

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PREFACE

The AP-K2 semi-automatic crimping machine is easy to operate, and is suitable

for mass production of crimped harnesses with chain terminals.

Before using the AP-K2 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, fault-finding and adjustment of the crimping machine and its

associated tooling.

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CONTENTS

Specifications

Page 4

1-1. Crimping machine specifications

Page 4

1-2. Applicator Specifications

Page 4

Installing the machine

Page 5

2-1. Machine Installation

Page 5

Machine preparation

Page 6

3-1. Mounting of the Reel hanger

Page 6

3-2. Mounting of the Applicator

Page 6

Prevention of tooling damage

Page 7

Prevention of terminal damage

Page 8

3-3. Mounting the Terminal reel

Page 9

3-4. Setting the counter

Page 10

3-5. Mounting the Safety guard

Page 10

Operation

Page 11

4-1. Manual operation

Page 11

4-2. Inspection before operation

Page 12

4-3. Operation under power

Page 12

Applicator

Page 13

5-1. Terminal feed position adjustment

Page 13

5-2. Bell mouth adjustment

Page 14

5-3. Feed-finger travel adjustment

Page 15

5-4. Crimp height adjustment

Page 15

5-5. Die part replacement

Page 16

5-6. Lubrication of Applicator

Page 16

Maintenance

Page 17

6-1. Lubrication

Page 17

6-2. Inspection and repair

Page 19

6-3. Positioning the solenoid bracket

Page 20

Fault finding

Page 21

Electrical circuit diagram

Page 25

Exploded views and parts list

AP-K2 Crimping machine exploded view

Page 26

MK-L Applicator

Page 28

MKS-L Applicator

Page 30

MKF-L Applicator

Page 32

MKS-LS Applicator

Page 34

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1. SPECIFICATIONS

The crimping machine is composed of the

crimping press and an applicator.

There are two basic types of applicators

(a total of four models).

1.1 Crimping Machine Specifications

1.2 Applicator specifications

Model no. MK-L (for-end feeding terminals)

º Weight 6.8 Kg

º Feed pitch 30mm max.

º Crimp height adjustment: Dial type

Model no. MKF-L (for-end feeding flag terminals)

º Weight 6.8 Kg

º Feed pitch 30mm max.

º Crimp height adjustment: Dial type

Models MK-L and MKF-L for end feeding

terminals, and models MKS-L and MKS-LS for

side feeding terminals. The crimping machine

utilises a quick-change system thus allowing quick

changeover times.

Model no: AP-K2

º External dimensions: 280mm Wide x

480mm Long x 560mm High

º Weight: 95 Kg

º Power supply: 220/240V AC single phase

50/60 Hz

º Power consumption: 680VA

º Crimping force: 1500 Kg

º Ram stroke: 30mm

º Ram speed: 260 strokes per minute

(60 Hz), and 220 strokes per minute

(50 Hz)

º Closed height: 160.0 mm ± 0.01 at B.D.C

Model no. MKS-L (for side-feeding terminals)

º Weight 6.4 Kg

º Feed pitch 30mm max.

º Crimp height adjustment: Dial type

Model no. MKS-LS (for side feeding terminals)

º Weight 4.5 Kg

º Feed pitch 30mm max.

º Crimp height adjustment: Dial type

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2. INSTALLING THE MACHINE

2.1 Installation

Mount the crimping machine on a solid foundation,

place a rubber mat between the machine and

foundation to reduce vibration and stabilise the

machine.

The diagram to the left illustrates the footprint

dimensions of the machine. Secure the machine to

the foundation with four M8 bolts.

The machine should be mounted so that the

crimping dies are at the approximate eye level of a

seated operator.

CAUTION

Ensure that the belt cover of the crimping machine

does not overhang the edge of the mounting

surface.

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3. MACHINE PREPARATION

3.1 Mounting the Reel hanger

Due to packing considerations, when you receive the machine the Reel hanger is not mounted on the

machine. Assemble the Reel hanger then mount it on the machine as illustrated below.

Step 1

Assemble the Reel hanger as shown in the photo

below.

Step 2

Mount the Reel hanger on the Crimping machine.

3.2 Mounting the Applicator

Step 1

Loosen bolts A and B with a 5mm hexagon

wrench supplied with the tool-kit.

Step 2

Remove the protective rubber collar from under the

dials on the applicator ram.

Step 3

CAUTION

Ensure that the shank is correctly located in the

ram. There is a danger of major tooling damage if

the tooling is not located correctly (as in the

photograph below).

Step 4

Securely fasten the clamps with the 5mm hexagon

key, and visually check that the tooling is mounted

correctly.

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PREVENTION OF TOOLING DAMAGE.

Place the rubber collar under the

ram head as shown in picture 1.

IMPORTANT.

Repeat this procedure every time

you remove an applicator from

the press.

Picture 1.

DO NOT leave the applicator

without the rubber collar attached,

as shown in picture 2.

Picture 3.

Picture 2

Picture 3, is a zoomed in view of

the punch and anvil when the

rubber collar is left off.

The two circled points are the

points of contact where the

damage will be caused.

Picture 3.

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PREVENTION OF TERMINAL DAMAGE.

1. Mount reel on reel holder attached to the

side of the press, as shown.

2. Adjust the collar; ensure that the collar is

adjusted so there is a light drag on the reel

prior to untying the reel.

3. Terminals are tied with wire, do not untie

before collar is fitted as the windings will

become loose, always re-tie after each

production run.

4. Make sure the reels are stored up on end in

the original box, do not lay the terminals on their

side as they can drop and get tangled.

CORRECT.

INCORRECT.

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3.3 Mounting the Terminal reel

Step 1

Mount the terminal reel to the reel hanger so

that the terminal barrels are facing the reel

guide.

Step 2

Feed the terminals through the terminal guide.

Mounting the MK-L applicator

Step 3

Push down the tension lever and engage the

hook with the feed plate so that the pressure

pad rises. Feed the terminal strip between the

guide rails.

Step 4

Place the first terminal at the correct crimping

position. Release the hook from the feed plate to

allow the pressure pad to apply pressure on the

strip.

Mounting the MKS-L applicator

Step 3

Rotate the wing bolt clockwise to raise the

pressure plate. Feed the terminal strip between

the guide rails.

Step 4

Place the first terminal in position so that the

terminal is centralised over the anvil. Rotate the

wing bolt counter- clockwise to lower the pressure

plate so that pressure is applied to the terminal.

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3-4. Setting the counter

The counter (5 digits) helps you to count the

number of crimped terminals processed.

Press the reset button to reset the counter to

zero.

3-5. Mounting the safety guard

There are many types of safety guards available, please consult JST for details.

A RELEVANT SET OF SAFETY GUARDS IS ALWAYS DESPATCHED WITH THE MACHINE

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