AP-K2N

CRIMPING

MACHINE

OPERATION
MANUAL

-:c: .:
.1ST

TheQualityConnection
 PREFACE

The AP-K2N automatic crimping machine is easy to operate, and suitable for mass

production of crimped harnesses with chain terminals.

Before using the AP-K2N, please read this manual so you can understand the proper

operating procedures and utilize all the features ofthe machine. We recommend you always

keep this manual near the machine to use as a reference. This manual also describes part­

replacement and repair procedures.

For Safe Operation

• For safety, you must always keep the safety guards mounted to the applicator and foot
switch while operating this machine.

• If you think something is wrong with the machine, immediately tum OFF the power
supply, then inspect the machine. If you must touch a part of the machine that moves,
always disconnect the power cord first.

• When you must touch an applicator mounted to the crimping machine; that is, when
mounting the applicator to the crimping machine, removing it from the machine, or
adjusting the crimp height, first tum OFF the power supply.

• When you manually operate the machine, first make sure the flywheel is not moving.
After manual operation, do not forget to remove the hand crank.

• Do not remodel the crimping machine.

 Table of Contents
,: ,,'.' .

1. Specifications 1

1-1 Crimping Machine Specifications 1

1-2 Applicator Specifications ~: , 1

2. Installing and Transporting the Machine . : ",' .: 3

2-1 Installation ~ ....•.........' 3

2-2 Transporting 3

3. Preparing for Operation 4

3-1 Mounting the Reel Hanger , 4

3-2 Mounting the Applicator 4

3-3 Mounting the Terminal Reel 5

3-4 Mounting the Safety Guard 6

4. Control Box Configuration 8

5. Operati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5-1 Manual Operation 9

5-2 Operation 10

6. Applicator Adjustment 12

6-1 Terminal Feed Position Adjustment '.' 12

6-2 Bell Mouth Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6-3 Feed Finger Travel Adjustment. 14

6-4 Crimp Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6-5 Die Part Replacement .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15

6-6 Greasing the Applicator 15

7. Crimping Machine Maintenance 16

7-1 Lubrication 16

7-2 Inspecti on and Repair .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

8. Trouble Shooting 19

9. Electrical Circuit Configuration 23

9-1 Electrical Circuit Diagram 23

9-2 AP-K2N Crimping Machine Exploded Diagram 24

9-3 Applicator Exploded Diagram 26

... , . AP-K2N CRIMPING MACHINE •

1. Specifications
The automatic crimping machine is com­ Models MK-L and MKF-L for end-feeding ter­
posed ofthe crimping machine and an appli­ minals, and models MKS-L and MKS-LS for
cator. There are 2 basic types of applicators side- feeding terminals. The crimping machine
(a total of 4 models): uses a quick-change system, so you can easily
switch between various applicators.

1-1 Crimping Machine Specifications

Model No. : AP-K2N

o External dimensions: 11.0" (280 mm)(W) x 18.9"
(480 mm)(L) x 19.9" (505
mm)(H)
o Weight 198 Ibs. (90 kg)
o Power supply : 100/110/220/240V AC single
phase, 50/60 Hz
o Power consumption : 680V A
o Pressure output 3,307 lbs. (1500 kgf)
o Ram stroke 1.18 (30 mm)
o Ram speed 260 strokes per minute (60
Hz), and 220 strokes per
minute (50 Hz)

1-2 Applicator Specifications

Model No.: MK-L (for end-feeding terminals) Model No.: MKS-L (for side-feeding terminals)
o Weight: 14.3 lbs. (6.5 kg) o Weight: 14.1 Ibs. (6.4 kg) .
o Feed distance: 1.18" (30 mm) max. o Feed distance: 1.18" (30 mm) max.
o Crimping height adjustment: Dial type o Crimping height adjustment: Dial type

Model No.: MKF-L (for end-feeding flag terminals) Model No.: MKS-LS (for side-feeding terminals)
o Weight: 15.0 Ibs. (6.8 kg) o Weight: 9.9Ibs. (4.5 kg)
o Feed distance: LI8" (30 mm) max. o Feed distance: 1.18" (30 mm) max.
o Crimping height adjustment: Dial type o Crimping height adjustment: Dial type

1
.AP-K2N-CRIMPING MACHINIi ..... ­

• Strip-crimp Applicator
Model No. : MKS-SC
o Dimensions 7.8" (198 mm)(W) x 7.3"
(186 mm)(L) x 8.0" (203
mm)(H)
D Weight 14.3 lbs. (6.5 kg)
o Applicable crimping
machines AP-K2, AP-K2N
o Applicable terminal : Small side-feeding contact
o Applicable wire : AWG#30 through AWG#20o)
o Operation method : Touch sensor operated, and
Foot switch operatedci

Note: 1. The touch sensor cannot be used for certain

wires.
2. When using the vacuum unit.

• Vacuum Unit
The MKS-SC applicator is designed to problems. The vacuum unit sucks away refuse to
drop stripped wire refuse into the hole. prevent such problems. Always use the vacuum
However, some refuse may remain because unit (SC-50l) with the MKS-SC applicator.
of static electricity and cause crimping

Model No. : RC-501

D Dimensions 6.3" (160 mm)(W) x 6.7" (170
mm)(D) x 2.8" (70 mm)(H)
DWeight 5.5 Ibs. (2.5 kg)
o Air pressure : 490 kPa (5 kgf/crrr')

.• ~ -".~-=-:"

2
... ,......• __.._.IIIIIiIlll"._IIII._AP-K2N CRIMPING MACHINE.

2. Installing and Transporting the Machine

2-1 Installation

10.3'" (260nvn)
Mount the crimping machine on a solid founda­
4-.394" (IOmm) cfia.
tion. If the location permits, place a rubber mat
between the machine and foundation to reduce
vibration and stabilize the machine. The diagram
to the left shows the footprint dimensions of the
machine. Secure the machine with four (4) M8­
bolts.

2-2 Transporting

Always mount the handles stored in the tool box

to move the machine. (As shown in the photo to
the left.) Never carry the machine by putting
your hands under the bottom ofthe belt cover, for
example.

3
• AP-K2N CRIMPING MACHINE . . , . . ,.

3. Preparing for Operation

3-1 Mounting the Reel Hanger
Because of packing considerations, when
you receive the machine the reel hanger is
not mounted to the machine. Assemble the
reel hanger then mount it to the machine as
shown on the right.
"""

Reel hanger- ­ T

3-2 Mounting the Applicator

Step 1 Step 2
You only need to loosen 2 bolts, A and B. Remove the rubber protector from the applica­
tor.

Step 3 Step 4
Place the applicator on the applicator base of the Snugly tighten bolts A and B.
machine. Pull up the slide while pushing the
lever in the direction of the arrow shown in the
photo below so the collar on the top shank slides
into the ram groove of the machine. Then push
the applicator until it stops.

4
_.I.,.
AP-K2N CRIMPING MACHINE.

3-3 Mounting the Terminal Reel

Mount the terminal reel to the reel hanger so
the terminal barrels are facing the reel guide.
Then, feed the terminals through the termi­
nal guide to the applicator.

Mountlna the MK-l Applicator

Step 1 Step 2
Push down the lever, and engage the hook with Place the first terminal at the correct crimping
the feed plate so the pressure pad rises. Feed the position. Release the hook from the feed plate to
terminal strip between the guide plates. let the pressure pad come down.

i ...
!
. I
'1·
J

•
Mounting the MK8-l or MKS-lS Applicator
Step 1 Step 2
Rotate the wing bolt clockwise to raise the pres­ Place the first terminal in position in the applica­
sure plate. Feed the terminal strip between the tor. Rotate the wing bolt counterclockwise to
guide plates. lower the pressure plate so pressure is applied to
the terminal.

5
• AP-K2N CRIMPING MACHINE • • • • • • • • • • • • • • • • . . . , . . "

• Applicator and Terminal Reel Mounted on the Crimping Machine

MK-L MKS-L

3-4 Mounting the Safety Guard

For safety, you must always keep a safety guard mounted to the applicator. In the photos above,
the safety guards have been removed for clarity.

When Using the MK-l. MKS-l,Or MKF-L Aoplicator

Step 1
Remove the second set (from the top) of hex. socket
head screws securing the left and right plates.
Step 2
Mount the safety guard mounting lugs to the tapped
holes.
Step 3
Mount the safety-guard to the mounting lugs with the
screws as shown in the figures to the right.

6
• ..., AP-K2N CRIMPING MACHINE.

When Using the MKS-LS ApplicatOr

Step 1
Mount the safety guard mounting lugs in the tapped
holes in the left and right plates.

Step 2
Mount the safety guard to the mounting lugs with the
screws as shown in the figure to the right.
MKS-LS

When Using the MKS-L (For SPC or PSL Splices) Applicator

Old tyoei
Mount the safety guard to the adjustment plate as
shown in the figure to the right.

New tvpei
Step 1
Mount the 2 safety guard mounting lugs to the feed
plate base.
Step 2
Mount the safety guard to the mounting lugs with the
2 screws.

..

-AP-K2N CRIMPING MACHINE .......

4. Control Box Configuration

1. COUNTER 4. POWER ON pushbutton

Counts the number of crimped terminals. Reset (green indicator lamp)

the counter to 0 to begin counting crimped termi­ Press this pushbutton to tum ON the motor. The
nals. indicator lamp lights, and stays lit while the
motor is running.
2. RESET pushbutton
Press this button to reset the counter (sets the 5. POWER OFF pushbutton

display to 0). (red indicator lamp)

Press this pushbutton to tum OFF the motor. The

3. Function indicator lamps POWER ON indicator lamp (green) turns OFF.
• REAR COVER
6. Circuit Protector pushbutton
The REAR COVER indicator lamp is lit when
the belt cover or hand crankcoverisopen. While When the crimping machine is overloaded, the
this lamp is lit, the motor doesn't operate even if circuit protector pushbutton pops out and the
you tum ON the power supply. If you open either motor stops. Wait for at least one minute, press
of the covers while the motor is running, the the circuit protector pushbutton in, then press the
POWER ON pushbutton.
motor stops.
Consult JST if you think the circuit protector is .
• AUTO POWER OFF
activated too often - the crimping machine may
When the crimping operation stops for 3 minutes be damaged.
or more, for example when you unintentionally
leave the power ON after finishing work or 7. OPE. LIGHT switch
temporarily stop the operation, the motor auto­ This switch controls the operation light. Press it
matically stops and the AUTO POWER OFF to the right to tum the light ON, and to the left to
indicator lamp lights. tum it OFF.
If the REAR COVER indicator lamp lights,
close the cover and press the POWER ON
pushbutton to restart. If the AUTO POWER OFF
indicator lamp is lit, just press the POWER ON
pushbutton to restart.

I. COUNTER

2. RESET pushbutton

3. Function indca1Dr lamps

4. POWE R ON pushbul1Dn (ll'"" indca1Dr lamp)

5. POWER OFF pushbUllon (red indicator lamp)

6. Circuit Prolec1Dr pushbutton

7. OPE. LIGHT swi1ch

8
• .IST AP-K2N CRIMPING MACHINE.

5. Operation
5-1 Manual Operation
. When you first use an applicator or whenever you
replace a die part, manually operate the machine
before executing automatic operation to make
sure the terminals are crimped correctly.

Step 1
Disconnect the power cord to prevent a potentially
dangerous accident. Do not skip this step!

Step 2
Insert your finger in the clutch lever operation opening
located on the side of the body and push down the
connecting pin.

Step 3
Rotate the hand crank cover so the hand crank hole is
visible. Mount the hand crank and use it to rotate the
main shaft one revolution counterclockwise. The ram
moves one stroke and crimps the terminal.

ICAUTIONI
Be sure to rotate the hand crank one complete revolu­
tion (until it stops). If you don't turn the hand crank
(main shaft) one complete revolution, the ram moves
automatically when you turn on the machine: this is
very dangerous.

Step 4
Remove the hand crank, and cover up the hand crank
hole with the cover. The machine motor doesn't tum
ON unless you cover up the hole.

9
• AP-K2N CRIMPING MACHINE - - - - - - - - - - - - - .

5-2 Operation
Step 1
Connect the power supply cord and the foot switch
cord to the control box. Connect the other end of the
power supply cord to the power supply.

. Step 2
Press the OPE. LIGHT switch to the right to turn ON
the operation light power.

Step 3
Rotate the rotary switch on top of the operation light
clockwise to tum ON the light. Rotate the switch
clockwise also to tum OFF the light. A 20W bulb
comes standard with the lamp. You can replace the
bulb with a bulb of up to 60W.

Step 4
To count the number of crimped terminals, press the
.RESET pushbutton to set the counter display to O.

10
 • .IBT AP-K2N CRIMPING MACHINE.

Step 5
Check that neither ofthe function indicator lamps is lit,
then press the POWER ON pushbutton (green). The
motor starts .
Note: If a. function indicator lamp is lit, the motor
doesn't start even if you press the POWER ON
pushbuttop.The photo to the right indicates
w hen the rear cover is open.

Step 6
Position a wire over the terminal, and press the foot
switch once to activate it. The terminal is crimped, and
the following terminal is fed to the crimping position.

Step 7
When you finish work, rotate the operation light rotary
switch clockwise to tum it OFF, tum OFF the OPE.
LfGl-l'Tswitch, then press the POWER OFF pushbutton
(red).

!CAUTION I
If any problems occur during operations, immediately
,.. press the POWER OFF pushbutton to turn OFF the
motor, and find the problem. When you inspect a
moving section ofthe crimping machine or applicator,
not only turn OFF the power supply but also disconnect
the power cord for safety.

11
• AP-K2N CRIMPING MACHINE - - - - - - - - -. . ---!!IIIII-....,.."
6. Applicator Adjustment
6-1 Terminal Feed Position Adjustment
When Using the MK-L Applicator
Adjust the terminal feed position to adjust the terminal
Adjusbnenl shaft .
crimping position. Before making this adjustment, be
sure the applicator is mounted on the crimping ma­
chine and the ram is at top dead center.
Loosen the bolt and nut shown in the photo to the right.
Use the hand crank to rotate the adjustment shaft so the
feed finger moves to place the terminal in the right
position. Rotate the adjustment shaft counterclockwise
to move the terminal toward the die side, and clockwise
to move it away from the die. When you finish the
adjustment, re-tighten the bolt and nut.

When Using the MKS-L Applicator

Adjust the terminal feed position to adjust the terminal
crimping position. Before making this adjustment, be
sure the applicator is mounted on the crimping ma­ Adjuslmenl shaft

chine and the ram is at top dead center.

To position a terminal to the center of the die, follow
the procedure below.
Loosen the bolt and nut. Use a hand crank to rotate the
adjustment shaft so the feed finger moves to place the
terminal in the correct position. Rotate the adjustment
shaft counterclockwise to move the terminal toward
the die, and clockwise to move it away from the die.
When you finish the adjustment, re-tighten the bolt and
nut.

12
·JIIT---------------AP-K2N CRIMPING MACHINE.

6-2 Bell Mouth Adjustment

When Usjng the MK-L Applicator
Adjust the terminal feed position to adjust the bell
mouth. Refer to section 6- I.
When Using the Old Type MKS-L Applicator
Move the entire feed plate to obtain the desired bell
mouth crimp. First, loosen the feed fingerbolt located
on the back side of the applicator. Then loosen the 2
feed plate bolts located at the bottom of the applicator.
Rotate the adjustment screw clockwise to increase the
bell mouth (move the feed plate to the front), and
counterclockwise to decrease the bell mouth (move the
feed plate to the back). Re-tighten the bolts, and make
a sample crimp to be sure the bell mouth is appropriate.
If not, repeat the procedure above until you attain the
desired bell mouth.
You need to loosen the feed finger bolt because the feed
finger may be broken in the guide/feed plate groove
when the feed plate moves. After adjusting the feed Adjustment screw

plate position, re-tighten the feed finger bolt so the

finger is positioned in the center of the guide groove.
When Using the New Type MKS-L Applicator
Move the entire feed plate to adjust the bell mouth.
Follow the 4-step procedure below.

Step 1
Loosen the feed finger bolt.

Step 2
Loosen the 2 hexagon nuts.

Step 3
Rotate the hexagon socket bolt behind the hexagon
nuts counterclockwise to increase the bell mouth,
clockwise to decrease it.

Step 4
Re-tighten the hexagon nuts and feed finger bolt.

13
 -0. '<

6-3 Feed Finger Travel Adjustment

Applicators are adjusted at ex-works to obtain appropriate feed distance according tothe terminal
type. Adjustment is required only when a terminal with a different pitch is used; or when the dies
are replaced to use a different type of terminal. Consult JST for details .

. 6-4 Crimp Height Adjustment

The applicator has 2 dials to adjust the crimp height. Use the upper dial to adjust the conductor crimp
height - the dial is graduated with letters from A through H. Use the lower dial to adjust the
insulation crimp height - the lower dial is graduated with numbers from 1 through 8..
Note, however, these dials do not indicate the graduation according to the wire size. Make some
samples to measure the crimp height, and adjust the dials to attain the desired crimp height.

• Conductor Crimp Height Adjustment • Insulation Crimp Height Adjustment

(wire barrel) (insulation barrel)
Setting the applicator crimp height adjustment to The crimp height increases (the crimp gets
graduation A produces the lowest height crimp weaker) as you increase the graduation number.
(the strongest), and setting it to H produces the Make some samples to attain the desired crimp
highest. The crimp height increases approxi­ height.
mately .002" (0.05) mm per graduation. Make
some samples to attain the desired crimp height.

ICAUTIONI
1. Set the dials at H-8 to begin crimp height 2. The proper dial settings may dijferdepending
adjustment. This prevents die parts from be­ on the wire. Thus, always measure the crimp
ingdamaged by excessive crimping. height with a micrometer to be sure the crimp
height meets the desired value.

3. If the applicator doesn'tprovide the desired 4. Do not adjust the shut height of AP-K2N
crimp height by adjusting the dials, replace crimping machine for adjusting the crimp
the wire block or insulation block: Various height.
size blocks are available from 1ST. Tell 1ST
the Nos. ofthe blocks you are using now, and
we will send you the appropriate block.

14
_ ...,. AP;.K2N CRIMPING MACHINE.

6-5 Die Part Replacement

The crimping dies are consumable parts. When a

die is worn to the point it results in a bad crimping NOTE:

shape, replace it with a new one of the same part

Refer to Crimping Manuals
number impressed on the die; The replacement is to check the crimping shape.
not difficult but requires some experience. Con­

sult 1ST if you have a problem changing a crimp­

ing die.

6-6 Greasing the Applicator

Periodically, lightly grease the parts indicated in

the photos on this page.

Remove the slide from the body, then apply grease

to the oil grooves on the front and back surfaces

and both sides of the slide.

Loosen the locking bolt until its head appears, Apply grease here
remove the feed shaft, then apply grease to the oil
groove and roller section of the feed shaft.
locking boll
When you re-mount the feed shaft to the body,
assemble them so the feed shaft slot is engaged
with the tip of the locking bolt.

Loosen the hex. nut and hex. socket head bolt, and
remove the feed lever pin.•. Then apply grease to
the feed lever pin oil groove.

15
.AP-K2N CRIMPING MACHINE ----------..,..

7. Crimping Machine Maintenance

ICAUTION I
Disconnect the power cord before doing crimping machine maintenance.
7-1· Lubrication
Main shaft bearing
Lightly grease the main shaft bearing once a year.

Ram Section
Open the ram cover and add a few drops ofmachine oil
in the 3 oiling holes once a day.

Note: Do not add too much oil; excessive oil may

spatter during crimping operation.

Clutch Section
Clutch section oiling locations
Open the belt cover once a month, and add a few drops
of machine oil to the oiling locations of the clutch
section.

Roller Clutch
Step 1
While slowly rotating the flywheel, pull the V-belt to
the side to remove it.

Step 2
Use a retaining ring extractor to remove the retaining
ring on the flywheel.

16
 ',;, .

Step 3
Pull out the flywheel to remove it. At this time be
'.
careful because the stick rollers inside of the flywheel
can fall out. Check that a tptat 6f 7 stick rollers are
assembledto the clutch cam> .

Step 4
Remove any old grease, and lightly apply grease (I to
2 cm3) to the flat face of the inside clutch cam and the
7 stick rollers.

Specified grease: Multemp PS No.1 mfd by Kyodo Yushi Co. Ltd.

Step 5
Assemble the flywheel, V-belt, and rings as shown in
Photo A. Photo B is an example of an incorrect assem­
bly. If the clutch lever is not engaged with the clutch
cam (Photo B), the flywheel cannot be mounted
properly.

Notes
1. Use the specified grease. Using a different type of
grease may cause problems.
Photo A
2. Generally, you seldom need to apply grease.

Photo B

7-2 Inspection and Repair

• Ram Stability
Every 6 months, physically check that the ram is not
wobbly. During normal operation you can also tell if •
the ram is unsteady because the noise during crimping
increases and/or the crimp height is unstable.
Grip and shake the ram to check for stability. If it is not
stable, use the 5-step procedure on the next page to
CJ!
•. !
adjust it. : !
n

17

-AP-K2N CRIMPING MACHINE ",..,. . -.

• Adjustment Procedure .
Step 1
Remove the 2 box-nuts from the side wall of the ram.

Step 2
Loosen the 3 bolts on the right side of the adjustment
ram guide.

Step 3
Snug up the ram guide adjustment screws just tight
enough so you can manually move the ram up and
down with your hand, but it does not slide down by
itself. Next, use your hand to check that the ram does
not wobble, and that it moves smoothly.

Step 4
Re-tighten the bolts, then replace and tighten the box
nuts.

StepS
Make a final check to be sure the ram operation is
smooth and stable.

• Positioning of the Solenoid Bracket

Once a year, remove the belt cover and check that the
solenoid bracket is properly positioned. As shown in
the photo, the clearance should be .236 to .276" (6 to •
7 mm). Adjust the clearance to that height, and tighten
the bolts. After you make the adjustment, press the
clutch lever several times to check for smooth motion.

lR
• ..,-• •- -• •- -. . . . AP-K2N CRIMPING MACHINE.

a.Trouble ShooUng

OK

Press
The motor the foot switch (1) The connecting pin is broken.
runs.: (2) A solder joint on the foot
once.
switch metalsocket is bad.
(3) The foot switch cord is broken.
(4) A clutch spring has gone slack
or broken.
(5) The control box is defective.

( 1) The power cord

is disconnected.

Press the (2) The power cord (l) A suspension spring has gone
POWER ON is broken. slack or is removed,
pushbutton. (2) The clutch lever or stopper is
(3) A solder joint on ·womout.
the power cord (3) The solenoid is defective.
metal socket is (4) The control box is defective.
bad.
1.
The motor (4) The circuit pro­ (l) The solenoid is defective.
doesn't run. tector is tripped. (2) A suspension spring is broken.
The ram clunks (3) The control box is defective.
(5) The hand crank
many times.
hole cover on
the flywheel is
open. (1) A stick roller is wom out.
5. (2) Grease is applied incorrectly, or
The ram moves
(6) The clutch is the wrong grease is applied to
too slowly, or
engaged. the roller clutch.
stops at bottom
(3) The applicator is seized.
dead center.
(4) The clutch plate is removed.

19
.AP-K2N CRIMPING MACHINE . . . . . . . . __

1. The motor doesn't run.

(1) The power cord is disconnected.
Connect the power cord.
(2) The power cord is broken.
Replace the power cord with a new one.
. (3) A solder joint on the power cord metal socket
is bad.
Solder the metal socket.
B;:~:~I :1 • :l'-::: ­
t~!MI.·"'­
n:,-;-,'

(4) The circuit protector is tripped.

IT)

o r~
: M:i1!­~...:~.
..:".'".--'
';II-I1:t"1',­
:P'IJ!':-'
.::>,,'
, ...~.lt~n 11 : ... ;1:-' ;
; ~­
'!:: Ii;~"
Press in the circuit protector. pushbutton. If the "

circuit protector has just tripped, wait for a minute \[2)

. :=:
'!~'!""f r.'
.~ .....
: .. I·II'r'I'····
,:~o./. il;l!"!
"
"','.-0:'
_rio ,";
.,",,01:

or more before you press it in. Consult JST if it . Normal po~ition ,: ~r. ,i"

-~;r

••
trips too often.

(5) The hand crank hole cover on the flywheel is

open.
Close the cover to cover the hole.
(6) The clutch is engaged. -­

Use the hand crank to rotate the main shaft

counterclockwise until it stops.
--~.

r~nk hole cover

2. The ram doesn't move.

(1) The connecting pin is broken.
Replace the connecting pin with a new one.

20
_JBT C

. " . . . ._ ­ IIIIIIIIiI AP-K2N CRIMPING MACHINE.

(2) A solder joint on the foot switch metal socket

is bad,
Solder the metal socket.

(3) The foot switch cord is broken.

Replace the foot switch cord with a new one. Wire
the micro switches and metal socket as shown in
the figure to the right.

(4) The clutch spring has gone slack or is broken.

Replace the clutch spring with a new one.

(5) The control box is faulty.

The control box needs repair. Send the control box
to the nearest JST office.

3.The ram clunks a coupleot times.

(1) A suspension spring has gone slack.
Replace the suspension spring with a new one.

(2) The clutch lever or stopper is worn out.

Replace the part with a new one.

21
.AP-K2N CRIMPING MACHINE ----------------In­
(3) The solenoid is defective.
Adjust the mounting between the solenoid core
and connecting plate. Check from the directions
of A and B as shown in the photo at the bottom of
the page, and adjust them so they are aligned.
(4) The control box is defective.
The control box needs repair. Send the control box
to the nearest JST office.

4. The ram clunks many times.

(1) The solenoid is defective.
Refer to 3-(3) above.
(2) A suspension spring has gone slack.
Replace the suspension spring with a new one.
(3) The control box is defective.
The control box needs repair. Send the control box
to the nearest JST office.

5. The ram moves too slowly, or stops at

bottom dead center.
(1) A stick roller is worn out.
Replace the stick roller with a new one. Refer to
Section 7 Crimping Machine Maintenance for
details ..
(2) Grease is applied incorrectly, or the wrong
grease is applied to the roller clutch.
Apply the specified grease in the prescribed loca­
tions. Refer to Section 7 Crimping Machine Main­
tenance for details.
(3) The applicator is seized.
The applicator needs repair. Consult JST.
(4) The clutch plate is removed.
Mount the clutch plate.

22
• .IBT AP-K2N CRIMPING MACHINE.

9. Electrical Circuit Configuration

9-1 Electrical Circuit Diagram

lODV AC
nsv AC
nOVAC
240VAC

10A l00V AC
SA llSV AC
3A 220VAC
240VAC

,......,.11----..1 1--­ --1 SSR2

t--------{ M

@]Q]
J P
PCB9006
-214-+35+

P.M.S. (for hand crank hole cover)

P.M.S. (for flywheel cover)

Metal socket for F/S PCB9006C PCB9006B

(power supply switch (reset switch)

23
.AP-K2N CRIMPING MACHINE - ------­ ......
9-2 AP-K2N C· .
rampmg Machine Exploded Diagram

'><t.
-.IST------...--­ AP-K2N CRIMPING MACHINE.

No. Part Name Part No. No. Part Name Part No.
101 Body K2-1101 146 Spacer K2-4163
102 Motor plate K2-4105 147 Connecting pin K2-4164N
103 Belt cover K2-21 06 148 Connecting plate K2-4165N
104 V-pully K2-4107 149 Solenoid bracket K2-4166N
105 V-belt (M-39) K2-Pl09 150 Spring-loaded hinge K2-P167
106 Flywheel K2-3110 151 Reel hanger K2-3173
107 Back stop cam K2-3111 152 Reelguicle K2-4175
108 Spring post K2-4112 153 Solenoid K2-P176
109 Clutch cam K2-3113 154 Spring post K2-4177
110 Spacer K2-4114 155 Spring K2-4178
111 Ball bearing (6205ZZ) K2-Pl15 156 Spring post K2-4179
112 Key (8x7x59 I, both edges rounded) K2-Pl16 157 Terminal guide K2-4180
113 Retaining ring (C-25) K2-Pl17 158 Hand crank K2-3181
114 Retaining ring (C-52) K2-Pl18 159 Grip bar K2-4182
115 Outside clutch ring K2-4120 160 Reel collar K2-4183
116 Stick roller K2-4121 161 Reel rod K2-4185
117 Plate K2-4122 162 Elbow K2-4186
118 Inside clutch cam K2-4124 163 Nut K2-4187
119 Retaining ring (C-62) K2-P125 164 Motor (SP-KR, 200W, by Mitsublshi) K2-P190
120 Retaining ring (C-30) K2-Pt26 165 Positioning block K2-4192
121 Ball bearing (6206ZZ) K2-P127 166 Applicator guide (lor lixing) K2-4193
122 Retaining ring (C-40) K2-P128 167 Applicator guide (lor gUiding) 1<2-4194
123 Needle bearing (NA5908) K2-P129 168 Applicator base K2-P196
124 Main shaft K2-3130 169 Hand crank bar (not shown) K2-4197
125 Bush K2-4131 170 Operation light K2-P198
126 Ram cover K2-3132 171 Needle bearing (NTN RNM9132R) K2-P201
127 Pressure plate K2-4135 172 Handle crank hole cover K2-4202N
128 Split nut K2-4136--1 173 Shaft K2-4205N
129 Adjustment screw K2-4137 174 Flange K2-4206N
130 Ram head K2-3138 175 Internal gear washer K2-P207
131 Hexagon box nut M6type-l, 3 shapes K2-P141 176 Hex. nut K2-P208
132 Adjustment ram guide K2-3145 177 Hand crank hole delecting plate 1<2-4209N
133 Hook key (C-18, by Takigen) K2-P146 178 Wave washer rNW-8, by OChiai Seisakusho) K2-P21 0
134 Ram K2-3147 179 Photo microsensor mounting eye K2-4212N
135 Fixed ram guide K2-3148 180 Photo microsensor (EE-SX672, by Omran) K2-P213
136 Fulcrum pin K2-4152 181 Socket (EE-l001, by Omron) K2-P214
137 Back stop lever K2-4153 182 Rear cover detecting plate K2-4216N
138 Spring post K2-4154 183 Retaining ring (SlW-8, by OChiai Seisakusho) K2-P218
139 Spring K2-4155 184 Rivet (No. 2X4.8) K2-P219
140 Stopper K2-4156--1 185 Spring pin (3x22) K2--P220
141 Pad K2-4157 186 Nylon damp (NK-3N. by Kitagawa Kogyo) (not shown) K2-P221
142 Clutch lever K2-3159 187 E-shaped retaining ring ("3) K2-P223
143 Fultrumpiri K2-4160 188 Rat hinge (B43ISU5-1. by Takeshita Klnzoku) K2-P224
144 conar K2-4161 189 Name plate K2-423°N
145 E-shaped retaining ring ("9) K2-P162

No. Part Name Part No. No. Part Name PartNo.

SOO Control box (ASS'¥) K2-35OO 511 Metal socket (F/S) K2-PSl1
SOl Control box K2-3S01 512 Power cord (ASS'Y) K2-PS12
S02 PCB (9006A. ASS'¥) K2-3502 513 F001 switch cord (ASS"¥) K2-PS13
S03 PCB (9006B, ASS'¥) K2.3503 514 PCB (9006A) K2-4502-1
504 PCB (9006C, ASS'¥) K2-3504 515 PCB (9006B) K2-4503-1
S05 Counter K2-P5Q5 516 Reset pushbuflon K2-P503-1
S06 Circuit protector K2-PS06 517 PCB (9006C) K2-4504-1
S07 Operation light switch K2-PS07 518 Power ON pushbutton K2-P504-2
SOS Translormer K2-P50S 519 Power OFF pusobutton K2.P504-3
509 Solid state relay K2-P509 520 Socket K2-P504-5
510 Metal socket (POWER) K2-PS10

Note: Nos. 501 through 51 I, and Nos. 514 through 520 are not shown in !!t.~ diagram.

25
.AP-K2N CRIMPING MACHINE - - - - - - - - _ - - - - - - . . , . . "

9-3 Applicator Exploded Diagram

1. MK-L Applicator

26
• ..,. AP-K2N CRIMPING MACHINE.

No. Part Name Part No. No. Part Name Part No.
101 Body MA02-101 141 Release lever MAO1-473
102 Slide MA02-210 142 Release lever pin MAOl-474
103 Copper bar (03.8x2) 143 Pressure pad pin MAOl-472
104 Positioning spring MAOl-214 144 Pressure pad MAOl-470
105 Positioning pin MAOl-213 145 Feed plate
,I
106 Insulation disk MAOl-215 146 Spring anchor MAOl-350
107 Spring MAOl-216 147 Die block MA01-l05
108 Steel ball (03) 148 Die plate MA01-l04
109 Wire disk MAOl-211 149 Side block MA01-l07 I'

110 Shank MAOl-217 150 Wire block I

111 Cam MA02-335 151 Insulation block I

112 Spring cap MAOl-477 152 Block ring MAOl-225

113 Spring block MAOl-479 153 Crimper (A)
114 Spring MAOl-480 154 Crimper (8)
115 Feed lever support pin MAOl-343 155 Die holder ring
116 Stripper hanger MA02-481 156 Stripper
117 Plate (L) MA02-102 157 Guide plate (R)
118 Plate (R) MA02-103 158 Guide plate (L)
119 Feed shaft MAOl-338 159 Shear blade anvil (A)
120 Ring nut MAOl-341 160 Shear blade anvil (B)
121 E-shaped retaining ring (06) 161 Crimper anvil (A)
122 Lever block MAOl-340 162 Crimper anvil (B)
123 Adj. bolt MAOl-339 163 Shear blade
124 Cam roller MAOl-308A 164 Spacer
125 Cam roller shaft MAOl-337A
126 Feed lever (A) MAOl-342
127 Feed lever pin MAOl-344
128 Feed lever (B) MAOl-345
129 Feed finger pin MAOl-347
130 Feed finger spring MAOl-348
131 Feed finger
132 Return spring MAOl-349
133 Hex. nut (M4. type-l)
134 Stroke adj. shaft MAOl-331
135 Stroke adj. bearing MAOl-332
136 Stroke adj. plate MA02-330
137 Stroke adj. bearing nut (M12 type-4)
138 Stroke adj. screw MAOl-334
139 Hook MAOl-475
140 Hook pin MAO1'-476

Note
0: mmdia
I: mmlength 27
·AP-K2N CRIMPING MACHINE
2. MKS-l (new type) - - - - - - -. . . . . . "

28

• JBT AP-K2N CRIMPING MACHINE.

NO}'·········<··········<·······_ ·::,:::::::p.::Nqt:.::.::::::·:·
. ... . .........

Nd.··· ............·partt#lIJ'lEJ :~ ~ ~ ;~:.: ~ ~ >:~: ~ [;~: ~ ;:~:~ ~; ~ ;:;[~ :

.?\Part··Noy·
101
Body MA03-101 141
Pressure plate
102
Slide MA03-210 142
Pressure spring
103
Copper bar (3.8mm dia. x 2) 143
Return spring MA03-349
104
Spring MAOl-214 144
Feed finger
105
Positioning pin MAOl-213 145
Feed finger holder
106
Insulation disk MAOl-215 146
Stripper bracket
107
Spring MAOl-216 147
Stripper
108
Steel ball (3mm dia.) 148
Stripper screw
109
Wire disk MAOl-211 149
Plain washer
110
Shank MAOl-217 150
Guide plate (R)
111
Cam MA03-335 151
Guide plate (l)
112
Die block MA03-105-1 152
Feed plate
113
Die plate MA03-104-1 153
Spacer
114
Side block MA03-107-1 154
Crimper (A)
115
Feed lever support pin MAOl-343 155
Spacer
116
Feed plate base MA03-106-1 156
Crimper (B)
117
Spring MA03-355 157
Punch (R)
118
Adjustment bolt MA03-399-1 158
Shear blade
119
Feed shaft MAOl-338 159
Shear blade spring
120
Ring nut MAOl-341 160
Shear blade supporter
121
E-shaped ret. ring (6mm dia.) 161
Shear blade base
122
lever block MAOl-340 162
Crimper anvil (B)
123
Adjustment bolt MA03-339 163
Crimper anvil (A).
124
Cam roller MAOl-30BA 164
Spacer
125
Cam roller shaft MAOl-337A 165
Scrap cover
126
Feed lever (A) MAOl-342 166
Wire block
127
Feed lever pin MAOl-344 167
Insulation block
128
Feed lever (B) MAOl-345 168
Block ring MA01-225
129
Feed finger pin MAOl-347
130
Feed finger spring LS-4321

131
Plate (l) MA03-1 02
132
Plate (R) MA02-103
133
Hex.nut (M4, type-1)
134
Stroke adj. shaft MAOl-331
135
Stroke adj. bearing MAOl-332
136
Stroke adj. plate MA03-330
137
Stroke adj. nut (M12, type-4)
138
Stroke adj. screw MAOl-334
139
Spring anchor pin MA03-352
140
Spring anchor MA03-350

29
• AP-K2N CRIMPING MACHINE

3. MKS-L Applicator (old type) -.-r." ­

_ - - -. . . .

30

_ .IBT . ._I11111 AP-K2N CRIMPING MACHINE.

•...
. PartNam~«, •.... ...• F'ai:tN~e/:·:i
.""

No. . Part No.. )\f<K ::..-x-...... ::;:<::;:: =}:::"::: ;..;

'iPad.NqLJU •
101 Body MA03-101 141 Pressure plate
102 Slide MA03-210 142 Pressure spring
103 Copper bar (3.8mm dia. x 2) 143 Return spring MA03-349
104 Spring MA01-214 144 Feed finger
105 Positioning pin MA01-213 145 Feed finger holder
106 Insulation disk MA01-215 146 Stripper bracket
107 Spring MA01-216 147 Stripper
108 Steel ball (3mm dia.) 148 Stripper screw
109 Wire disk MA01-211 149 Plain washer
110 Shank MA01-217 150 Guide plate (R)
111 Cam MA03-335 151 Guide plate (L)
112 Die block MA03-105-1 152 Feed plate
113 Die plate MA03-104-1 153 Spacer
114 Side block MA03-107-1 154 Crimper (A)
115 Feed lever support pin MA01-343 155 Spacer
116 Feed plate base MA03-1 06-1 156 Crimper (B)
117 Spring MA03-355 157 Punch (R)
118 Adjustment bolt MA03-399-1 158 Shear blade
119 Feed shaft MA01-338· 159 Shear blade spring
120 Ring nut MA01-341 160 Shear blade supporter
121 E-shaped ret. ring (6mm dia.) 161 Shear blade base <,

122 Lever block MA01-340 162 Crimper anvil (B)

123 Adjustment bolt MA03-339 163 Crimper anvil (A)
124 Cam roller MA01-30BA 164 Spacer
125 Cam roller shaft MA01-337A 165 Scrap cover
126 Feed lever (A) MA01-342 166 Wire block
127 Feed lever pin MA01-344 167 Insulation block
128 Feed lever (B) MA01-345 168 Block ring MAOt-225
129 Feed finger pin MA01-347
130 Feed finger spring (O.6mm dia.) MA01-348
Feed finger spring (0.45mm dia.) LS-4321
131 Plate (L) MA03-1 02
132 Plate (R) MA02-103
133 Hex.nut (M4, type-l)
134 Stroke adj. shaft MA01-331
135 Stroke adj. bearing MA01-332
136 Stroke adj. plate MA03-330
137 Stroke adj. nut (M12, type-4)
138 Stroke adj. screw MA01-334
139 Spring anchor pin MA03-352
140 Spring anchor MA03-350

31

_ AP-K2N CRIMPING MACHINE

4. MKF-LAppl· --------
"" •. " .

Icator

--­ .. -

32
• .IST . ._ _. . .IIIIIII._AP-K2N CRIMPING MACHINE.

No. Part Name Part No. No. Part Name Part No.
101 Body NF-2101 141 Bracket NF-4133
102 Slide NF-3118 142 Spring post NF-4159
103 Copper bar (03.8x2 I) 143 Return spring MA01-349
104 Positioning spring MA01-214 144 Spring NF-4126N
105 Positioning pin MA01-213
106 Insulation disk NF-4121 146 Keep plate NF-4125
107 Spring MA01-216 147 Crimper anvil base NF-4105
108 Steel ball (03) 148 Feed plate NF-2129
109 Wire disk NF-4120 149 Feed lever support pin NF-4163
110 Shank MA01-217 150 Needle bearing (K12x15x13)
111 Cam NF-4168 151 Collar NF-4154
112 Guide shoe NF-4140 152 E-shaped retaining ring (09)
113 Tension spring NF-4117 153 Guide block NF-4165
114 Fulcrum bolt NF-4115 154 Holder block NF-4147
115 Feed lever support pin MA01-343 155 Pressure plate
116 Spring post NF-4116 156 Guide plate (R)
117 Plate (L) NF-4114 157 Guide plate (L)
118 Plate (R) MA02-103 158 Pin NF-4109
119 Feed shaft MA01-338 159 Feed finger
120 Ring nut MA01-341 160 Shear blade
121 E-shaped retaining ring (06) 161 Shear blade anvil (A)
122 Lever block MA01-340 162 Shear blade anvil (B)
123 Adj. bolt MA01-339 163 Tension spring NF-4110
124 Cam roller MA01-308A 164 Spring post NF-4108
125 Cam roller shaft MA01-337A 165 Spring post NF-4111
126 Feed lever (A) MA01-342 166 Wire block
127 Feed lever pin MA01-:l44 167 Insulation block
128 Feed lever (B) NF-4138 168 Block ring MA01-225
129 Feed finger pin MA01-347 169 Crimper (A)
130 Feed finger spring MA01-348 170 Crimper (B)
131 Feed adj. plate NF-4137 171 Die holder ring
132 Spring post NF-4139 172 Crimper anvil (A)
133 Hex. nut (M4. type-1) 173 Crimper anvil (B)
134 Stroke adj. shaft MA01-331 174 Feed finger holder
135 Stroke adj. bearing MA01-332
136 Hook NF-4113 •

137 Stroke adj. nut (M12, type-4)

138 Stroke adj. screw MA01-334
139 Punch NF-4122
140 Die plate NF-3149

Note
0: mmdia
I: mmlength 33
34

• .In

»_.
AP-K2N CRIMPING MACHINE.

:No?

..

N<L.· ::..: .....

: .: : .. . ······.PartNeith~ .........< ····#art~Qr::I ....
· · •·•· · •·• eaftNo;.·\
301
Body 2301
346
Hex. socket head bolt (M4x10)
302
Plate LS-4302
347
Hex. nut (M4)
303
Slide LS-3303

304
Spring MA01-214
305
Positioning pin MA01-213
306
Block ring MA01-223
307
Cam LS-4307

308
Shank LS-4308

309
Wire disk LS-4309

310
Insulation disk LS-4310

311
Die plate LS-4311

312
Feed plate base LS-4312

313
Die block LS-4313

314
Retaining bolt LS-4314

315
Feed shaft LS-4315

316
Cam roller LS-4316

317
Pin LS-4317

318
Feed lever LS-4318

319
Feed lever pin LS-4319

320
Adjustment screw
321
Feed finger spring LS-4321

322
Feed finger pin LS-4322

323
Hook LS-4323

324
Nameplate LS-4324

325
Protection rubber LS-4325

330
Hex. socket head bolt (M6x18)
332
Spring washer (Smm dia.)
333
BuUonhead screw (MSx12)
334
Hex. socket head bolt (MSx18)
335
Hex. socket head bolt (MSx10)
336
Hex. socket head bolt (M4x8)
337
Spring pin
338
Hex. socket head bolt (M4x4)
339
Hex. socket head bolt (MSxSO)
340
Rivet (1.Smmm dia. x 5)
341
Hex. nut (M6, type-1)
342
Spring washer (6mm dia.)
343
Compressed coil spring
344
Tension spring
345
Ball plunger

35
JAPAN
JST

J.S.T. MFG. CO., LTD.

6-8, z-cnoms, Shigino-nishi, Joto-ku, Osaka, 536-0014 JAPAN.
Phone:+81-6-6968-6855 Fax<G4>:+81·6-6964.2085
KOREA <Seoul office>
Rm 1701, Sam sung Cheil Bldg., 1/102-2Yuksam-Dong, Kangnam-ku, Seoul 135-080, KOREA.
Phone:+82-2-521-3334 Fax:+82·2-521-3336

SINGAPORE J.S.T. COMPONENTS (S) PTE. LTD.

601, Sims Drive 1/04-11/13, Pan-I Complex, SINGAPORE 381382.
Phone:+65-143-0405 Fax<G4>:+65-146-1181
THAILAND <Bangkok Uaison Representative Office>
252/95 18th Fir. Muang Thai Phatra Office Tower 2, Rachadaphisek Road,
Huaykwang, Bangkok, 10320, THAILAND:
Phone:+66-2-693-2905 Fax:+66-2-693-2906

MALAYSIA J.S.T. COMPONENTS (MALAYSIA)SDN. BHD. .

Ground Floor, WISMA CSA, Lot 4, Jalan 13/4, Section 13,46200 Petaling Jaya, Selangor, MALAYSIA.
Phone: +60-3-1554620 Fax:+60-3-1583802
<Penang Branch>
No.441·3-2, Pulau Tikus Plaza, Jalan Bruma 10350, Penang, MALAYSIA.
Phone:+60-4-226-1258 Fax:+6Q-4-226-1269

CHINA J.S.T. (H.K.) CO., LTD.

Unit J, 14/F., C.DW. Building, 382-392, Castle Peak Road, Tsuen Wan, N.T., HONG KONG.
Phone:+852-24131919 Fax:+852-24111193

J.S.T. (SHANGHAI) CO., LTD.

F4, No2 Bldg., 288 Futebei Road, Waigaoqiao Free Trade Zone,
Pu Dong, Shanghai. 200131 CHINA.
Phone:+86-21-58663418 Fax:+86-21-58663421

INDONESIA P.T. J.S.T. BATAM

Jalan Gaharu, Lot 220 Muka Kuning, Batamindo Industrial Park, Batam 29433 INDONESIA.
Phone:+62-110-611683 Fax:+62-110-611684
<Jakarta Office>
Wisma Danamon Aetna life 19th Fl. JI. Jend. Sudirman. Kav. 45-46 Jakarta 12930 INDONESIA.
Phone:+62·21-515-0816 Fax:+62-21-515-0803

TAIWAN J.S.T. ELECTRONICS CO., LTD.'

10F. No. 100, Sec. 2, Nanking E. Road, Taipei, Taiwan, R.O.C.
Phone:+886-2-2531·8500 Fax:+886-2-2531-8485

U.SA J.S.T. SALES AMERICA CO., LTD.! J.S.T. CORPORATION

1951 South Lakeside Drive, Waukegan, Il. 60085 U.SA
Phone:+1-841·413-1951 Fax<G4>:+1-841-413-0144

BElGIUM J.S.T. EUROPE N.V.

Industrieterrein "SAS" Oudestraat 15,1910 Kampenhout, BELGIUM.
Phone:+32-16-600525 Fax:+32-16-605811

SPAIN J.S.T. ESPANA, SA .

Pol. Ind. Coli de Montcada - C/Sant Iscle, sin Nave 8,08110 Montcada I Reixach. Barcelona, SPAIN.
Phone:+34-93-564-212O Fax:+34-93-564-8266

U.K. J.S.T. (U.K.) LTD.

BIy1h Road Halesworth, Suffolk, IP19 8EW, U.K.
Phone:+44-1986-814131 Fax:+44-1986-814216

GERMANY J.S.T. DEUTSCHLAND GMBH

Kuferstr. 15.13650 Winterbach/ P.O. Box 1210. 13644 Winterbach. F.R. OF GERMANY.
Phone: +49-7181-4001-0 Fax:+49-7181-4oo7-21

FRANCE J.S.T. FRANCE SA

Z.1. Vitry MaroUes B.P. 23, 51301 Vitry Ie Francois FRANCE.
Phone:+33·3-261245D3 Fax:+33-3-26121088

ITALY J.S.T.ITAUAS.R.L
Via Giuseppe di Vittorio 1, 20017 Mazzo di Rho. Milano. ITALY.
Phone: +39-02-93900418 Fax:+39-02-93900421

AUSTRALIA J.S.T. (AUSTRAUA) PTY. LTD.

23 Moncrief Road, Nunawading Victoria AUSTRALIA 3131.
Phone:+61-3-9811-6444 'Fax:+61-3-9811-6395

1999. 8. 500 TE·4010(G)

In line with a policy of continual product development JST reserves the right to
change the specifications of the goods described in this catalogue at any time and
without prior notice.