JST AP-F6 Bedienungsanleitung

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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

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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