Instruction Sheet
408-- 4040
0.8mm CHAMP* Crimper Assemblies
122842- 1, 122842- 2, and 122842- 3
Manual Arbor Frame
Assembly 91085-- 2 (Ref)
Setscrew
(Ref)
25 FEB 10 Rev C
Adjustment Ring
(Ref)
Handle (Ref)
Flat Head Cap
Screw (Qty: 2)
Socket Head Cap Screw
(Ref)
Tool Mount
Rear Tool Stop
Crimper
Frame Assembly
Slide Base (Ref)
Ram (Ref)
Cable Clamp
Spring
Tool Stop (Ref)
Support
Block
Slide Plate
Figure 1
1. INTRODUCTION
2. DESCRIPTION (See Figure 1)
0.8mm CHAMP Crimper Assemblies 122842--1,
122842--2, and 122842--3 are designed for use in
Manual Arbor Frame Assembly 91085--2 (shown in
Figure 1) and are used to crimp metal backshell
assemblies onto 0.8mm CHAMP connectors. This
instruction sheet provides procedures for crimper
assembly installation, adjustments, crimping, and
maintenance and inspection. Refer to instruction
sheet 408--7777 for details concerning the operation
and maintenance of the arbor frame assembly.
The crimper assembly consists of an upper and lower
tooling assembly.
Read these instructions thoroughly before using the
crimper assembly.
NOTE
i
All numerical values in this instruction sheet are
in metric units [with U.S. customary units in
brackets]. Dimensions are in millimeters [and
inches]. Figures are not drawn to scale.
The upper tooling assembly consists of a tool mount
and a crimper. The crimper is secured to the tool
mount, which is mounted to the ram of the arbor
frame assembly with the socket head cap screws
supplied with the crimper assembly.
The lower tooling assembly consists of a slide plate, a
support block, and a cable clamp spring. The lower
tooling assembly mates with the slide base of the
arbor frame assembly.
3. INSTALLATION OF CRIMPER ASSEMBLY
To install the crimper assembly, refer to Figure 1, and
proceed as follows:
DANGER
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2010 Tyco Electronics Corporation, Berwyn, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products names, logos, or company names might be trademarks of their respective owners.
The frame assembly must be secured to a work
bench to ensure stability during operation.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
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LOC B
408- 4040
0.8mm CHAMP Crimper Assemblies 122842- 1, 122842- 2, and 122842- 3
3.1. Lower Tooling Assembly
4.1. Cable Clamp Springs
1. Remove the tool stop from the slide base of the
arbor frame assembly.
2. Slide the lower tooling assembly into the tracks
of the frame assembly slide base. The cable clamp
spring must be oriented to the left side of the slide
base as shown in Figure 1.
3. Re--install the tool stop and secure it with the
socket head cap screw.
3.2. Upper Tooling Assembly
1. Remove the upper tool mount (supplied with the
arbor frame assembly) by removing the two flat
head cap screws. Do not discard this tool mount.
The cable clamp springs can be adjusted for various
cable diameters by loosening the socket head cap
screws and re--positioning the cable clamp springs.
4.2. Crimp Height
To check crimp height, a test crimp should be made
(refer to Section 5); then, measure the crimp height of
the backshell ferrule. Refer to the appropriate
application specification (114--series) for the crimp
height. If the actual crimp height does not conform to
that dimension, proceed as follow:
1. Loosen the setscrew on the adjustment ring.
Turn the adjustment ring CLOCKWISE to increase
crimp height or COUNTERCLOCKWISE to
decrease crimp height.
2. Install the tool mount (supplied with the crimper
assembly) to the ram of the arbor frame assembly
and secure it with the flat head cap screws.
3. Position the crimper in the tool mount with the
longer offset to the right (as shown in Figure 1).
Secure crimper to tool mount with the socket head
cap screw.
2. Re--tighten the setscrew.
5. CRIMPING PROCEDURE
Refer to Figure 2 and proceed as follows:
4. TOOLING ADJUSTMENTS
The following adjustments are required during the
initial setup of the crimper assembly and when
changing cable size.
1. Using the ball handle, slide the lower tooling
assembly out from under the ram of arbor frame
assembly.
2. Position the connector backshell assembly in
the support block.
Adjustment
Ring
Handle
Ram
Cable Clamp
Spring
Connector
Lower Tooling
Assembly
Rear Tool
Stop
Tool Stop
Cable
Support
Block
Ball Handle
Figure 2
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Tyco Electronics Corporation
Rev C
0.8mm CHAMP Crimper Assemblies 122842- 1, 122842- 2, and 122842- 3
3. Secure the cable in the cable clamp spring.
4. Slide the lower tooling assembly back against
the rear tool stop of the arbor frame assembly.
5. To crimp the metal backshell onto the cable,
lower the ram using the handle until the adjustment
ring is flush with the top of the arbor frame
assembly.
6. After the connector is crimped, use the handle
to raise the ram; then slide the lower tooling
assembly out from under the ram. Remove the
connector.
6. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. Frequency of
inspection depends on:
1. The care, amount of use, and handling of the
crimper assembly.
2. The presence of abnormal amounts of dust and
dirt.
3. The degree of operator skill.
4. Your own established standards.
The crimper assembly is inspected before being
shipped; however, it is recommended that the
assembly be inspected immediately upon its arrival at
your facility to ensure that it has not been damaged
during shipment. Due to the precision design, it is
important that no parts of the crimper assembly be
interchanged except the replacement parts listed in
Figure 3.
6.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
with a clean brush, or a soft, lint--free cloth. DO
NOT use objects that could damage the crimper
assembly.
Rev C
408- 4040
2. Make certain that upper and lower
subassemblies and cable clamp springs are in
place and properly secured.
3. When the assembly is not in use, store it in a
clean, dry area.
6.2. Periodic Inspection
1. Remove all lubrication and accumulated film
with a suitable commercial degreaser that will not
affect paint or plastic material.
2. Make certain that all assembly components are
in place. If replacements are necessary, refer to
Section 7, REPLACEMENT AND REPAIR.
3. Inspect crimper assembly for worn, cracked,
chipped, or broken areas. If damage is evident,
return the assembly for evaluation and repair. See
Section 7, REPLACEMENT AND REPAIR.
7. REPLACEMENT AND REPAIR
Customer--replaceable parts are listed in Figure 3.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
parts is necessary. Parts other than those listed
should be replaced by Tyco Electronics to ensure
quality and reliability. Order replacement parts
through your representative, or call 1--800--526--5142,
or send a facsimile of your purchase order to
717--986--7605, or write to:
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
For customer repair service, call 1--800--526--5136.
8. REVISION SUMMARY
Revisions to this instruction sheet include:
S Updated instruction sheet to corporate
requirements
Tyco Electronics Corporation
3 of 4
408- 4040
0.8mm CHAMP Crimper Assemblies 122842- 1, 122842- 2, and 122842- 3
7
3
2
13 15
6
1
8
101.6
[4.00]
11
4
5
9
10
12 14 16
67.3
[2.65]
100.3
[3.95]
Weight: 1.36 kg [3 lbs]
REPLACEMENT PARTS
ITEM
PART NUMBER
DESCRIPTION
QTY PER ASSEMBLY
122842-- 1
122842-- 2
122842-- 3
1
527246--1
TOOL MOUNT
1
1
1
2
122839--1
CRIMPER, 50--Position
1
—
—
3
2--21000--6
SCREW, Socket Head Cap, 8--32¢.38 in.
1
1
1
4
543156--1
SPRING, Cable Clamp
2
2
2
5
2--21000--5
SCREW, Socket Head Cap, 8--32¢.25 in.
2
2
2
6
856593--1
SLIDE
1
1
1
7
1--21003--9
SCREW, Flat Head Cap, 6--32¢.32 in.
2
2
2
8
23673--1
HANDLE, Ball
1
1
1
9
21018--7
NUT, Hex 10--32
1
1
1
10
5--21012--4
SCREW, Set 10--32¢.50 in.
1
1
1
11
122841--1
BLOCK, Support, 50--Position
1
—
—
12
2--21000--7
SCREW, Socket Head Cap, 8--32¢.50 in.
1
1
1
13
189544--1
CRIMPER, 68--Position
—
1
—
14
189543--1
BLOCK, Support, 68--Position
—
1
—
15
189544--2
CRIMPER, 36--Position
—
—
1
16
189543--2
BLOCK, Support, 36--Position
—
—
1
Figure 3
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Tyco Electronics Corporation
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