Molex 207129 Series Manual de usuario

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 1 of 8

Revision: D Revision Date: 07-22-20

CONDUCTOR BRUSH

STRIP LENGTH

SEAM

INSULATION CRIMP

CUT-OFF

TAB

BELL MOUTH

TWISTING

ROLLING

BEND DOWN

WIRE

SEAL

TERMINAL WIDTH NOT TO EXCEED

2.65mm AFTER CRIMPING

BEND UP

THIS AREA

CONDUCTOR CRIMP

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position

Right- and left-handed applications

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: MX150 Cable Seal Blade and Receptacle Crimp Terminals, 1.50mm2metric and 16 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size and Type

Insulation Diameter

Strip Length

AWG

mm²

In.

34080

34080-1001

34080-0001

34080-1102

34080-0202

34080-1202

34080-0102

TXL-16

—

2.18-2.34

.086-.092

6.00

.236

—

ISO 1.50

2.20-2.40

.087-.094

34081

34081-2003

34081-4001

34081-3003

34081-5001

TXL-16

—

2.18-2.34

.086-.092

—

ISO 1.50

2.20-2.40

.087-.094

34083

34083-2001

34083-3001

TXL-16

—

2.18-2.34

.086-.092

—

ISO 1.50

2.20-2.40

.087-.094

34751

34751-0001

34751-1001

TXL-16

—

2.18-2.34

.086-.092

—

ISO 1.50

2.20-2.40

.087-.094

34783

34783-0001

34783-1001

TXL-16

—

2.18-2.34

.086-.092

—

ISO 1.50

2.20-2.40

.087-.094

See crimp specification for the individual Insulation Diameter.

Terminals were validated per USCAR-21 using the following wire specifications:

M1L-123A (TXL), and M1L-126A1(metric)

DEFINITION OF TERMS (BLADE)

Order Number

63819-9000

Type 4D

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 2 of 8

Revision: D Revision Date: 07-22-20

CONDUCTOR BRUSH

STRIP LENGTH

SEAM

INSULATION CRIMP

CUT-OFF

TAB

BELL MOUTH

TWISTING

ROLLING

BEND DOWN

WIRE

SEAL

TERMINAL WIDTH NOT TO EXCEED

2.62mm AFTER CRIMPING

BEND UP

THIS AREA

CONDUCTOR CRIMP

DEFINITION OF TERMS (RECEPTACLE)

CRIMP SPECIFICATION

Terminal

Series No.

Bell Mouth

Conductor Brush Maximum

In.

34080

0.30-0.70

.012-.028

1.60

.063

34081

34083

34751

34783

0.40 mm (.016”) Max exceeds above the conductor crimp height allowable.

Terminal Series

No.

Bend Up

Bend Down

Twist

Roll

Seam

Degree

34080

Seam shall not be open

and no wire allowed out

of the crimping area

34081

34083

34751

34783

After crimping, the crimp profiles should measure the following:

Terminal Series No.

Wire Size and Type

Conductor

Pull Force Minimum

Crimp Height

Crimp Width

AWG

mm²

In.

Lb.

34080

TXL-16

—

1.30-1.40

.051-.055

2.35-2.55

.093-.100

120

27.0

—

ISO 1.50

1.35-1.45

.053-.057

2.35-2.55

.093-.100

150

33.7

34081

TXL-16

—

1.30-1.40

.051-.055

2.35-2.55

.093-.100

120

27.0

—

ISO 1.50

1.35-1.45

.053-.057

2.35-2.55

.093-.100

150

33.7

34083

TXL-16

—

1.30-1.40

.051-.055

2.35-2.55

.093-.100

120

27.0

—

ISO 1.50

1.35-1.45

.053-.057

2.35-2.55

.093-.100

150

33.7

34751

TXL-16

—

1.30-1.40

.051-.055

2.35-2.55

.093-.100

120

27.0

—

ISO 1.50

1.35-1.45

.053-.057

2.35-2.55

.093-.100

150

33.7

34783

TXL-16

—

1.30-1.40

.051-.055

2.35-2.55

.093-.100

120

27.0

—

ISO 1.50

1.35-1.45

.053-.057

2.35-2.55

.093-.100

150

33.7

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 3 of 8

Revision: D Revision Date: 07-22-20

WIRE

INSULATION

SEAL

0.70mm (REF)

SEAL POSTION

Terminal Series No.

Wire Size and Type

Insulation Diameter

Insulation

Crimp Height

Crimp Width

AWG

mm²

In.

34080

TXL-16

—

2.18-2.34

.086-.092

3.70-3.90

.146-.154

3.55-3.75

.140-.148

—

ISO 1.50

2.20-2.40

.087-.094

3.70-3.90

.146-.154

3.55-3.75

.140-.148

34081

TXL-16

—

2.18-2.34

.086-.092

3.70-3.90

.146-.154

3.55-3.75

.140-.148

—

ISO 1.50

2.20-2.40

.087-.094

3.70-3.90

.146-.154

3.55-3.75

.140-.148

34083

TXL-16

—

2.18-2.34

.086-.092

3.70-3.90

.146-.154

3.55-3.75

.140-.148

—

ISO 1.50

2.20-2.40

.087-.094

3.70-3.90

.146-.154

3.55-3.75

.140-.148

34751

TXL-16

—

2.18-2.34

.086-.092

3.70-3.90

.146-.154

3.55-3.75

.140-.148

—

ISO 1.50

2.20-2.40

.087-.094

3.70-3.90

.146-.154

3.55-3.75

.140-.148

34783

TXL-16

—

2.18-2.34

.086-.092

3.70-3.90

.146-.154

3.55-3.75

.140-.148

—

ISO 1.50

2.20-2.40

.087-.094

3.70-3.90

.146-.154

3.55-3.75

.140-.148

Terminal Series No.

Wire Size and Type

Cable Seal

AWG

mm²

Manufacturer and Part No.

Color

34080

TXL-16

—

QSR

E-1644-02

Yellow

—

ISO 1.50

QSR

E-1644-02

Yellow

34081

TXL-16

—

QSR

E-1644-02

Yellow

—

ISO 1.50

QSR

E-1644-02

Yellow

34083

TXL-16

—

QSR

E-1644-02

Yellow

—

ISO 1.50

QSR

E-1644-02

Yellow

34751

TXL-16

—

QSR

E-1644-02

Yellow

—

ISO 1.50

QSR

E-1644-02

Yellow

34783

TXL-16

—

QSR

E-1644-02

Yellow

—

ISO 1.50

QSR

E-1644-02

Yellow

Cable Seal Position on a Wire

(Before crimping)

OPERATION

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened

objects as damage can occur to the tool frame or crimp dies.

Open the tool by squeezing the handles together. At the end of the closing stroke, the ratchet

mechanism will release the handles and the hand tool will spring open. See Figure 1.

Crimping Terminals

1. Select the desired terminal listed in the

preceding charts.

2. Make sure the center of the locator is in

the down position. With the locator

attached, push the locator button on the

back of the hand tool to bring the

locator forward through the tooling. See

Figure 2.

3. While holding the locator button in, load

the terminal into the proper nest

opening in the locator based on the wire

gauge or terminal type markings on the

hand tooling. See Figure 3.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON

THE

LOCATOR

BUTTON

Figure 2

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 4 of 8

Revision: D Revision Date: 07-22-20

RELEASE LOCATOR

BUTTON

TERMINAL

Figure 3

LOCATOR

PUSHED THROUGH

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

Figure 4

TERMINAL

WIRE AGAINST

THE

WIRE STOP

WIRE AND

SEAL POSITON

WIRE STOP IS

PART OF THE

LOCATOR

WIRE AND SEAL

POSITIONED IN

LOWER PART OF

THE PUNCHES

TERMINAL

4. Release the locator button, allowing the locator to return to the crimping position.

5. With the hand tool open, insert the properly stripped wire and seal under the punches into

the lower part of the upper tooling until the wire is against the wire stop. See Figure 4.

6. Seal position should be under and inside the punches. Keep this position while crimping.

7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has

been completed. Release the handles to open the jaws.

Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.

8. Remove the crimped terminal from the terminal locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper crimp location.

Note

A crimp height chart is provided with this manual as reference only. Due to the wide range of

wires, strands, insulation diameters and durometers available, actual crimp height measurements

may very slightly. An occasional destructive pull force test should be performed to check hand tool

crimp. Pull force value must exceed the minimum pull force specifications listed.

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 5 of 8

Revision: D Revision Date: 07-22-20

Locator Replacement

See the parts list on the last page of this document for the proper locator order number. Follow

the steps below to replace the locator:

1. Open the hand crimp tool.

2. Gently squeeze on the lower area

shown in Figure 5A with your thumb

and index finger. The lower tabs of the

locator should disengage from the hand

tool.

3. Lift and pull away from the hand tool.

The top locator hooks should slip out of

the top slots easily. See Figure 5A.

4. To reinstall the new locator, make sure

the hand tool is in the open position.

5. Press the center of the locator down as

far as it will go, as shown in Figure 5B.

6. Holding onto the lower part of the

locator with your thumb and index

finger, insert the locator’s top hooks

into the hand tool’s top slots.

7. Rotate the locator down and press the

lower tabs into the two bottom slots of

the hand tool. To secure the locator

into place, the lower tabs must snap into place on the hand tool frame.

Right- or Left-Handed Operation

This hand tool has an added feature that can be converted from a right-handed application to a

left-handed application. It is necessary to reverse the tooling if using the left-handed application

along with the locator. Follow the steps below:

1. The locator must be removed before

reversing the tooling.

2. Remove the M3 BHCS that is holding the

upper tooling.

3. Flip the upper tooling to the opposite side and

replace the M3 BHCS. Make sure the small

markings on the front and back of the hand

tool frame match up and are on the outside

of the hand tool frame. See Figures 6 and 7.

4. Do the same thing with the lower tooling and

tighten the M3 screws. Be sure the small

markings line up.

5. Reinstall the locator by following the

instructions in the locator replacement

section.

Figure 6

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 5B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 5A

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

FRONT

BACK

MATCH

UP MARKS

Figure 7

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 6 of 8

Revision: D Revision Date: 07-22-20

MAINTENANCE

It is recommended that each operator of the tool be made aware of and responsible for the

following maintenance steps:

1. Remove dust, moisture and other contaminants with a clean

brush or a soft, lint-free cloth.

2. Do not use any abrasive materials that could damage the tool.

3. Make certain all pins, pivot points and bearing surfaces are

protected with a thin coat of high-quality machine oil. Do not oil

excessively. The tool was engineered for durability, but like any

other equipment, it needs cleaning and lubrication for a

maximum service life of trouble-free crimping. Light oil such as

30 weight automotive oil used at the oil points every 5,000

crimps or 3 months will significantly enhance the tool life. See

Figure 8.

4. Wipe excess oil from hand tool, particularly from the crimping

area. Oil transferred from the crimping area onto certain

terminations may affect the electrical characteristics of an

application.

5. When the tool is not in use, keep the handles closed to prevent

objects from becoming lodged in the crimping dies, and store the tool in a clean, dry area.

Miscrimps or Jams

Should this tool ever become stuck or jammed in a partially closed

position, do not force the handles open or closed. The tool will open

easily by pressing up on the ratchet release lever in the movable

handle. See Figure 9.

How to Adjust Tool Preload (See Figure 10)

Hand tool frame preload is factory preset to ensure crimp quality. It

may be necessary over the life of the tool to adjust tool handle

preload force. Listed below are the steps required to adjust the

crimping force of the hand tool to obtain proper crimp conditions:

1. Open the hand tool.

2. Close the handle 2 ratchet clicks.

3. Hold the hand tool in the palm of

your hand as shown in Figure 10.

Using your index finger, squeeze the

link toward the top of the hand tool

frame. This will release the preload

adjustment wheel.

4. Rotate the setting wheel

counterclockwise (CCW) to increase

handle force. The numbers will

display higher. To decrease handle

force, rotate the setting wheel

clockwise (CW).

5. Release the link to lock the setting

wheel in place.

6. Check the crimp specifications or conduct a pull test after tool handle preload force is

adjusted.

RATCHET RELEASE

LEVER

Figure 9

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 8

HANDLE CLOSED

2 CLICKS

SQUEEZE THE

LINK IN THE

HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING WHEEL

Figure 10

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 7 of 8

Revision: D Revision Date: 07-22-20

Warranty

This tool is for electrical terminal crimping purposes only. This tool is made of the best quality

materials. All vital components are long-life tested. All tools are warranted to be free of

manufacturing defects for a period of 30 days. Should such a defect occur, Molex will repair or

exchange the tool free of charge. This repair or exchange will not be applicable to altered,

misused or damaged tools. This tool is designed for hand use only. Any clamping, fixturing or

use of handle extensions voids this warranty.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and

tooling.

CAUTIONS:

1. Manually powered hand tools are intended for low-volume use or field repair. This tool is NOT

intended for production use. Repetitive use of this tool should be avoided.

2. Insulated rubber handles are not protection against electrical shock.

3. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

CERTIFICATION

Molex does not certify or re-certify hand tools but rather supplies the following guidelines for

customers to re-certify hand tools.

This tool is qualified to pull force only. See the Molex website for the Quality Crimp Handbook for

more information on pull testing.

If the tool does not meet minimum pull force values, handle preload should be increased and the

pull test rerun, (See How to Adjust Preload).

When the hand tool is no longer capable of achieving minimum pull force, it should be taken out

of service and replaced.

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: 638199000 Release Date: 11-10-09 UNCONTROLLED COPY Page 8 of 8

Revision: D Revision Date: 07-22-20

Figure 11

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63819-9000

Hand Crimp Tool

Figure 11

63819-9075

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other

trademarks listed herein belong to their respective owners.

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