Molex 207129 Series Manual de usuario

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 1 of 9

Revision: D Revision Date: 07-22-20

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, 0.75-1.00mm2metric and 18-

20 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size and Type

Insulation Diameter

Strip Length

AWG

mm²

In.

34080

34080-0002

34080-1002

34080-0104

34080-1104

34080-0204

34080-1204

TXL-18

—

1.91-2.06

.075-.081

5.15

.203

TXL-20

—

1.70-1.85

.067-.073

—

ISO 1.00

1.90-2.10

.075-.083

—

ISO 0.75

1.70-1.90

.067-.075

34081

34081-2004

34081-3004

34081-4002

34081-5002

TXL-18

—

1.91-2.06

.075-.081

TXL-20

—

1.70-1.85

.067-.073

—

ISO 1.00

1.90-2.10

.075-.083

—

ISO 0.75

1.70-1.90

.067-.075

34083

34083-2002

34083-3002

TXL-18

—

1.91-2.06

.075-.081

TXL-20

—

1.70-1.85

.067-.073

—

ISO 1.00

1.90-2.10

.075-.083

—

ISO 0.75

1.70-1.90

.067-.075

34751

34751-0002

34751-1002

TXL-18

—

1.91-2.06

.075-.081

TXL-20

—

1.70-1.85

.067-.073

—

ISO 1.00

1.90-2.10

.075-.083

—

ISO 0.75

1.70-1.90

.067-.075

34783

34783-0002

34783-1002

TXL-18

—

1.91-2.06

.075-.081

TXL-20

—

1.70-1.85

.067-.073

—

ISO 1.00

1.90-2.10

.075-.083

—

ISO 0.75

1.70-1.90

.067-.075

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)

TYPE 4D

Order Number

63819-9200

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 2 of 9

Revision: D Revision Date: 07-22-20

CONDUCTOR BRUSH

STRIP LENGTH

SEAM

INSULATION CRIMP

CUT-OFF

TAB

BELL MOUTH

TWIST

ROLL

BEND DOWN

WIRE

SEAL

TERMINAL WIDTH NOT TO EXCEED

2.65mm AFTER CRIMPING

BEND UP

THIS AREA

CONDUCTOR CRIMP

CONDUCTOR BRUSH

STRIP LENGTH

SEAM

INSULATION CRIMP

CUT-OFF

TAB

BELL MOUTH

TWIST

ROLL

BEND DOWN

WIRE

SEAL

TERMINAL WIDTH NOT TO EXCEED

2.62mm AFTER CRIMPING

BEND UP

THIS AREA

CONDUCTOR CRIMP

DEFINITION OF TERMS (BLADE)

DEFINITION OF TERMS (RECEPTACLE)

CRIMP SPECIFICATION

Terminal

Series No.

Bell Mouth

Conductor

Brush Maximum

Bend Up

Bend Down

Twist

Roll

Seam

In.

Degree

34080

0.30-0.70

.012-.028

0.40

.016

Seam shall not be

open and no wire allowed

out of the crimping area

34081

34083

34751

34783

Not to exceed above the conductor crimp height

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 3 of 9

Revision: D Revision Date: 07-22-20

WIRE

INSULATION

SEAL

0.70mm (REF)

SEAL POSTION

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-18

—

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

TXL-20

—

1.10-1.20

.043-.047

2.05-2.25

.081-.089

16.9

—

ISO 1.00

1.25-1.35

.049-.053

2.05-2.25

.081-.089

120

27.0

—

ISO 0.75

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

34081

TXL-18

—

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

TXL-20

—

1.10-1.20

.043-.047

2.05-2.25

.081-.089

16.9

—

ISO 1.00

1.25-1.35

.049-.053

2.05-2.25

.081-.089

120

27.0

—

ISO 0.75

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

34083

TXL-18

—

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

TXL-20

—

1.10-1.20

.043-.047

2.05-2.25

.081-.089

16.9

—

ISO 1.00

1.25-1.35

.049-.053

2.05-2.25

.081-.089

120

27.0

—

ISO 0.75

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

34751

TXL-18

—

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

TXL-20

—

1.10-1.20

.043-.047

2.05-2.25

.081-.089

16.9

—

ISO 1.00

1.25-1.35

.049-.053

2.05-2.25

.081-.089

120

27.0

—

ISO 0.75

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

34783

TXL-18

—

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

TXL-20

—

1.10-1.20

.043-.047

2.05-2.25

.081-.089

16.9

—

ISO 1.00

1.25-1.35

.049-.053

2.05-2.25

.081-.089

120

27.0

—

ISO 0.75

1.20-1.30

.047-.051

2.05-2.25

.081-.089

20.2

Terminal Series No.

Wire Size and Type

Insulation Diameter

Insulation

Crimp Height

Crimp Width

AWG

mm²

In.

34080

TXL-18

—

1.91-2.06

.075-.081

3.60-3.80

.142-.150

3.45-3.65

.136-.144

TXL-20

—

1.70-1.85

.067-.073

3.50-3.70

.138-.146

3.45-3.65

.136-.144

—

ISO 1.00

1.90-2.10

.075-.083

3.60-3.80

.142-.150

3.45-3.65

.136-.144

—

ISO 0.75

1.70-1.90

.067-.075

3.50-3.70

.138-.146

3.45-3.65

.136-.144

34081

TXL-18

—

1.91-2.06

.075-.081

3.60-3.80

.142-.150

3.45-3.65

.136-.144

TXL-20

—

1.70-1.85

.067-.073

3.50-3.70

.138-.146

3.45-3.65

.136-.144

—

ISO 1.00

1.90-2.10

.075-.083

3.60-3.80

.142-.150

3.45-3.65

.136-.144

—

ISO 0.75

1.70-1.90

.067-.075

3.50-3.70

.138-.146

3.45-3.65

.136-.144

34083

TXL-18

—

1.91-2.06

.075-.081

3.60-3.80

.142-.150

3.45-3.65

.136-.144

TXL-20

—

1.70-1.85

.067-.073

3.50-3.70

.138-.146

3.45-3.65

.136-.144

—

ISO 1.00

1.90-2.10

.075-.083

3.60-3.80

.142-.150

3.45-3.65

.136-.144

—

ISO 0.75

1.70-1.90

.067-.075

3.50-3.70

.138-.146

3.45-3.65

.136-.144

34751

TXL-18

—

1.91-2.06

.075-.081

3.60-3.80

.142-.150

3.45-3.65

.136-.144

TXL-20

—

1.70-1.85

.067-.073

3.50-3.70

.138-.146

3.45-3.65

.136-.144

—

ISO 1.00

1.90-2.10

.075-.083

3.60-3.80

.142-.150

3.45-3.65

.136-.144

—

ISO 0.75

1.70-1.90

.067-.075

3.50-3.70

.138-.146

3.45-3.65

.136-.144

34783

TXL-18

—

1.91-2.06

.075-.081

3.60-3.80

.142-.150

3.45-3.65

.136-.144

TXL-20

—

1.70-1.85

.067-.073

3.50-3.70

.138-.146

3.45-3.65

.136-.144

—

ISO 1.00

1.90-2.10

.075-.083

3.60-3.80

.142-.150

3.45-3.65

.136-.144

—

ISO 0.75

1.70-1.90

.067-.075

3.50-3.70

.138-.146

3.45-3.65

.136-.144

Cable Seal Position On a Wire

(Before crimping)

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 4 of 9

Revision: D Revision Date: 07-22-20

RELEASE LOCATOR

BUTTON

TERMINAL

Figure 3

LOCATOR

PUSHED THROUGH

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

Terminal Series No.

Wire Size and Type

Cable Seal

Profile

AWG

mm²

Manufacturer and Part No.

Color

0.75

1.00

34080

TXL-18

—

QSR

E-1644-00

Green

—

ISO 0.75

QSR

E-1644-00

Green

—

ISO 1.00

QSR

E-1644-00

Green

TXL-20

—

QSR

E-1644-00

Green

34081

TXL-18

—

QSR

E-1644-00

Green

—

ISO 0.75

QSR

E-1644-00

Green

—

ISO 1.00

QSR

E-1644-00

Green

TXL-20

—

QSR

E-1644-00

Green

34083

TXL-18

—

QSR

E-1644-00

Green

—

ISO 0.75

QSR

E-1644-00

Green

—

ISO 1.00

QSR

E-1644-00

Green

TXL-20

—

QSR

E-1644-00

Green

34751

TXL-18

—

QSR

E-1644-00

Green

—

ISO 0.75

QSR

E-1644-00

Green

—

ISO 1.00

QSR

E-1644-00

Green

TXL-20

—

QSR

E-1644-00

Green

34783

TXL-18

—

QSR

E-1644-00

Green

—

ISO 0.75

QSR

E-1644-00

Green

—

ISO 1.00

QSR

E-1644-00

Green

TXL-20

—

QSR

E-1644-00

Green

OPERATION

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects

because damage can occur to the tool or die.

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 tool. See Figure 3.

LOCATOR

IN DOWN

POSTION

PUSH ON

THE

LOCATOR

BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 5 of 9

Revision: D Revision Date: 07-22-20

Figure 4

TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE AND

SEAL

POSITION

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. Because of 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.

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.

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

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 6 of 9

Revision: D Revision Date: 07-22-20

Right- or Left-Handed Operation

This hand tool 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, which 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.

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 the 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.

Figure 6

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

FRONT

BACK

MATCH

UP MARKS

Figure 7

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY 3 MONTHS

5,000 CRIMPS)

Figure 8

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals

Doc. No: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 7 of 9

Revision: D Revision Date: 07-22-20

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.

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.

RATCHET RELEASE

LEVER

Figure 9

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: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 8 of 9

Revision: D Revision Date: 07-22-20

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 should be 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: ATS-638199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 9 of 9

Revision: D Revision Date: 07-22-20

Figure 11

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63819-9200

Hand Crimp Tool

Figure 11

63819-9275

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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