molex 207129 Series User manual

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals
Doc. No: ATS-638199300 Release Date: 11-30-09 UNCONTROLLED COPY Page 1 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
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, 0.50mm2metric and 22 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size and Type
Insulation Diameter
Strip Length
AWG
mm²
mm
In.
mm
In.
34080
34080-0003
34080-1003
34080-0106
34080-1106
34080-0206
34080-1206
TXL-22
—
1.50-1.65
.059-.065
5.15
.203
—
ISO 0.50
1.40-1.60
.055-.063
—
AVSS 0.50
1.60-1.70
.063-.067
34081
34081-2005
34081-3005
34081-4003
34081-5003
TXL-22
—
1.50-1.65
.059-.065
—
ISO 0.50
1.40-1.60
.055-.063
—
AVSS 0.50
1.60-1.70
.063-.067
34083
34083-2003
34083-3003
TXL-22
—
1.50-1.65
.059-.065
—
ISO 0.50
1.40-1.60
.055-.063
—
AVSS 0.50
1.60-1.70
.063-.067
34751
34751-0003
34751-1003
TXL-22
—
1.50-1.65
.059-.065
—
ISO 0.50
1.40-1.60
.055-.063
—
AVSS 0.50
1.60-1.70
.063-.067
34783
34783-0003
34783-1003
TXL-22
—
1.50-1.65
.059-.065
—
ISO 0.50
1.40-1.60
.055-.063
—
AVSS 0.50
1.60-1.70
.063-.067
See crimp specification for the individual Insulation Diameter.
Terminals were validated per USCAR-21 using the following wire specifications:
M1L-123A (TXL), M1L-126A1(metric) and JASO D 611(AVSS)
DEFINITION OF TERMS (BLADE)
Order Number
63819-9300
Type 4D

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals
Doc. No: ATS-638199300 Release Date: 11-30-09 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
2.62mm AFTER CRIMPING
BEND UP
THIS AREA
CONDUCTOR CRIMP
DEFINITION OF TERMS (RECEPTACLE)
CRIMP SPECIFICATION
Terminal
Series No.
Bell Mouth
Conductor Brush Maximum
mm
In.
mm
In.
34080
0.30-0.70
.012-.028
0.40
.016
34081
34083
34751
34783
Not to exceed above the conductor crimp height
Terminal
Series No.
Bend Up
Bend Down
Twist
Roll
Seam
Degree
Degree
34080
3
3
3
3
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
mm
In.
mm
In.
N
Lb.
34080
TXL-22
—
0.95-1.05
.037-.041
1.50-1.70
.059-.067
50
11.2
—
ISO 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
—
AVSS 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
34081
TXL-22
—
0.95-1.05
.037-.041
1.50-1.70
.059-.067
50
11.2
—
ISO 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
—
AVSS 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
34083
TXL-22
—
0.95-1.05
.037-.041
1.50-1.70
.059-.067
50
11.2
—
ISO 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
—
AVSS 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
34751
TXL-22
—
0.95-1.05
.037-.041
1.50-1.70
.059-.067
50
11.2
—
ISO 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
—
AVSS 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
34783
TXL-22
—
0.95-1.05
.037-.041
1.50-1.70
.059-.067
50
11.2
—
ISO 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9
—
AVSS 0.50
1.05-1.15
.041-.045
1.50-1.70
.059-.067
75
16.9

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals
Doc. No: ATS-638199300 Release Date: 11-30-09 UNCONTROLLED COPY Page 3 of 9
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
mm
In.
mm
In.
mm
In.
34080
TXL-22
—
1.50-1.65
.059-.065
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
ISO 0.50
1.40-1.60
.055-.063
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
AVSS 0.50
1.60-1.70
.063-.067
3.40-3.60
.134-.142
3.35-3.55
.132-.140
34081
TXL-22
—
1.50-1.65
.059-.065
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
ISO 0.50
1.40-1.60
.055-.063
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
AVSS 0.50
1.60-1.70
.063-.067
3.40-3.60
.134-.142
3.35-3.55
.132-.140
34083
TXL-22
—
1.50-1.65
.059-.065
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
ISO 0.50
1.40-1.60
.055-.063
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
AVSS 0.50
1.60-1.70
.063-.067
3.40-3.60
.134-.142
3.35-3.55
.132-.140
34751
TXL-22
—
1.50-1.65
.059-.065
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
ISO 0.50
1.40-1.60
.055-.063
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
AVSS 0.50
1.60-1.70
.063-.067
3.40-3.60
.134-.142
3.35-3.55
.132-.140
34783
TXL-22
—
1.50-1.65
.059-.065
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
ISO 0.50
1.40-1.60
.055-.063
3.40-3.60
.134-.142
3.35-3.55
.132-.140
—
AVSS 0.50
1.60-1.70
.063-.067
3.40-3.60
.134-.142
3.35-3.55
.132-.140
Terminal Series No.
Wire Size and Type
Cable Seal
Profile
AWG
mm²
Manufacturer and Part No.
Color
0.50
22
34080
TXL-22
—
QSR
E-1644-01
Pink
X
—
ISO 0.50
QSR
E-1644-01
Pink
X
—
AVSS 0.50
QSR
E-1644-01
Pink
X
34081
TXL-22
—
QSR
E-1644-01
Pink
X
—
ISO 0.50
QSR
E-1644-01
Pink
X
—
AVSS 0.50
QSR
E-1644-01
Pink
X
34083
TXL-22
—
QSR
E-1644-01
Pink
X
—
ISO 0.50
QSR
E-1644-01
Pink
X
—
AVSS 0.50
QSR
E-1644-01
Pink
X
34751
TXL-22
—
QSR
E-1644-01
Pink
X
—
ISO 0.50
QSR
E-1644-01
Pink
X
—
AVSS 0.50
QSR
E-1644-01
Pink
X
34783
TXL-22
—
QSR
E-1644-01
Pink
X
—
ISO 0.50
QSR
E-1644-01
Pink
X
—
AVSS 0.50
QSR
E-1644-01
Pink
X
Cable Seal Position On a Wire
(Before crimping)

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals
Doc. No: ATS-638199300 Release Date: 11-30-09 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
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
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.
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.
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-638199300 Release Date: 11-30-09 UNCONTROLLED COPY Page 5 of 9
Revision: D Revision Date: 07-22-20
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-638199300 Release Date: 11-30-09 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 8
FRONT
BACK
MATCH
UP MARKS
Figure 7
Figure 6
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS

Hand Crimp Tool for MX150 Cable Seal Crimp Terminals
Doc. No: ATS-638199300 Release Date: 11-30-09 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-638199300 Release Date: 11-30-09 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-638199300 Release Date: 11-30-09 UNCONTROLLED COPY Page 9 of 9
Revision: D Revision Date: 07-22-20
2
Figure 11
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819-9300
Hand Crimp Tool
Figure 11
1
63819-9375
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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.