molex 207129 Series User manual

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
mm
In.
mm
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
mm
In.
mm
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
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-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
mm
In.
mm
In.
mm
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
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
2
Figure 11
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819-9000
Hand Crimp Tool
Figure 11
1
63819-9075
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.