33472-100 Appl Spec Datasheet by Molex

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REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
1 of 73
01/10/2018
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M. Hussain
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
MX150 System
Sealed Product Line
D AS-33472-100 REVTSTON. ECR/ECN \NFORMATTON. TTTLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV.
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
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M. Hussain
M. Vanslambrouck
TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Table of Contents
Section 1: Product Introduction
Section 2: Product Summary
Section 3: Connector Assembly
Section 4: Connector Mating
Section 5: Service Instructions
Section 6: Electrical Continuity Checking
Section 7: Crimping
Section 8: Hybrid Connector
Section 9: Troubleshooting Guide
Section 10: Packaging
D AS-33472-100 REVTSTON. ECR/ECN \NFORMATTON. TTTLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV.
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
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C
EC No:
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
This instructions manual contains supplemental information pertaining to
the Molex 1.50 mm sealed Product Line. Additional information, keyway
and knockout patterns can be found on the sales drawings.
SD-33471-**** (multiple documents)
SD-33472-**** (multiple documents)
SD-33481-**** (multiple documents)
SD-33482-**** (multiple documents)
SD-160008-**** (multiple documents)
SD-160011-**** (multiple documents)
SD-34986-**** (multiple documents)
SD-34985-**** (multiple documents)
Section 1: Product Introduction MX150 System
Section 1: Product Introduction MX150 System
D molex“ C Features and Benefits REVTSTON. ECR/ECN \NFORMATTON. TTTLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV. AS-33472-100
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
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M. Vanslambrouck
TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Features and Benefits:
Pre-assembled connector housings, seals and TPA components
Simple crimp, poke and plug application
Integral Terminal Position Assurance (TPA)
Integral two way, mat and interface seals designed and tested to IP
67 and SAE USCAR-2, Rev 3 standards
Easy terminal extraction and insertion
Compatible with a wide range of UL (22 to 14 AWG), SAE
Automotive (22 to 14) and ISO (0.35 to 1.5mm²) style wires
Integral locking latch with secondary connector position assurance
(CPA) option
Applied cost savings
No need to crimp individual wire seals
Locks terminals into housings and prevents terminals from backing
out
More than just waterproof, a true sealed connector system tested
under submersed conditions
Quick, low cost field repairs
Supports a wide range of power and signal applications
Assures positive mating of connector and prevents accidental
disengagement during high vibration and severe shock application
D molex“ C MX150 Agplications: www.molex.com/ind/mx150.htm| www.molex.com REVISION. ECR/ECN \NFORMATTON. TITLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV. AS-33472-100
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 1: Product Introduction MX150 System
MX150 Applications:
Passenger Automobiles (Exclusively for MX150 family)
Off Highway Construction Equipment
Agriculture Equipment
Trucks, Busses and RVs
Commercial and Recreational Marine Equipment
Material Handling Equipment
Lawn and Garden Equipment
Outdoor Lighting
Industrial Control
This User Manual can be found at www.molex.com/ind/mx150.html
To order, please contact your Molex Sales Representative or check
www.molex.com
D molexfi' C ection 2: Product Summary Connector Assemblies t3 Grommet Seal «9% REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 2: Product Summary
A. Connector Assemblies
Grommet Seal
Housing
TPA
Grommet Cap
6 Way 2X3
Blade Connector
D molexfi' C Z ‘NQB \ REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
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Housing
Grommet Seal
Grommet Cap
Perimeter Seal
TPA
CPA
(Optional)
16 Way 2X8 Standard
Receptacle Connector
Section 2: Product Summary
B. Connector Assemblies (continued)
D molexfi' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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ECR/ECN INFORMATION:
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MX150 Application Guide
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C
EC No:
107594
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
CPA
(Optional)
Grommet Cap
Grommet Seal
Housing
Perimeter Seal
TPA
16 Way Hybrid
Receptacle Connector
Section 2: Product Summary
C. Connector Assemblies (continued)
(é) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
APPLICATION SPECIFICATION
REVISION:
ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
SHEET No.
C
EC No:
107594
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
20 Way 2X10
Receptacle Connector
Section 2: Product Summary
C. Connector Assemblies (continued)
CPA
(Optional)
Grommet Cap
Grommet Seal
Housing
Perimeter Seal
TPA
(é) Grommet Cap / Grommet Seal Housing REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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ECR/ECN INFORMATION:
TITLE:
MX150 Application Guide
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C
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107594
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 2: Product Summary
C. Connector Assemblies (continued)
20 Way 2X10
Blade Connector
TPA
D molexfi' C Terminal Features AS-33472-100 m / REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I FIEVISED BY: CHECKED BY: APPROVED BY:
APPLICATION SPECIFICATION
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Section 2: Product Summary
D. Receptacle/Blade Terminal
Terminal Features
Base Material - Copper Alloy
Plating Options - Tin, Gold, Silver
Wire Sizes: 14,16,18,20,22 AWG
1.5, 1.0, 0.8, 0.75, 0.5, 0.35 mm2
Refer to Section 7 for crimping details.
Blade Terminal
Receptacle Terminal
Orientation Feature
Orientation Feature
(é) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
APPLICATION SPECIFICATION
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Section 2: Product Summary
E. Product Identification
- All parts are laser etched with:
1. Molex Part Number
2. Date Code (YYDDD)
- YY = Last Digit of Year
- DDD = Day of Year
Note Presence of laser marking for MX 150 16 way Hybrid depends on the
manufacturing place.
YY =
Last
Digit of
Year
DDD = Day of Year
Molex Part Number
YY = Last Digit of Year
Molex Part Number
(é) shipped" REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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MX150 Application Guide
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C
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CPA is shown in “as shipped” pre-lock condition:
TPA’s shown in pre-lock
TPA’s shown in “As Shipped” condition.
The TPA should remain in the pre-lock position until all circuits are loaded.
TPA movement distance from pre-lock to final lock = 5.0 mm in both Blade
and Receptacle connectors.
The TPA should never be removed from the connector!
Section 3: Connector Assembly
A. “As Shipped” connector positions
D molex“ REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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If CPA gets moved from pre-lock to final lock position during shipping, pull CPA
to bring it back to the pre-lock position.
CPA’s shown in pre-lock
CPA’s shown in final-lock
D AS-33472-100 REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:
APPLICATION SPECIFICATION
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TPA shown in “Pre-lock” position.(Fig.10-a)
TPA shown in “lock” position. (Fig 10-b)
The TPA should never be removed from the connector!
Cross section of TPA in pre-lock / lock
Pre-lock
Lock
Section 3: Connector Assembly
B. TPA in Pre-lock and Lock
5.0 mm
Fig. 10-a
Fig. 10-b
(é) I; -< revision:="" ecr/ecn="" information:="" title:="" sheet="" no.="" ec="" no:="" document="" number:="" created/revised="" by:="" checked="" by:="" approved="" by:="" as-33472-100="">
APPLICATION SPECIFICATION
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ECR/ECN INFORMATION:
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MX150 Application Guide
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C
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Section 3: Connector Assembly
C. Seal Plug Installation
With TPA still in pre-lock position, orient seal plug to rear of connector. Align
the orientation feature and insert through appropriate circuit opening. If
resistance is encountered, retract the terminal and adjust the angle of
insertion. Continue inserting the terminal until it stops and locks up on the
lock finger with an audible click. Seal plugs can be used on both Blade, and
Receptacle connectors.
Orientation feature is highlighted blue for reference only
Seal plug can not be used in shorting bar circuits!
Orientation Feature
PUSH
CLICK
PULL
Caution: Once fully seated, the seal plug is not a serviceable item.
D molexfi' C Backwards REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I FIEVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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Section 3: Connector Assembly
C. Seal Plug Installation continued
YES!
CORRECT!
NO!
WRONG!
Backwards
!
180° out of alignment!
90° out of alignment!
REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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Cavity plugs can be trimmed flush to avoid
wire chafing and avoid cavity plug
dislocation/push through, the decision to trim
is the discretion of the harness supplier
Cavity plugs must be installed, and trimmed
before wires are installed. Cavity plugs can
be used on both Blade, and Receptacle
connectors.
Never trim cavity plugs with
wires installed!
Section 3: Connector Assembly
C. Seal Plug Installation continued
P molex' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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TITLE:
MX150 Application Guide
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C
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Cavity plugs can be trimmed flush to avoid
wire chafing and avoid cavity plug
dislocation/push through, the decision to trim
is the discretion of the harness supplier
Cavity plugs must be installed, and trimmed
before wires are installed. Cavity plugs can
be used on both Blade, and Receptacle
connectors.
Never trim cavity plugs with
wires installed!
Section 3: Connector Assembly
C. Seal Plug Installation continued
Caution: Once fully seated, the seal plug is not a serviceable item.
C) molex“ Receptacle Connector AS-33472-100 REVISION. ECR/ECN INFORMATION. TITLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED BY. APPROVED BY.
APPLICATION SPECIFICATION
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2.8 cavity plug step by step installation is shown in
the illustrations below. The cavity plug must be fully installed with all 3 seal glands
engaged in the seal cavity.
Section 3: Connector Assembly
C. Seal Plug Installation continued
1
2
3
Receptacle Connector
Blade Connector
1
2
3
Yazaki Seal Plug PN: 7158-3114-90
CORRECT to push in the plug REVISION. ECR/ECN INFORMATION. TITLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED BY. APPROVED BY. AS-33472-100
APPLICATION SPECIFICATION
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CORRECT
WRONG
Never use a screw driver or an
object with sharp edge to push in
the plug as it will damage seal
If a tool will be used to seat the
plug, only use a rounded blunt end
to push in the plug
WRONG
The cavity plug must be fully installed with
all 3 seal glands engaged in the seal cavity
(é) 0° REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
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With TPA still in pre-lock position, orient terminal to rear of connector. For the
receptacle terminal, grip the wire no less than 20 mm from the terminal insulation
crimp, align the orientation feature, and insert through appropriate circuit opening.
For the blade terminal, grip the wire no less than 25 mm from the terminal
insulation crimp, align the orientation feature, and insert through appropriate
circuit opening. If resistance is encountered, retract the terminal and adjust the
angle of insertion. Continue inserting the terminal until it stops and locks up on
the lock finger with an audible click.
MX150 Receptacle Installation
Correct Orientation
90 Mis-orientation
Section 3: Connector Assembly
D. Terminal Installation
D molex“ C REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Dual Row MX150 Blade Installation
X
X
Do not install the blade terminal away
from the grommet cap orientation feature
Orientation Feature
O
OK
K
Install blade terminal straight or slightly angled
towards the grommet cap orientation feature
Orientation Feature
D molexfi' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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MX150 Application Guide
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Single Row MX150 Blade Installation
Orientation Feature
O
OK
K
Install blade terminal straight or slightly angled
towards the grommet cap orientation feature
Orientation Feature
X
X
Do not install the blade terminal away
from the grommet cap orientation feature
D molexfi' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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Hybrid MX150 Blade Installation
Warning: Hold the wire at least 25mm away from crimp location while installing
terminals to avoid terminal rotation during installation. Installation should be
completed in one push, click pull operation.
Do not install the blade terminal away
from the grommet cap orientation feature
Install blade terminal straight or slightly angled
towards the grommet cap orientation feature
Orientation Feature
Orientation Feature
X
X
O
OK
K
Follow Push, Click, Pull method of terminal installation. REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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MX150 Application Guide
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With TPA still in pre-lock position,
orient terminal to rear of connector.
Align the orientation feature and insert
through appropriate circuit opening. If
resistance is encountered, retract the
terminal and adjust the angle of
insertion. Continue inserting the
terminal until it stops and locks up on
the lock finger with an audible click.
Once the audible click is heard, stop
inserting the terminal.
Follow Push, Click, Pull method of
terminal installation.
PUSH
PULL
NO!!!
WRONG!!
CLICK
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TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
With the Receptacle terminals fully installed, the TPA can be seated into its final
lock position by applying an even force to both ends until it comes to a stop, with
an audible click. TPA movement distance from pre-lock to final lock is 5.0 mm.
The TPA should never be fully removed!
Section 3: Connector Assembly
E. Seating the TPA Receptacle side
(é) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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A modified process can be used for the Blade terminal. Using a pair
on needle nose pliers, apply even pressure to the TPA. If the TPA
resists it may be detecting a partially installed terminal. Pull the TPA
back into its pre-lock position and make sure all terminals are fully
installed. Upon completion, the TPA can be seated. TPA movement
distance from pre-lock to final lock is 5.0mm.
The TPA should never be fully removed!
Section 3: Connector Assembly
F. Seating the TPA Blade side
D molex“ C REVISION. ECR/ECN \NFORMATTON. TITLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED BY. APPROVED BY. AS-33472-100
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30 mm
Section 3: Connector Assembly
G. Harness taping recommendations
Industry standard for harness taping: Molex recommends tape should be
a minimum of 30mm from the back of connector housing.
TPA must be seated before any tape is applied to the harness!
Tape must not contact the back of connector housing!
REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Industry standard for harness routing: Molex recommends gradual
bends in wire harnesses.
Sharp 90 degree bends in the harness should be avoided!
Excessive force, or severe bending of the wire harness may damage
the harness.
WRONG!
TO PREVENT DAMAGE TO THE CONNECTOR ASSEMBLY ANY ASSEMBLY
FIXTURE OR TEST FIXTURE THAT INTERFACES WITH THE INTERIOR OF THE
CONNECTOR MUST COMPLY WITH EITHER THE USCAR INTERFACE OR THE
MOLEX DEFINED INTERFACE. SEE MOLEX DRAWING FOR INTERFACE
DEFINITION
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Note and align connector keying features, from connector to connector. Begin
mating procedure by sliding the two connectors together, press firmly until you
hear an audible click from the primary latch.
Keying features
Keying Features
Section 4: Connector Mating
A. Connector mating
Primary Latch
Primary Latch
D AS-33472-100 REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I REVISED BY: CHECKED BY: APPROVED BY:
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Once together the final step will be locking the CPA. Simply press in to the
center of the connector, until you see/feel positive engagement.
Section 4: Connector Mating
B. Connector mating (continued)
D molexfi' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 5: Service Instructions
A. Un-mate procedure
To un-mate the connectors, pull back on the CPA (step 1, and step 2). Push
connector together to unload the latch system. Then depress the latch with your
thumb (step 3). Continue to depress the latch, and gently pull apart connector
assemblies (step 4).
Step 1
Step 2
Step3
Step 4
(é) S REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Step 1: Insert a small screwdriver (2.4 mm 3.5 mm) into the designated pry point
The TPA should never be fully removed from the connector housing!
Excessive force may damage the TPA!
Step 1: Insert a small pair of needle nose pliers to the designated grab point
Step 2: Pull back 5.0 mm, gently, until the TPA reaches pre-lock position.
Grab point
Pull back gently
Approximately 5.0mm
Section 5: Service Instructions
B. TPA servicing Blade side
Section 5: Service Instructions
C. TPA servicing Receptacle side
(é) 'cm connector housing! Excessive force may damage REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Step 2: Using the housing as a pivot point gently pry out on the TPA, until it reaches
pre-lock position (5.0 mm, travel)
The TPA should never be fully removed from the
connector housing! Excessive force may damage
the TPA!
Step 1
Step 2
Pry Point
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Step 1: Using the 1.50 mm service tool #63813-1500, insert the tip into the terminal
service hole adjacent to the terminal to be serviced.
Step 2: Push straight down gently and apply pressure to release locking finger. This
motion will release the locking finger, “picking” is not required. Cavity plugs are
removed in the same manner.
Do not apply any lateral force, this may damage the tool, or the locking finger!
Do not use excessive force, excessive force can damage the lock finger!
Do not insert the service tool at an angle, this may cause damage to the
terminal!
Section 5: Service Instructions
D. 1.50 mm terminal removal
Service Ports
Service tool must be 90° to the connector face!
D molexfi' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I FIEVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 5: Service Instructions
E. Terminal removal (continued)
Step 3: Once the Lock finger is disengaged, gently pull on the wire to release the
terminal.
If the terminal resists, the service tool may not be fully engaged. Push the service tool
straight into the service opening to ensure that it has fully disengaged the locking
finger.
Do not insert the service tool into the terminal opening!
Do not use excessive force, excessive force can damage the lock finger!
Do not insert the service tool at an angle, this may cause damage to the
terminal!
Do not apply any lateral force, this may damage the terminal or lock finger!
Service Ports
Service tool must be 90° to the connector face!
D molexfi' C YES! NO REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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C
CO
OR
RR
RE
EC
CT
T!
!
Y
YE
ES
S!
!
W
WR
RO
ON
NG
G!
!
N
NO
O!
!
Service tool must be 90° to the connector face!
Section 5: Service Instructions
(é) Service tool must be 90° to the connector face! REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 5: Service Instructions
F. Terminal removal (continued)
1
2
3
Service tool must be 90° to the connector face!
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Section 5: Service Instructions
G. Service tools
If the 1.50 mm terminal needs to be replaced, a new one can be hand
crimped using the Molex Crimp tool # 63811-5900(Female)16,14 AWG
1.3-2.00mm², and # 63811-2600 (Male)22,20,18AWG 0.35, 0.50, 0.75mm²
Shown in (Fig.22a) #63811-2400(Male)16,14AWG 1.5, 2.00mm² #63811-
6000(Female)22,20,18AWG 0.35, 0.50, 0.75mm².
Also shown Molex Terminal removal tool # 63813-1500
Fig. 22a
D molex“ C Probe gin recommendations: Probing damage can occur: REVTSTON. ECR/ECN \NFORMATTON. TTTLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV. AS-33472-100
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Section 6: Electrical Continuity Checking
Fixtures that may come in contact with the perimeter seal must have the
interface lead-in geometry as defined on the USCAR and/or Molex
interface drawing
Fixtures used for continuity testing must meet the row and pitch
dimensions as identified in Section 6.
Fixtures outside these requirements could result in damage to the
connector and/or terminal.
Probe pin recommendations:
1. When testing the connector for continuity it is imperative that you do not
damage the terminals!
2. Pogo pins should be checked for damage or sticking several times a shift.
This should assure containment if an issue is found.
3. First a visual inspection of all the pins for damage should be performed.
4. Next a testing block should be used to depress all the pogo pins up into
the barrel. If there is a bent or sticking pin, it should remain stuck in the barrel
of the pogo pin. A damaged or stuck pin should be replaced before any
additional testing is performed.
Probing damage can occur:
1. If a sharp ended probe is inserted into the contact of the terminal it may
damage the plating and increase contact resistance
2. If an oversized diameter probe is inserted into the terminal, this will
overstress the beam in the terminal. This will create an environment for
intermittent connections, and increased contact resistance.
3. If a probe is inserted into the connector on an angle or off center it may
damage the terminal, and or the connector.
(é) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
Preferred method of probing receptacle
Fixtures used for continuity testing must meet the row and pitch
dimensions as identified in Section 6. Fixtures outside these
requirements could result in damage to the connector and/or
terminal.
When TPA allows access to the box, probe using this method.
Check electrical continuity on the terminal by inserting probe pin between
terminal access hole and terminal opening with a 0.50 mm probe.
Shown below are pictures of MX150 Sealed connector. Unsealed connectors
must be probed at the same location (between access hole and terminal
opening)
Molex Receptacle connector
View of probe pin female terminal
(0.50) mm probe
Must use this pin
or damage will
occur!
D molex“ C Preferred method of probing receptacle 4. Probe pin details 02.3 POGO-72 7 J i | PROBE MODEL ITIF‘ STVLE ISF'FIING FORCE POGO—72d POGO-72J-S fl Full Radius .020 {.31 {0.501 Typical .u 73, Dimensions shown are in (mm) POGOE72 Patent-9d REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
Preferred method of probing receptacle
Dimensions shown are in (mm)
Probe pin details
Manufacturer: Everett Charles technologies
Preferred probe number: POGO-72J-4
Pin length 0.330”(8.38 mm)
Pin diameter: (0.50 mm)
Tip shape: Spherical
Must use this pin or damage will
occur!
4
.330
(8.38)
1.70
(43.18)
(é) on it REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
B. Alternative method of probing receptacle
Fixtures used for continuity testing must meet the row and pitch dimensions
as identified in Section 6. Fixtures outside these requirements could result in
damage to the connector and/or terminal.
Molex Receptacle connector
View of probe pin
female terminal
When TPA does not allow access to the box you must probe down the throat
using this method.
Shown below are pictures of MX150 Sealed connector. Unsealed connectors
must be probed at the same location (center of receptacle TPA opening)
Check electrical continuity on the terminal by inserting probe pin down the
center of receptacle TPA opening
Must use this pin or damage will occur!
(0.64) mm probe
D molexfi' C Probe pin details POGO, I PROBE MODEL —J|T|F' STV LE —|SFRING FORCE POG 0 —1 J POGO-1J-S Full Radlus .024 ‘ ‘ [30.51) i 7‘ I1 OZI WM) POGO—1 Patented REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED I REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
REVISION:
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Dimensions shown are in (mm)
Probe pin details
Manufacturer: Everett Charles Technologies
Alternative probe number: POGO-1-J-4
Pin length 0.330” (8.38mm)
Pin diameter: (0.64 mm)
Tip shape: Spherical
Must use this pin or damage will
occur!
.330
(8.38)
1.30
(33.02)
4
1
Section 6: Electrical Continuity Checking Alternative
(é) Probe pin details Recommended Pin Tig Dimensions shown are in (mm) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Dimensions shown are in (mm)
Probe pin details
Manufacturer: Lone Star Industrial
Recommended Probe number: LS054MR-849-4.6
Alternative Probe Number: LS054MR-846-4.6
Pin length .335” (8.51mm)
Pin diameter: .060” (1.52 mm)
Recommended Tip shape: Serrated
Alternative Tip shape: Large Concave
.335
(8.51)
1.35
(34.29)
Recommended Pin Tip
Alternative Pin Tip
Section 6: Electrical Continuity Checking - Blade
D molex“ C PREFERRED PROBING DUAII A 5011 ‘0‘ SH own A REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
MX150 16 WAY HYBRID RECEPTACLE
PREFERRED PROBING
D molex“ C PREFERRED PROBING 41w TIP. DETAIL A SCALI IO‘I SEE DETAIL REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
MX150 16 WAY RECEPTACLE
PREFERRED PROBING
D molex“ C PREFERRED PROBING —- "P MTAIL A SEMI low 5U. 0mm )1 Noam. IS on Mmm: or uousmc REVISION. ECR/ECN INFORMATION. TITLE. SHEET N0. EC No. DOCUMENT NUMBER. ' W CKED BY. APPROVED BY. AS-33472-100Ifl—T—SWV—BI -
APPLICATION SPECIFICATION
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Section 6: Electrical Continuity Checking
MX150 6 WAY RECEPTACLE
PREFERRED PROBING
Section 6: Electrical Continuity Checking
MX150 20 WAY RECEPTACLE
PREFERRED PROBING
D molex“ C |,05 DITAIL A SCME IO'I SEE DETAIL A REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
MX150 16 WAY RECEPTACLE
ALTERNATE PROBING
D molex“ C DETAIL A SCILI REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
MX150 16 WAY HYBRID RECEPTACLE
ALTERNATE PROBING
D molex“ C HF, T (JEA * L4 IP I f\‘ T DETAIL A SCALE ID | SEE DETAIL A {PROBING IS ON CENIIIIIINI OF HOUSING REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED EIY: APPROVED BY: AS-33472-100
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M. Hussain
M. Vanslambrouck
TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC
Section 6: Electrical Continuity Checking
MX150 6 WAY RECEPTACLE
ALTERNATE PROBING
Section 6: Electrical Continuity Checking
D molexfi' C REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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Section 6: Electrical Continuity Checking
MX150 16 WAY HYBRID BLADE
MX150 20 WAY RECEPTACLE
ALTERNATE PROBING
D molex“ C REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
APPLICATION SPECIFICATION
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Section 6: Electrical Continuity Checking
MX150 16 WAY BLADE
D molex“ C 2X 8.75 70.70 REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 6: Electrical Continuity Checking
MX150 6 WAY BLADE
Section 6: Electrical Continuity Checking
MX150 20 WAY BLADE
D molex“ C REVISION. ECR/ECN \NFORMATTON. TITLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV. AS-33472-100
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D AS-33472-100 www.molex.com/|nd/mx150.htm| REVTSTON. ECR/ECN \NFORMATTON. TTTLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV.
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This MX150 crimping information can be found at:
www.molex.com/ind/mx150.html
MX150 Terminal Sales drawing
MX150 Female Terminal Sales Drawing: SD-33012-002
MX150 Female Terminal Crimping Specification: AS-33012-002
MX150 Male Blade Terminal Sales Drawing: SD-33000-001
MX150 Male Blade Terminal Crimping Specification: AS-33000-001
Section 7: Crimping
Issue: No Insulation grip step allowed on 22 gage - 0.35-0.5mm²
MX150 Female terminal
Part Numbers:
33012-2003 & 33012-3003 Tin Plated Terminals
33001-2005 & 33001-3005 Gold Plated Terminals
33001-4003 & 33001-5003 Silver Plated Terminals
Section 7: Crimping
D molex“ C Oriqinal 22 qaqe crimped terminal with Insulation Grip Step: Modified Tool Set Up 22 qaqe crimped terminal without Insulation Grip Step: REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED EIY: APPROVED BY: AS-33472-100
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Original 22 gage crimped terminal with Insulation Grip Step:
Modified Tool Set Up 22 gage crimped terminal without Insulation Grip Step:
0.785mm to
CL of wire
0.3mm offset from
back of terminal
0.0mm offset from
back of terminal
D molexfi' REVISION: ECR/ECN INFORMATION: TITLE: SHEET N0. EC No: DOCUMENT NUMBER: CREATED I REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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1.085mm to
CL of wire
(é) This failure can limit the ability to seat the T PA Proger wire brush m® Excess: ve wire brush REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 7: Crimping
2.8 Male Blade
Used in MX150 16 way hybrid
Issue: 2.8 terminals, and excessive wire brush
Excessive wire brush
Proper wire brush
OK
This failure can limit the ability to seat the TPA
REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
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Section 8: Hybrid Connector
A. Un-populated shorting bar connector (TPA in pre-lock)
D molexfi' C 4— deflector REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 8: Hybrid Connector
B. Shorting Bar Blade Terminal (gold plating only)
Crimp information can be found on the corresponding terminal drawing.
Wire insulation grip is critical to prevent the rotation of the terminal
during installation into the connector.
Orientation
Feature
Wire
Insulation
Orientation
Feature
Shorting bar
deflector
Polarization
feature
Shape of body
REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
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Section 8: Hybrid Connector
C. Single cavity populated shorting bar connector (TPA in
Lock)
Shorting Bars
NOTE! Lifted shorting bar
Blade Terminal
(é) 1 80° Do not apply excessive force, this may damage the terminal orientation feature! REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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With TPA still in pre-lock position, orient terminal to rear of connector. Grip
the wire no less than 30 mm from the terminal insulation crimp and insert
through appropriate circuit opening. If resistance is encountered, retract the
terminal and adjust the angle of insertion. Continue inserting the terminal until
it stops and locks up on the lock finger with an audible click.
Correct Orientation
180 Mis-orientation
Section 8: Connector Assembly
D. 1.5 mm Shorting Bar Terminal Installation
Do not apply excessive force, this may damage the terminal
orientation feature!
D molex“ C Aliqn tabs and insert until you hear/feel positive enqaqement with an M REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Note alignment tabs on Blade
terminal
Note alignment tabs on
Receptacle terminal
Align tabs and insert until you hear/feel positive engagement with an
audible click
Section 8: Connector Assembly
E. Populating the 2.8 mm Terminal
as /'\ molex V Do not apply any lateral force, this may damaqe the tool. or the Iockinq finger! REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
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Section 8: Service Instructions
F. 2.8 mm Terminal Servicing
Step 1: Using the 2.8 mm service tool #63813-1500, insert the tip into the
terminal service hole adjacent to the terminal to be serviced.
Step 2: Push down gently to release locking finger.
Do not apply any lateral force, this may damage the tool, or the locking
finger!
REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Damage to Shorting Bar
Terminal Orientation
feature from being put
into the grommet cap the
wrong way.
Section 9: Troubleshooting
A. MX150 16 Way Male Hybrid
Issue: Damage on Shorting Bar Terminal
OK
nal Proger Alignment of D d T . IO . t t' Shorting Bar Orientation a'r:nate ggmltljla brlen a P" Feature Un-damaged W Ilfted REVISION! ECR/ECN INFORMATION: TITLE: SHEET NO. EC No: DOCUMENT NUMBER! CREATED/REVISED BY: CHECKED BY! APPROVED BY! AS-33472-100
APPLICATION SPECIFICATION
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Section 9: Troubleshooting
B. MX150 16 Way Male Hybrid
Issue: Damage to Orientation Feature Shorting Bar Terminal
Proper Alignment of
Shorting Bar Orientation
Feature Un-damaged
Damaged Terminal Orientation
Feature Shorting bars not
lifted
OK
REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BV: APPROVED BV: AS-33472-100
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Section 9: Troubleshooting
D. MX150 16 Way Male Hybrid
Issue: TPA should never be fully removed from connector for any reason. If
the TPA has been removed, replace entire connector.
(é) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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1.5mm Terminal is turned upside-down
1.5mm Terminals proper
orientation
OK
Section 9: Troubleshooting
E. MX150 16 Way Male Hybrid
Issue: Terminal inserted rotated 180 degrees out
(é) REVISION: ECR/ECN INFORMATION: TITLE: SHEET No. EC No: DOCUMENT NUMBER: CREATED/REVISED BY: CHECKED BY: APPROVED BY: AS-33472-100
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Section 10: Packaging
Assembly at Tier 1(Wire Harness Assembly Plant)
Unpacking:
TPA as received, The TPA are locked in place in the pre-lock position. If
the TPA is in final lock follow the service section in section 5.
Handling in Plant:
Harness build board/fixture: Molex recommends moving the cell pack box
or box to the line, this will insure against damage. Parts should remain in
Molex cell pack until assembled placed on a harness assembly build
board.
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Section 10: Packaging
Bulk Pack with 4 Compartments
Female 2x2 1x3
Male 2x2, 2x3, 2x4, 1x2, 1x3,
1x4,1x5, 1x6
Male 16 way Hybrid
Bulk Pack
MX150 Seal Plug
Male 1x4 through 1x6
Male 2x3 through 2x8
Male 16 way Hybrid
Cell Pack
Female 1x4 through 1x6
Female 2x3 through 2x10
Female 16 way Hybrid
Male 2x10
D AS-33472-100 REVTSTON. ECR/ECN \NFORMATTON. TTTLE. SHEET No. EC No. DOCUMENT NUMBER. CREATED / REVISED BY. CHECKED EV. APPROVED EV.
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Document Change History:
Revision
Date
Description
A
12/6/16
Added 2.8mm cavity seal plug installation
procedure: section 3 Pages: 20, 21
B
03/15/17
Added “and avoid cavity plug dislocation/push through” to cavity
plug trimming note on pages 18 & 19
C
1/10/18
Removed change history information for revisions 1-
7
Section 3.D Terminal installation revised.
Changed the distance to grip the receptacle
terminal lead from 30 to 20mm, changes the
distance to grip the blade terminal lead from 30 to
25mm
Section 11: Appendix A

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