0348994025

MXP120 Sealed Connection System Application Specification 1.0 Scope: This manual contains supplemental information pertaining to the Molex 1.2mm Sealed product line, Molex series numbers 34899 and 34900 2.0 Product Description: The Molex 1.2 sealed system is a series of connectors with 1x2, 1x3, 1x4 and 1x6 terminal configurations, designed to be used with the following Tyco 1.2 MCON terminals MCON-1.2 LL (Locking- Lance) Receptacle terminal (wire size 0.25 - 0.35mm²) MCON-1.2 LL (Locking- Lance) Receptacle terminal 1452668-3 (wire size 0.50 - 0.75mm²) MCON-1.2 LL (Locking-Lance) Receptacle terminal 7-1452671-1 (wire size 1.0 - 1.5mm²) MCON-1.2 CB (Clean- Body) Blade terminal 2141114-3 (wire size 0.25 - 0.35mm²) MCON-1.2 CB (Clean- Body) Blade terminal 2141116-3 (wire size 0.50 - 0.75mm²) MCON-1.2 CB (Clean- Body) Blade terminal 2177610-3 (wire size 0.75 - 1.0mm²) per TE DWG C-1718398 Or the following Kostal MLK 1.2 terminals 1452665-3 32124734110 32124734120 32124734130 ATS-638246300 MLK-1.2mm Single wire seal LL (Locking- Lance) receptacle terminal (wire size 0.35mm²) MLK-1.2mm Single wire seal LL (Locking- Lance) receptacle terminal (wire size 0.5mm²) MLK-1.2mm Single wire seal LL (Locking- Lance) receptacle terminal (wire size 0.75 - 1.0mm²) Application Tooling Specification Sheet Note: System is not approved for 1.5 mm² wire Female Terminal Connector Male Terminal Connector REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 1 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 3.0 Reference Documents: 3.1 Molex Drawings SD-34899-2001 SD-34899-6001 SD-34900-2001 SD-34900-6001 SD-160091-0001 PS-34900-0001 PK-31301-898 SD-34996-1501 SD-34996-1901 1.2mm Sealed Inline 1 x 2, 1 x 3 Blade Assembly 1.2mm Sealed Inline 1 x 4, 1 x 6 Blade Assembly 1.2mm Sealed Inline 1 x 2, 1 x 3 Receptacle Assembly 1.2mm Sealed Inline 1 x 4, 1 x 6 Receptacle Assembly 1.2mm Sealed Wire Dress Cover 1.2mm Sealed Inline Product Specification 1.2mm Sealed Inline Packaging Specification Cavity Plug Pin Cavity Plug Seal 3.2 Tyco Drawings C-1452674 C-1418754 C-1718398 967056GEN Rev. C2 Rev. C6 Rev. B4 Rev. B1 Single wire sealed receptacle terminals (Locking Lance) Single wire sealed blade terminals (Locking Lance) Single wire sealed blade terminals (Clean Body) Rubber plug for cavity DIA 3.45 Rev. 03 Single Wire sealed receptacle terminals (Locking Lance) 3.3 Kostal Drawings DOC00079128 REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 2 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.0 Procedure 4.1 General Requirements: 4.1.01 Receptacle Terminals 4.1.02 Blade Terminals 4.2 Assembly Instructions: 4.2.01 Connector Assembly, as shipped: Cutaway view of male connector shown for clarity The PLR/ISL is shown in the as shipped position. The PLR/ISL should remain in the prelock position until all circuits are fully loaded. THE PLR/ISL SHOULD NEVER BE REMOVED FROM THE ASSEMBLY! REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 3 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.2.02 ISL “slide to pre-lock” If during shipping the ISL of receptacle connector moves from its pre-lock position, it must be moved back to its pre-lock position. The ISL must be in pre-lock position to populate the connector. Slide a small (3.5mm maximum) flat tip blade screwdriver under the edge of the ISL on one side. Using the blade of the screwdriver gently slide the ISL out. THE ISL SHOULD NEVER BE FULLY REMOVED! REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 4 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.2.03 If during shipping the PLR of blade connector moves from its pre-lock position, it must be moved back to its pre-lock position. The PLR must be in pre-lock position to populate the connector. Using a set of serrated tip tweezers (refer to section 5.0 for details), grab the center rib feature of the PLR in order to lift the PLR to the pre-lock position. The PLR should never be fully removed! 4.2.04 Molex Cavity Plug Installation 4.2.04.1 A 2-piece assembly is available for plugging un-used circuits in the connector assembly. This assembly consists of a seal, part number 349961902 and a plastic pin, Part Number 349961501. The cavity plug should be installed prior to terminal insertion. REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 5 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.2.04.2 The seal is to be installed over the long, cylindrical portion of the pin and pressed on until it contacts the head of the pin 4.2.04.3 - The cavity plug assembly can then be installed into the connector. Insert the plug assembly into the circuit you wish to plug and carefully press the cavity plug in until the head of the pin is flush with the surface of the connector NOTE: Care must be exercised while installing the cavity plug assembly such that the seal is not pinched. A pinched seal may increase the force required to completely seat the cavity plug. REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 6 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.2.05 TE Cavity Plug #967056-1 4.2.05.1 Installation per TE Application Specification 114-18025 4.2.06 Terminal Installation – Blade and receptacle 4.2.06.1 With ISL/PLR in pre-lock position, orient terminal to rear of connector. Grip the wire no less than 1.25 inches 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 and ensure by pulling the wire gently, following “PUSH, CLICK, and PULL”. Cable seal terminal orientation feature (proper orientation) REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 7 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification Cable seal terminal orientation feature (proper orientation) After installing the terminals, use a small (3.5mm maximum) flat tip screwdriver to seat the PLR. Care must be exercised to prevent damaging the terminal blades. PLR Insertion Force (Max. Required) PLR Insertion Force (Actual Recorded) PLR Insertion Force (Min. Required) 30N Max. 2.4N Max, (Avg. 2.16N) 40N Min. (for improperly seated terminal) REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 8 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification After Installing the terminals, push the ISL into the lock position. If the ISL is difficult to seat, verify that all terminals are seated properly. ISL Insertion Force (Max. Required) ISL Insertion Force (Actual Recorded) ISL Insertion Force (Min. Required) 30N Max. 14.10 N Max, (Avg. 8.6N) 60N Min. (Terminal not fully seated) REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 9 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.2.07 Harness taping recommendation There should be a minimum of 15mm between the back of the connector and the tape used on the wire harness. The PLR/ISL must be closed prior to the taping operation. The tape must not contact the connector housing. REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 10 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.3 Connector Mating 4.3.01 Begin mating procedure by sliding the connector and header together, press firmly until the connectors are fully mated and locked REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 11 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.3.02 Once the connector halves are mated, seat the CPA by pressing in the center of the CPA until positive engagement is felt REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 12 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.4 Connector Un-mating 4.4.01 Disengage the CPA by pulling back as shown 4.4.02 Push the connector halves together to unload the pressure on the latch system 4.4.03 Depress the latch with your thumb and hold it down while gently pulling the connector halves apart REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 13 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.5 Terminal servicing 4.5.01 Male Connector 4.5.01.1 Lift the PLR to the pre-lock position using a set of serrated tip tweezers (refer to section 5.0 for details); grab the center rib feature of the PLR and lift the PLR to the pre-lock position. THE PLR SHOULD NEVER BE FULLY REMOVED! Use serrated, medium tweezers to lift PLR to pre-lock position. Grab the center rib feature of the of PLR Magnified view (male connector) REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 14 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification PLR in locked position PLR in unlocked position 4.5.01.2 Disengage the terminal lock finger by inserting the service tool (Molex #63824-2900) through the service hole in the PLR. Push straight down gently and apply pressure to release the lock finger/ This motion will release the lock finger, “picking” is not required REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 15 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification Holes to insert service tool to disengage terminal 4.5.01.3 While holding pressure on the lock finger with the service tool, gently pull on the wire to remove the terminal REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 16 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.5.02 Female connector 4.5.02.1 Slide a small (3.5mm maximum) slotted tip screwdriver under the edge of the ISL on one side. Using the blade of the screwdriver gently slide the ISL out. THE ISL SHOULD NEVER BE FULLY REMOVED! ISL in unlocked position ISL in locked position Do not insert the service tool in to the receptacle terminal; damage to the contact beam will occur Magnified view showing Service hole to insert tool to disengage the terminal REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 17 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.5.02.2 Disengage the terminal by inserting the service tool (Molex #63824-2900) through the service hole in the PLR. Push straight down gently and apply pressure to release the terminal, “picking” is not required 4.5.02.3 While holding pressure on the terminal release feature with the service tool, gently pull on the wire to remove the terminal. REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 18 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.6 Electrical Continuity Checking 4.6.01 Male Connector 4.6.01.1 Recommended Pogo Pin Lone Star Industrial part number LS054RS-318 with the standard spring force (3.7oz) option (or equivalent). www.lonestarindustrial.com 4.6.01.2 Pogo Pin Contact Point The pogo pin is positioned to contact the tip of the blade terminal. 4.6.01.3 REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 Pogo Pin Patterns TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 19 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.6.02 Female Connector 4.6.02.1 Recommended Pogo Pin Lone Star Industrial part number LS054RS-312 with the standard spring force (3.7oz) option (or equivalent). www.lonestarindustrial.com 4.6.02.2 Pogo Pin Contact Point The pogo pin is positioned to contact the visible edge of the terminal box located within the terminal service hole REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 20 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 4.6.02.3 Pogo Pin Patterns NOTE: To design electrical counterpart to detect terminal pushed out (TPO) conditions, refer to PLR insertion force requirements table defined in section 4.2.06.1 REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 21 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 5.0 Service tool information 5.1 Slotted tip screwdriver with a maximum tip width of 3.5 mm 5.2 Straight tip, serrated, medium point tweezers 5.2.01 Reference: http://www.excelta.com/product_categories/general-purposetweezers/products/straight-tip-medium-point-tweezer 5.3 Terminal service tool: Molex Part Number 638242900 5.4 Alternative Terminal Service tool: GM #J-38125-22 5.5 Application Tool Specification (ATS) Kit P/N: 638246300 – Application Tooling Specification Sheet contains all service tools required for this product REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 22 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC MXP120 Sealed Connection System Application Specification 6.0 Revision Information Revision 1 A Date 8/1/2012 1/30/2014 B 6/27/2014 C 1/21/2015 D 3/16/2015 D1 D3 4/27/2015 12/08/2015 D4 12/15/2016 REVISION: D4 ECR/ECN INFORMATION: EC No: 10841244 Description Initial draft Updated with 1x3, 1x4 CKT sizes and added Kostal terminal part# Removed Tyco ‘Locking Lance’ blade terminals, Added photos of service tools Removed USCAR interface drawing information; Added cavity plug installation procedure. Added GM service and probe tool information. Added fixture probing information. Removed GM probing tool information. Added taping recommendation LL terminal added for 1.0 – 1.5mm² wire size. Addition of TE Cavity Plug #967056-1. Added dress cover drawing ref. - Section 3.1, Added PLR insertion force table - Section 4.2.06.1, Added ISL insertion reference note - section 4.6.02.3 TITLE: SHEET No. MXP120 Sealed Connection System DATE: 2017/05/18 DOCUMENT NUMBER: AS-34900-0001 23 of 23 CREATED / REVISED BY: CHECKED BY: APPROVED BY: M. Hussain J. Pate K. Dekoski TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC