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MX150 System
Sealed Product Line
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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
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Section 1: Product Introduction
MX150 System
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.
Single Row Assembly Sales Drawing
Receptacle
Blade
Dual Row Assembly
Receptacle
Blade
SD-33471-031.drw
SD-33471-041.drw
SD-33471-051.drw
SD-33471-061.drw
SD-33481-031.drw
SD-33481-041.drw
SD-33481-051.drw
SD-33481-061.drw
SD-33472-041.drw
SD-33472-061.drw
SD-33472-081.drw
SD-33472-121.drw
SD-33472-131.drw
SD-33472-161.drw
SD-33472-201.drw
SD-33482-041.drw
SD-33482-061.drw
SD-33482-081.drw
SD-33482-121.drw
SD-33482-161.drw
SD-33482-201.drw
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Section 1: Product Introduction MX150 System
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) and SAE
Automotive (22 to 14) 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
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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
For product ordering information, please contact your Molex Inside
Sales Representative at (800)786-6539. This User Manual can be
found at www.molex.com/ind/mx150.html
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Section 2: Product Summary
A. Connector Assemblies
TPA
Housing
Grommet Seal
Grommet Cap
6 Way 2X3
Blade Connector
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Section 2: Product Summary
B. Connector Assemblies (continued)
CPA
(Optional)
Housing
Perimeter Seal
TPA
16 Way 2X8 Standard
Receptacle Connector
Grommet Cap
Grommet Seal
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Section 2: Product Summary
C. Connector Assemblies (continued)
CPA
(Optional)
TPA
Grommet Cap
Grommet Seal
Housing
Perimeter Seal
16 Way Hybrid
Receptacle Connector
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Terminal Features
Section 2: Product Summary
D. Receptacle/Blade Terminal
Orientation Feature
Base Material - Copper Alloy
Plating Options - Tin, Gold, Silver
Wire Sizes: 14,16,18,20,22 AWG
1.5, 1.0, 0.8, 0.5 mm
Refer to Section 7 for crimping details.
2
Receptacle Terminal
Orientation Feature
Blade Terminal
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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 – MX150 16 way hybrid and MX150 20 way DO NOT
marking.
have Laser
Molex Part Number
DDD = Day of Year YY = Last Digit of Year
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Section 3: Connector Assembly
A. “As Shipped” connector positions
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!
TPA’s shown in pre-lock
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TPA shown in “Pre
-
lock” position.(Fig.10
-a)
Cross section of TPA in pre/ lock
Fig. 10
-a
Fig. 10
-b
Section 3: Connector
Assembly
B. TPA in Pre-lock and Lock
TPA shown in “lock” position. (Fig 10-b)
The TPA should never be removed from the connector!
Pre-lock
5.0 mm
Lock
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Correct Orientation
°°°°
Section 3: Connector Assembly
C. Terminal Installation
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
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.
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90
Mis-orientation
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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
PUSH
Follow Push, Click, Pull method
on the lock finger with an audible
click. Once the audible click is
heard, stop inserting the terminal.
of terminal installation.
CLICK
PULL
NO!!!
WRONG!!
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Section 3: Connector Assembly
D. 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
Orientation feature is highlighted
blue for reference only
Seal plug can not be used in shorting
ar circuits!
b
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Backwards
! 180
°
out of alignment!
90° out of alignment!
Section 3: Connector Assembly
D. Seal Plug Installation continued
YES!
CORRECT!
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Section 3: Connector Assembly
D. Seal Plug Installation continued
Cavity plugs can be trimmed flush to
avoid wire chafing, 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!
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Section 3: Connector Assembly
D. Seal Plug Installation continued
Cavity plugs can be trimmed flush to
avoid wire chafing, 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!
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Section 3: Connector Assembly
E. Seating the TPA Receptacle side
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!
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A modified process can be used for the Blade terminal. Using a pair on
Section 3: Connector Assembly
F. Seating the TPA Blade side
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!
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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!
30 mm
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Once together the final step will be locking the CPA. Simply press in
Section 4: Connector Mating
B. Connector mating (continued)
to the center of the connector, until you see/feel positive
engagement.
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Note and align connec
tor keying features, from connector
Keying features
Section 4: Connector Mating
A. Connector mating
to connector. Begin mating procedure by sliding the two
connectors together, press firmly until you hear an
audible click from the primary latch.
APPLICATION SPECIFICATION
Keying Features
Primary Latch
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Primary Latch
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Section 5: Service Instructions
To un
-
mate the connectors, pull
back on the CPA
(step 1, and step 2)
.
A. Un-mate procedure
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
Step3
Step 4
Step 2
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Pull back gently
Section 5: Service Instructions
B. TPA servicing Blade side
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.
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Grab point
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Approximately
5.0mm
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Step 1: Insert a small screwdriver (max width= 3.0 mm) into the designated
Step 1
Step 2
Section 5: Service Instructions
C. TPA servicing Receptacle side
pry point
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!
Pry Point
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Step 1: Using the 1.50 mm service too
l #63813
-
1500, insert the tip
Section 5: Service Instructions
Service Ports
D. 1.50 mm terminal removal
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!
Service tool must be 90° to the connector face!
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Section 5: Service Instructions
Step 3: Once the Lock finger is disengaged, gently pull on the wire to release the terminal.
Service Ports
E. Terminal removal (continued)
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 tool must be 90° to the connector face!
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YYEESS!!
NNOO!!
Section 5: Service Instructions
Service tool must be 90° to the connector face!
CCOORRRREECCTT!!
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WRROONNGG!!
W
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1 2 3
Service tool must be 90° to the connector face!
Section 5: Service Instructions
F. Terminal removal (continued)
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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,
and # 63811-2600 (Male)22,20,18AWG Shown in (Fig.22a) #638112400(Male)16,14AWG #63811-6000(Female)22,20,18AWG.
Also shown Molex Terminal removal tool # 63813-1500
Fig. 22a
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Probe pin recommendations
:
Section 6: Electrical Continuity Checking
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.
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.
REVISION: ECR/ECN INFORMATION: SHEET No.
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When TPA allows access to the box, probe using this method.
Section 6: Electrical Continuity Checking
• Preferred method of probing
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.
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
Must use this pin
or damage will
occur!
(0.50) mm probe
View of probe pin female terminal
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Section 6: Electrical Continuity Checking
Preferred method of probing
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
Tel: (909) 625-9390
Must use this pin or damage will
occur!
4
.330
(8.38)
1.70
(43.18)
Dimensions shown are in (mm)
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View of probe pin
Section 6: Electrical Continuity Checking
B. Alternative method of probing
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 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
Molex Receptacle connector
(0.64) mm probe
Must use this pin or damage will occur!
female terminal
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Section 6: Electrical Continuity Checking
Alternative
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
Tel: (909) 625-9390
Must use this pin or damage will
occur!
.330
(8.38)
1
Dimensions shown are in (mm)
4
1.30
(33.02)
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Section 6: Electrical Continuity Checking
MX150 16 WAY HYBRID RECEPTACLE
PREFERRED PROBING
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Section 6: Electrical Continuity Checking
MX150 16 WAY RECEPTACLE
PREFERRED PROBING
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Section 6: Electrical Continuity Checking
MX150 6 WAY RECEPTACLE
PREFERRED PROBING
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Section 6: Electrical Continuity Checking
MX150 16 WAY RECEPTACLE
ALTERNATE PROBING
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Section 6: Electrical Continuity Checking
MX150 16 WAY HYBRID RECEPTACLE
ALTERNATE PROBING
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Section 6: Electrical Continuity Checking
MX150 6 WAY RECEPTACLE
ALTERNATE PROBING
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Section 6: Electrical Continuity Checking
MX150 16 WAY HYBRID BLADE
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 6: Electrical Continuity Checking
MX150 16 WAY BLADE
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 6: Electrical Continuity Checking
MX150 6 WAY BLADE
REVISION: ECR/ECN INFORMATION: SHEET No.
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This MX150 crimping information can be found
at:
Section 7: Crimping
www.molex.com/ind/mx150.html
MX150 Terminal Sales drawing
MX150 Female Terminal Sales Drawing: SD-33012-002
MX150 Female Terminal Crimping Specification: CS-33012-002
MX150 Male Blade Terminal Sales Drawing: SD-33000-001
MX150 Male Blade Terminal Crimping Specification: CS-33000-001
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 7: Crimping
Issue: No Insulation grip step allowed on 22 gage MX150 Female
terminal
Part Numbers:
Original 22 gage crimped terminal with Insulation Grip Step:
0.3mm offset from back of
terminal
33012-2003 & 33012-3003 Tin Plated Terminals
3001-2005 & 33001-3005 Gold Plated Terminals
3
33001-4003 & 33001-5003 Silver Plated Terminals
0.785mm to
CL of wire
Modified Tool Set Up 22 gage crimped terminal without Insulation Grip Step:
0.0mm offset from back of
terminal
1.085mm
to CL of
wire
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 7: Crimping
MX150 Shorting Bar Blade
Used in MX150 16 way hybrid and MX150 4 way with shorting bars
Issue: Good VS Bent Shorting Bar Terminal
GOOD
OK
BAD, TERMINALS BENT
This failure can limit the ability to lift the shorting
bar to the correct height
REVISION: ECR/ECN INFORMATION: SHEET No.
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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
This failure can limit the ability to seat the TPA
OK
Proper wire brush
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 8: Hybrid Connector
A. Un-populated shorting bar connector (TPA in pre-lock)
REVISION: ECR/ECN INFORMATION: SHEET No.
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Feature
deflector
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 rota
during installation into the connector.
tion of the terminal
Orientation
Polarization
feature
Wire
Insulation
Orientation
Shorting bar
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 8: Hybrid Connector
C. Single cavity populated shorting bar connector (TPA in Lock)
NOTE! Lifted shorting bar
Shorting Bars
Blade Terminal
REVISION: ECR/ECN INFORMATION: SHEET No.
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°°°°
Section 8: Connector Assembly
D. 1.5 mm Shorting Bar Terminal Installation
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
Do not apply excessive force, this may damage the terminal
orientation feature!
180
Mis-orientation
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 8: Connector Assembly
E. Populating the 2.8 mm Terminal
Note alignment tabs on Blade terminal
Align tabs and insert until you hear/feel positive engagement with an audible click
Note alignment tabs on Receptacle terminal
REVISION: ECR/ECN INFORMATION: SHEET No.
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Step 2: Push down gently to release locki
ng finger.
Section 8: Service
Instructions
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.
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 9: Troubleshooting
A. MX150 16 Way Male Hybrid
Issue: Damage on Shorting Bar Terminal
OK
Damage to Shorting Bar
Terminal Orientation
feature from being put
into the grommet cap the
wrong way.
REVISION: ECR/ECN INFORMATION: SHEET No.
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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: SHEET No.
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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.
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 9: Troubleshooting
E. MX150 16 Way Male Hybrid
Issue: Terminal inserted rotated 180 degrees out
1.5mm Terminal is turned upside-down
1.5mm Terminals proper
OK
REVISION: ECR/ECN INFORMATION: SHEET No.
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orientation
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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.
REVISION: ECR/ECN INFORMATION: SHEET No.
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Bulk Pack with 4 Compartments
Bulk Pack
Cell Pack
Section 10: Packaging
MX150 Seal Plug
Male 1x4 through 1x6
Male 2x3 through 2x8
Male 16 way Hybrid
Female 2x2 1x3
Male 2x2, 2x3, 2x4, 1x2, 1x3, 1x4,1x5, 1x6
Male 16 way Hybrid
Female 1x4 through 1x6
Female 2x3 through 2x10
Female 16 way Hybrid
Male 2x10
REVISION: ECR/ECN INFORMATION: SHEET No.
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Section 11: Appendix A
• Document Change History:
REVISION: ECR/ECN INFORMATION: SHEET No.
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