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molex MX123 User Manual

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MX123 Connection System
User Manual
Revision C – November 15, 2018

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  • Page 1 MX123 Connection System User Manual Revision C – November 15, 2018...

  • Page 2: Table Of Contents

    Electrical Continuity Checking  Section 7: Tool Ordering Information  Section 8: Revision History  Section 9: Files  Section 10: Appendix A - Document Change History  Section 11: Appendix B - Cleaning Instructions MX123 Connection System User Manual - AS-34566-001...

  • Page 3: Product Introduction

    Section 1: Product Introduction The Molex MX123 Connection System is a sealed system consisting of a header/controller, mating connectors, and terminals with the following configuration options: A. 80-Ckt ~ (80) 0.64mm terminals B. 73-Ckt ~ (72) 0.64mm and (1) 2.8mm terminals C.
  • Page 4 Section 2: Product Summary: 18/73/80-Ckt Dress Cover Lever (Shipped Separately) Connector Position Assurance (CPA) Grommet Cap Grommet Seal Connector Housing Slides Terminal Position Assurance (TPA) Perimeter Seal MX123 Connection System User Manual - AS-34566-001...
  • Page 5 Section 2: Product Summary: 49/56-Ckt 49/56-Ckt Exploded View Dress Cover Lever (Shipped Separately) Connector Position Assurance (CPA) Grommet Cap Grommet Seal Connector Housing Slides Terminal Position Assurance (TPA) Perimeter Seal MX123 Connection System User Manual - AS-34566-001...
  • Page 6 Section 2: Product Summary: 10-Ckt 10-Ckt Exploded View Dress Cover Lever (Shipped Separately) Connector Position Assurance (CPA) Connector Housing Slides Terminal Position Assurance (TPA) Perimeter Seal MX123 Connection System User Manual - AS-34566-001...

  • Page 7: Product Summary

    Section 2: Product Summary MX64 Receptacle Terminal Orientation Tab Correct Orientation 90° Misorientation 180° Misorientation Lock-out Lock-out Orientation of receptacle terminal during insertion to connector MX123 Connection System User Manual - AS-34566-001...
  • Page 8 Section 2: Product Summary MX64 Receptacle Terminal Terminal Grip Code “A”: Terminal Grip Code “B”: 22 GA. Wire 18/20 GA. Wire Grip Codes Visibly Bigger! MX123 Connection System User Manual - AS-34566-001...
  • Page 9 2.80mm Receptacle Terminal (Yazaki Terminal and Cable Seal) 7116-4152-02 Yazaki 2.8mm RCPT TERM Tin 14 Cable Seal Orientation Tabs 90° Misorientation 180° Misorientation Correct Orientation Lock-out Lock-out Orientation of receptacle terminal during insertion to connector MX123 Connection System User Manual - AS-34566-001...
  • Page 10 (Aptiv Terminal and Cable Seal) P/NXXXXX Aptiv 2.8mm RCPT TERM Tin 14 Cable Seal No Orientation Tabs Conductor crimp Conductor crimp down Two (2) possible orientations of receptacle terminal during insertion to connector MX123 Connection System User Manual - AS-34566-001...
  • Page 11 (Aptiv Terminal and Cable Seal) P/NXXXXX Aptiv 6.3mm RCPT TERM Tin 14 Cable Seal No Orientation Tabs Conductor crimp Conductor crimp down Two (2) possible orientations of receptacle terminal during insertion to connector MX123 Connection System User Manual - AS-34566-001...
  • Page 12 Shoulder area provides cover. forward stop. Rectangular cross-section to prevent mis-orientation into the grommet seal cover. Lock tabs to provide seal plug retention to grommet seal cover Sealing surface MX123 Connection System User Manual - AS-34566-001...
  • Page 13 Lever will remain in pre-lock until mated with header/controller, or a force over 190N is achieved. If lever moves freely from pre-lock position without being mated to Header/Controller: Do Not Use Connector! Dress Cover Shipped Separately. MX123 Connection System User Manual - AS-34566-001...

  • Page 14: Harness Assembly Instructions

    TPA to remain in pre-lock position (as shipped) until all terminals are loaded (Figs. 3-1 and 3-2). TPA is not to be removed from connector! Fig. 3-1 Fig. 3-2 5.0mm TYP. Section View Views of TPA in “Pre-Lock” Position MX123 Connection System User Manual - AS-34566-001...
  • Page 15 Section 3: Harness Assembly Instructions B. Connector circuit locations as viewed from the wire lead insertion side 10-Ckt 80-Ckt 73-Ckt Wire dress direction (Option 0 shown) 18-Ckt 56-Ckt 49-Ckt MX123 Connection System User Manual - AS-34566-001...
  • Page 16 Refer to Fig 3-4 for proper MX64 terminal orientation. Fig. 3-4 Column1 Fig. 3-3 Column2 0.64mm Orientation Align terminal orientation tab with slot in grommet cap opening to install the terminal Orientation Tab MX123 Connection System User Manual - AS-34566-001...
  • Page 17 Continue inserting the terminal until it stops and locks up on the lock finger with an audible click. Tug slightly on wire to ensure terminal is locked. Fig. 3-5 Fig. 3-6 MX123 Connection System User Manual - AS-34566-001...
  • Page 18 Section 3: Harness Assembly Instructions D. Wire Dressing Method  After inserting a terminal, bend the wire as close to the grommet cap as possible and position as shown below. Continue populating terminals as necessary. MX123 Connection System User Manual - AS-34566-001...
  • Page 19 Molded-in grommet seal plug knockout patterns will vary based on application specific circuit locations. Single grommet seal plugs may still need to be used to seal circuits without molded-in seal plugs. Cavities Open For Circuits Molded-in grommet seal plugs MX123 Connection System User Manual - AS-34566-001...
  • Page 20 Step 3: Push seal plug until it locks into position into the grommet cap.  Step 4: Verify that seal plug shoulder is flush with grommet cap as shown in cavities 33 and MX123 Connection System User Manual - AS-34566-001...
  • Page 21 (Fig. 3-8). 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 seated. Upon completion, the TPA can be seated. Fig. 3-7 Fig. 3-8 MX123 Connection System User Manual - AS-34566-001...
  • Page 22 Table 1 (next page) and shown in Fig. 3-11 and Fig. 3- 12 (next page). Fig. 3-9 Fig. 3-10 MX123 Connection System User Manual - AS-34566-001...
  • Page 23 Height (H) Width (W) ≤ 44 mm ≤ 24 mm 34565-0003 73/80 Ckt 12582676 ≤ 43 mm ≤ 24 mm 34575-0003 49/56 Ckt 12582679 Fig. 3-11 Fig. 3-12 Wire Bundle Height and Width Specifications MX123 Connection System User Manual - AS-34566-001...
  • Page 24 TPA can be verified by ensuring MAX. height dimension (Fig. 3-14). Fig. 3-13 Fig. 3-14 47.8mm MAX. Top of dress cover to bottom of fully seated TPA Step 1: Insert front end into housing. Step 2: Press down to lock position. MX123 Connection System User Manual - AS-34566-001...

  • Page 25: Connector Mating Instructions

    Section 4: Connector Mating Instructions A. Harness Connector To Header/Controller Color Identification  The harness connector TPA will be color-coded to match the appropriate controller header (Fig. 4-1). Fig. 4-1 Header/Controller MX123 Connection System User Manual - AS-34566-001...
  • Page 26 (Fig. 4-2). Grip the top of the harness connector and evenly push the connector downward until the lever moves slightly forward (Fig. 4-3). Fig. 4-2 Fig. 4-3 Align Keying Features Align Keying Features MX123 Connection System User Manual - AS-34566-001...
  • Page 27 (see fig 4- 4 ) may result in seal “scooping” creating an environment for fluid ingress.  Damage to the header, or connector is possible if excessive force is used. MX123 Connection System User Manual - AS-34566-001...
  • Page 28 (Fig. 4- 5). Mating force should be smooth and continuous. If not, remove the connector and repeat step B.  Continue to rotate the lever arm (Fig. 4- 6). Fig. 4-5 Fig. 4-6 MX123 Connection System User Manual - AS-34566-001...
  • Page 29 Continue to rotate the lever until you hear the primary latch click into final lock over dress cover primary latch (Fig. 4-7a and 4-7b). Fig. 4-7a Fig. 4-7b Dress Cover Primary Latch Primary Latch Engaged MX123 Connection System User Manual - AS-34566-001...
  • Page 30 With the harness connector lever arm in its latched position, the CPA can now be engaged. Push the CPA toward the wire bundle (Fig. 4- 8) until it clicks into its final locked position (Fig. 4-9). Fig. 4- 9 Fig. 4-8 MX123 Connection System User Manual - AS-34566-001...

  • Page 31: Service Instructions

    To un-mate the harness connector from the header/controller, push the CPA away from the wire bundle. Depress the primary latch on the top of the harness connector so the lever arm releases from the harness connector (Fig. 5-1). Primary Latch Fig. 5-1 MX123 Connection System User Manual - AS-34566-001...
  • Page 32 The lever MUST be in the pre-lock position or the connector can not be easily removed from the module. The lever must be fully forward for the harness connector to be in pre-lock position. Fig. 5-2 Fig. 5-3 MX123 Connection System User Manual - AS-34566-001...
  • Page 33 A. Harness Connector Removal From Module (continued)  While pushing forward on the lever, grip the back of the harness and evenly pull straight upwards and away from the module (Fig. 5-4). Fig. 5-4 MX123 Connection System User Manual - AS-34566-001...
  • Page 34 (Fig. 5-6). A small screwdriver or similar tool can be used to release the latches. Fig. 5-5 Fig. 5-6 Latch Feature on each side MX123 Connection System User Manual - AS-34566-001...
  • Page 35 With the dress cover latch features unlatched, insert your finger into dress cover (Fig. 5-7) and pull up and away from the wire bundle. The dress cover can be completely removed at this point (Fig. 5-8). Fig. 5-7 Fig. 5-8 MX123 Connection System User Manual - AS-34566-001...
  • Page 36 The tie-wrap can now be removed from the wire bundle (Fig. 5-9) for easier access to the wire to be serviced. The tie-wrap MUST be cut under the wire dress tab to prevent damage to the wires! Fig. 5-9 Do not cut near wires! MX123 Connection System User Manual - AS-34566-001...
  • Page 37  Approximate TPA travel will be 5.0mm (See Figs. 5-12 and 5-13). Fig. 5-10 Fig. 5-11 Step 1: Pry up TPA Step 2: Pry up opposite end of TPA MX123 Connection System User Manual - AS-34566-001...
  • Page 38  Approximate TPA travel will be 5.0mm (See Figs. 5-12 and 5-13). Fig. 5-10a Fig. 5-11b Step 1: Pry up TPA Step 2: Pry up opposite end of TPA MX123 Connection System User Manual - AS-34566-001...
  • Page 39 Section 5: Service Instructions D. TPA Servicing (continued) Fig. 5-12 Fig. 5-13 5.0mm 5.0mm Views of TPA in “Pre-Lock” Position MX123 Connection System User Manual - AS-34566-001...
  • Page 40 Ensure TPA is in pre-lock position!  Holding the 0.64mm service tool (Fig. 14: Molex part no. 63813-1400 or alternate GM part no. J-38125-213) between middle finger and thumb, with index finger on top of the tool, insert the tip of the tool into the terminal service hole adjacent to the terminal to be serviced (Fig.
  • Page 41 Fig. 5-17a shows proper insertion of the service tool. Avoid inserting the service tool into the terminal opening (Fig. 5-17b) as this may damage the terminal. Fig. 5-17a Fig. 5-17b WRONG! Proper Insertion Incorrect Insertion MX123 Connection System User Manual - AS-34566-001...
  • Page 42 33.  Do not use excessive force. Excessive force can damage the lock finger. Do not apply any lateral force. The lock finger is displaced by linear insertion alone. Fig. 5-18 MX123 Connection System User Manual - AS-34566-001...
  • Page 43 Step 2. Use needle nose pliers to hold head of 0.64mm grommet seal plugs.  Step 3. Pull grommet seal plug out of back of grommet cap.  Do not re-use grommet seal plug once it has been removed! Head MX123 Connection System User Manual - AS-34566-001...
  • Page 44 X39899-J374). Insert the tip into the terminal service opening (Fig. 5-19). Avoid inserting the service tool into the terminal opening (Fig. 5-19a). This may cause damage to the 2.80mm terminal. Fig. 5-19 Fig. 5-19a WRONG! Proper Insertion Improper Insertion MX123 Connection System User Manual - AS-34566-001...
  • Page 45 Once the tool is inserted into the terminal service opening, push the service tool (Fig. 5-20) until it wedges between the female terminal and the lock finger (Fig. 5-21). Fig. 5-20 Fig. 5-21 Service Tool Female Terminal Lock Finger MX123 Connection System User Manual - AS-34566-001...
  • Page 46 If the terminal resists, the service tool may not be fully engaged. Push the service tool further into the service hole to ensure that it has disengaged the terminal lock finger. Fig. 5-22 MX123 Connection System User Manual - AS-34566-001...
  • Page 47 Ensure TPA is in pre-lock position!  Holding the Molex service tool (part number 63813-1500) between middle finger and thumb, with index finger on top of the tool, insert the tip of the tool into the terminal service hole adjacent to the terminal to be serviced (Fig. 5-23).
  • Page 48 Ensure TPA is in pre-lock position!  Holding the Molex service tool (part number 63813-1500) between middle finger and thumb, with index finger on top of the tool, insert the tip of the tool into the terminal service hole adjacent to the terminal to be serviced (Fig. 5-26).
  • Page 49 H. Terminal Crimping  If the 0.64mm receptacle terminal needs to be replaced, a new one can be hand crimped using GM Crimp Tool #XX019825 or Molex Crimp Tool #63811- 4200. 1.) Identify the wire gauge you need 2.) Insert the correct terminal 3.) Insert the wire until the wire...
  • Page 50 Section 5: Service Instructions I. Terminal Crimping (continued)  Contact Molex for terminal sales drawings. Hand crimp instructions, strip length recommendations, and crimp height requirements are available in the Molex Spec. Sheet for Tool #63811-4200.  If the Yazaki 2.80mm receptacle terminal needs to be replaced, a new one can be hand crimped with the appropriate cable seal using crimp tools #J- 38125-6 and #J-38125-7.

  • Page 51: Electrical Continuity Checking

    Section 6: Electrical Continuity Checking A. Pogo Pin Recommendation - 0.64mm Terminal Pogo Pin Specification – See next page.  TPA Stop Surface Spherical Tip 0.53 mm 5.75 mm MX123 Connection System User Manual - AS-34566-001...
  • Page 52 A. Pogo Pin Recommendation - 0.64mm Terminal (continued) Probe Pin Details (0.64mm terminal) Manufacturer: Lone Star Industrial Part number: LS040RS-ELW-277-N-4.7 Pin diameter: 0.020” (0.53 mm) Tip shape: Spherical Tel: (915) 779-7255 LS040RS-ELW-277-N-4.7 POGO PIN MX123 Connection System User Manual - AS-34566-001...
  • Page 53 Section 6: Electrical Continuity Checking B. Pogo Pin Recommendation – 2.8mm and 6.3mm Terminals Pogo Pin Specification – See next page.  TPA Stop Surface Spherical Tip 0.76 mm 7.40 mm MX123 Connection System User Manual - AS-34566-001...
  • Page 54 B. Pogo Pin Recommendation – 2.8mm Terminal (continued) Probe Pin Details (2.8mm terminal) Manufacturer: Lone Star Industrial Part number: LS054RS-ELW314 Pin diameter: 0.030” (0.76mm) Tip shape: Spherical Tel: (915) 779-7255 LS054RS-ELW314 POGO PIN MX123 Connection System User Manual - AS-34566-001...
  • Page 55 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (10-way) 9.50 Typ. Typ. 7.00 2.80 Pogo In Green On CL 9.60 Typ. 6.35 Pogo In Blue Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 56 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (66-way) 44.45 Typ. 2.54 2.80 Pogo 2.54 6.52 2.54 2.80 Pogo 3.81 Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 57 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (73-way) 44.45 Typ. 2.54 2.80 Pogo 2.54 6.52 2.54 Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 58 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (80-way) Typ. 2.54 2.54 6.52 2.54 Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 59 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (18-way) 2.54 Typ. 2.54 5.80 6.52 8.20 2.54 24.00 Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 60 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (49-way) 2.54 Typ. 2.54 6.52 2.54 Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 61 Section 6: Electrical Continuity Checking C. Pogo Pin Layout Recommendation (56-way) 2.54 Typ. 2.54 6.52 2.54 Test Pogo Pin Probing Array MX123 Connection System User Manual - AS-34566-001...
  • Page 62 Section 6: Electrical Continuity Checking D. Pogo Pin / Probe Opening  Check electrical continuity on the terminal by inserting probe pin down the center of receptacle TPA opening. Molex Receptacle connector Opening for probe pin/male terminal MX123 Connection System User Manual - AS-34566-001...
  • Page 63  If a probe is inserted into the terminal at an angle or off center. This may damage the terminal and/or the connector. MX123 Connection System User Manual - AS-34566-001...
  • Page 64 GM probe tool # J-35616-4A for the 2.8mm terminal (Fig. 6-1). – GM probe tool # J-35616-42 for the 6.3mm terminal (Fig. 6-1).  Insert the probe through the terminal opening as shown in Fig. 6-2. Fig. 6-1 Fig. 6-2 MX123 Connection System User Manual - AS-34566-001...
  • Page 65 If a probe is inserted into the back of the connector. This may damage the wire seal, creating an environment for fluid ingress. WRONG!  If the wire insulation is pierced or chafed. This may create a leak- path for fluid ingress and/or wire corrosion. MX123 Connection System User Manual - AS-34566-001...

  • Page 66: Tool Ordering Information

    Section 7: Tool Ordering Information  Contact your Molex Inside Sales Representative at (800) 786-6539.  For electronic copies and future updates of this document, refer to the Molex Website at http://www.molex.com/ind/mx123.html. Tool Description Molex Part No. GM or Supplier Part No.

  • Page 67: Revision History

    Oct 22, 2009 9 (same as revA) Dec 1, 2006 July 22, 2005 Feb 15, 2005 Aug 20, 2004 Jan 16, 2004 Oct 13, 2003 Sept 15, 2003 Sept 5, 2003 June 16, 2003 MX123 Connection System User Manual - AS-34566-001...

  • Page 68: Appendix A - Document Change History

    Revised Section 6. Added Pogo Pin and Probing Recommendations. – Added Section 7: Tool Ordering Information. • Rev 7 to Rev 8: – Revised Section 2: Product Summary – Revised Section 5: Servicing Instructions – Added Appendix B: Cleaning Instructions MX123 Connection System User Manual - AS-34566-001...

  • Page 69: Appendix B - Cleaning Instructions

    The more water used, the cleaner it will become. Do not attempt to un-mate any connectors until Step 4. Repeat Step 1 until there is no visual evidence of dirt, grit, or other debris. Water stream paths MX123 Connection System User Manual - AS-34566-001...
  • Page 70 ECM and connectors should be visibly dry and debris free. Do not attempt to un-mate any connectors until Step 4. Repeat Step 2 until there is no visual evidence of dirt, grit, or other debris. Air stream paths MX123 Connection System User Manual - AS-34566-001...
  • Page 71 Section 11 (Appendix B): Cleaning Instructions Enlarged area to show detail “Gritty” slides “Clean” slides MX123 Connection System User Manual - AS-34566-001...
  • Page 72 STEP 4: You will need to start to cycle the lever arm to determine if you have excessive resistance. If lever arm binds, or resistance is felt. Repeat steps 1, 2, and 3 until the connector is visibly clean and offers little resistance to un-mating. Step 1 Step 2 MX123 Connection System User Manual - AS-34566-001...
  • Page 73 STEP 6: Repeat Steps 1 through 5 until you can un-mate the connector with little resistance. DO NOT APPLY WATER TO ANY ECM ASSEMBLY IF ANY CONNECTORS ARE UN-MATED FROM THE ECM HEADERS! Water and Air Spray Paths MX123 Connection System User Manual - AS-34566-001...
  • Page 74 This effort should be directed at the connector housing, not the TPA or terminal openings. DO NOT APPLY WATER TO TPA OR EXPOSED TERMINAL OPENINGS! CLEAN HERE DO NOT WIPE HERE “Gritty” J2 Connector “Cleaned” J2 Connector MX123 Connection System User Manual - AS-34566-001...
  • Page 75 STEP 9: Blow off with high pressure air to dry and remove any grit particles inside the header. DO NOT APPLY WATER TO HEADER PINS OR EXPOSED CONTACT AREAS “Gritty” ECM Header “Cleaned” ECM Header MX123 Connection System User Manual - AS-34566-001...
  • Page 76 STEP 10: Once the connector is in pre-stage, use a few drops of water to lubricate the slides while re-mating. This will limit any potential binding. Arrows show where to place drops of water MX123 Connection System User Manual - AS-34566-001...
  • Page 77 (Fig:2) and the pivot posts of the header are aligned with the slots on the shroud (Fig:3) Fig: 2 Fig: 1 Fig: 3 MX123 Connection System User Manual - AS-34566-001...
  • Page 78 Step 3 – Rotate the lever of the fully mated connector (Fig: 5) to throw it on the other end of the wire dress cover (WDC) to lock it (Fig: 6). Fig: 4 Fig: 5 Fig: 6 MX123 Connection System User Manual - AS-34566-001...
  • Page 79 Step 3 – Push the lever down to lock it with the wire dress cover (Fig: 6) with an audible click. Completely locked lever is shown in (Fig: 7) Fig: 6 Fig: 7 MX123 Connection System User Manual - AS-34566-001...

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