LANGUAGE
APPLICATION SPECIFICATION
ENGLISH
ASSEMBLY PROCEDURE
36CKT. PROTECTED SPLASHING WATER RECTANGULAR CONNECTOR
【Scope】
This assembly procedure specifies the method of assembling the undermentioned composition parts and
cable in POWER CONN. 36 CKT.
【Application Products】
Product Name
PLUG COVER ASS’Y
PLUG SIDE
(CABLE SIDE)
Part Number
STRAIGHT TYPE
58696-0010
RIGHT-ANGLE TYPE
58696-1010
TYPE A
58687-0010
TYPE B
58687-0020
PLUG SHELL ASS’Y
END BELL CAP SET（PG29）
RECEPTACLE
SIDE
(PANEL SIDE)
RECEPTACLE SHELL ASS’Y
TYPE A
58691-0010
TYPE B
58691-0020
DUST COVER FOR RECEPTACLE
HOUSING
COMMON
PARTS
TERMINAL
51201-0001
PLUG HOUSING
503193-0600
RECEPTACLE HOUSING
503194-0600
PLUG CRIMP TERMINAL
503195-1＊00
RECEPTACLE CRIMP TERMINAL
RECEPTACLE COVER (FOR CONJUNCTION)
APPLICABLE
CRIMP TOOL
58550-000＊
APPLICABLE TO 503195-1000
AUTOMATIC CRIMP
TOOL（※１）
AND 503196-1000
HAND CRIMP TOOL（※２）
503196-1＊00
56386-0000
578056-3000
APPLICABLE TO 503195-1100
578056-5300
APPLICABLE TO 503196-1100
578056-5400
APPLICABLE WIRE（※１,※２）
AWG#16,18
TERMINAL EXTRACTION TOOL（※３）
578056-6000
＊ ：For details, please refer to the drawing.
※１：For details, please refer to the crimp specification, CS-503196-001.
※２：For details, please refer to the hand crimp tool operating manual, IS-0116JE.
※３：For details, please refer to the extraction tool operating manual, IS-578056-6000JE.
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DESIGN CONTROL
STATUS
J
DOCUMENT NUMBER
AS-58696-006
TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO
MOLEX INC. AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
WRITTEN BY: CHECKED BY: APPROVED BY:
H.KOBAYASHI
S.SATO
S.ICHIKAWA
DATE: YR/MO/DAY
'09/01/19
FILE NAME
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EN-37-1(019)
LANGUAGE
APPLICATION SPECIFICATION
ENGLISH
【INTRODUCTION】
1．
．Storage before usage
・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・
・・・・・・・・・・・・・
・・・・・・・・
2．
．Instructions during harnessing
P-3
・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・
P-3
・・・・・・・・
・・・・・・・・・・・・・・・・
P-4
・・・・・・・・・
・・・・・・・・・・・・・
・・・・・・
P-6
・・・・・・・・・・・・・・・・
P-7
3．
．Definitions
3-1．Composition parts of plug side and parts function
3-2．Composition parts of receptacle side and parts function
3-3．Composition parts of housing and parts function
3-4．Composition parts of terminal (crimp terminal) and parts function
・・・・・
・・・・・
・・・・・・・
P-8
4．
． Assembly procedure
4-1．Cable processing method ・・・・・・・・・・・・・・・・・・・・・・・・・・・
P-10
4-2．Installation of the plug cover ass’y ・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・
・・・・・・
・・・・・・
・・・・
P-10
・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・
・・・・・・・
P-11
4-3．Terminal crimping
4-4．Terminal insertion to the housing and housing insertion to the shell ・・・
・・・・・・・・・
・・・・・・
P-16
4-5．Installation of plug shell ass’y ・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・
・・・・・
P-21
・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・
・・・・
・・・・・・・・・・・・
・・・・・・・・・・・・・・
P-21
・・・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・・・・・・・
・・・・・・
P-22
4-6．Installation of end bell cap set
4-7．Installation to the panel
4-8．Installation of Receptacle cover (for conjunction)
・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・
・・・・・・・
P-22
5．
．Instruction on mating connectors
5-1．Mating
・・・・
・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・
・・・・・・・・・・
5-2．Un-mating
P-23
・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・
P-24
・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・
・・・・・・・・・・
・・・・・・
・・・・・・・・・・
・・・・・・・・
P-25
5-3．Mating dimension
・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・・・・・・・・・・・
・・・・・・・・・・・
6．
．Other
・
・
・
・
P-27
Please confirm this specification before using the connector.
The illustrations used in the spec may have a slight difference since they are printed.
The contents in this spec may change without notice.
In case there are any questions or comments regarding this spec, please feel free to
contact us.
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TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO
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FILE NAME
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EN-37-1(019)
LANGUAGE
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ENGLISH
【1. Storage before usage】
①
Please store the products in our boxes, in a cool, non-humid location avoiding direct sunshine.
This is necessary in order to keep the material from deforming or degradation.
②
Please store in a condition avoiding pressure. This is necessary in order to keep the material
from deforming or degradation.
③
When transferring the products, please be careful not to apply shock from dropping or hitting
the boxes.
【2. Instructions during harnessing】
①
Please confirm if you the HS'G, terminal, crimp condition, wire meets the crimp specification
before starting the harnessing. (In case they do not meet, please inform our sales.)
②
Do not use terminals with deformation on the contact boxes. These terminals may not meet the
required insertion force to the HS'G or not meet electrical requirements.
③
Do not touch the terminals with your hands directly. The oil and the organic substances could
apply negative effect to the plating leading to electrical failure.
④
Do not pull the terminals robustly when the terminals have problem fitting. It could deform the
terminal.
⑤
Do not apply extended force to the HS'G, terminals, products in line, harnesses. This could
cause connector deforming which leads to failure meeting connector requirements.
Keep away HS'G, terminals, products in line, and harnesses from dust, corrosive properties,
corrosive gas, high temperature, high humidity, and direct sunshine. This could lead to
product failure caused by contact failure, terminal corrosion, and HS'G insulation failure.
Please be careful when storing the products.
⑦
Do not deform the HS'G and terminals on purpose. It would lead to product failure.
⑧
Please use all products on that day after un-packing the box. The surrounding air condition
could cause material degradation. In case you have to store the parts for a while, please seal
the parts and keep them in the box.
⑨
Please look out for sharp edges to avoid injury.
⑩
Please look out for paper in the reels, to avoid paper cuts.
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TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO
MOLEX INC. AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
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EN-37-1(019)
LANGUAGE
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ENGLISH
【3. Definitions】
3-1．Composition parts of plug side and parts function
● PLUG SHELL ASS’Y
（58687-00＊
＊0)
Mating polarization key
（Four position）
Ground terminal
（Two position）
Mating polarization key type indication
M2.5 screw
（Four position）
Mating polarization key type
A
B
Type indication
Type indication
Type A
58687-0010
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Type B
58687-0020
TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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● PLUG COVER ASS’Y
（58696-＊＊＊
＊＊＊0）
＊＊＊ ）
● RECEPTACLE COVER FOR CONJUNCTION
（56386-0000）
）
Lever
58696-0010
(Straight type)
58696-1010
(Right-angle type)
● END BELL CAP SET（
（PG29）
）
（58550-000＊
＊）
58457-0000
(End bell cap)
58459-000＊
(End bell bush)
Part number
Color
Cable size
58550-0000
Blue
φ14～φ18
58550-0001
Brawn
φ17～φ21
58550-0002
Orange
φ20～φ25
58550-0003
Yellow
φ24～φ28
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RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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3-2．Composition parts of receptacle side and parts function
● DUST COVER FOR RECEPTACLE
（51201-0001）
）
● RECEPTACLE SHELL ASS’Y
（58691-00＊
＊0）
）
Waterproof
（Mate side）
Mating polarization key
（Four position）
Ground terminal
（Two position）
Locking pin
（Two position）
Waterproof
（Panel installation side）
Mating polarization key type indication
Mating polarization key type
Type indication
Type indication
Type A
58691-0010
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Type B
58691-0020
TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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3-3．Composition parts of housing and parts function
Positive lock
Lock feature to prevent miss unlocking. You need
to go through a special unlocking procedure when
removing the terminal.
● HOUSING
(503193-0600/503194-0600)
Circuit No.
Circuit No.
Material No.
Trademark and cavity No.
Trademark and cavity No.
503193-0600
(Plug housing)
503194-0600
(Receptacle housing)
Mold lance
Locks the terminals so it
does not fall out the housing.
Plug crimp terminal
503195-1＊00
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Receptacle crimp terminal
503196-1＊00
TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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3-4．Composition parts of terminal (crimp terminal) and parts function
● PLUG TERMINAL
(503195-1＊
＊00)
Pilot hole
This controls the stamping position.
Insulation barrel
This would crimp the insulation area.
Carrier
This connects the terminals
in a chain.
Wire barrel
This would crimp the wire.
Contact area
Where terminals meet to
have electrical connection.
Crimping pilot hole
This controls the crimping position.
Terminal
This enables electrical contact
between parts.
Lance
Secures the terminals so it
does not fallout the housing.
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● RECEPTACLE TERMINAL
(503196-1＊
＊00)
Insulation barrel
This would crimp the insulation area.
Wire barrel
This would crimp the wire.
Pilot hole
This controls the stamping position.
Contact box
The beam inside holds the
male side terminal.
Carrier
This connects the terminals
in a chain.
Terminal
This enables electrical contact
between parts.
Crimping pilot hole
This controls the crimping
position.
Lance
Secures the terminals so it
does not fallout the housing.
Contact area
Where terminals meet to
have electrical connection.
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【4. Assembly procedure】
4-1．Cable processing method
● Sheath stripping length（Reference［mm］）
● Wire length（Reference［mm］）
Dimension "L"
[mm]
Block number（shell）
1
70
2
3
60
4
5
50
6
4-2．Installation of the plug cover ass’y
The installation of the cover is passed through the cable witch peels off the sheath in order of the end bell
cap, bush, and the plug cover ass’y.
Cable
End bell bush
58459-000＊
End bell cap
58457-0000
Plug cover ass’y
58696-0010 / 58696-1010
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4-3．Terminal crimping
Crimp wires to terminal with exclusive crimping tools based upon crimping specification.
※For details, please refer to the crimp specification（CS-503196-001）or hand crimp tool
operating manual（IS-0116JE）.
503195-1＊00
(Plug crimp terminal)
503196-1＊00
(Receptacle crimp terminal)
● Appearance
②
③
④
①
⑤
① No deformation, straight.
② No deformation on the contact and box.
③ The wire is coming out from the wire barrel but does not jump out from the terminal.
④ The insulation ends just in the middle of the insulation barrel and the wire barrel.
⑤ No deformation on the lance.
⑥ No other abnormality.
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● Crimp rejects
Following rejects could apply negative impact toward housing insertion and product performance.
① Bend up
This could cause bad insertion force, retention force, and electrical failure.
② Bend down
This could cause bad insertion force, retention force, and electrical failure.
③ Twist
This could cause bad insertion force, retention force, and electrical failure.
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④ Rolling
This could cause bad insertion force, retention force, and electrical failure.
⑤ Contact box deformation
This could cause bad insertion force, retention force, and electrical failure.
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⑥ Wire jumping out
Bad efficiency when inserting terminal to the housing.
⑦ Crimping position too close
If you crimp the insulation with the wire barrel, this could lead to disconnection, low pull strength,
electrical failure and etc.
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⑧ Crimping position too far
When the crimping is be done outside the barrel, the pull strength could decline and
electrical performance may fail from meeting the requirements.
The insulation is not hold down with the barrel, therefore, the wire could easily be exposed
when the wire is moved.
Move wire
⑨ Deformation of terminal lance
Housing lock force too low which could cause retention force decline.
Crushed
Pulled
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4-4．Terminal insertion to the housing and housing insertion to the shell
Following defines the insertion of terminal and installation direction of housing to shell.
● Terminal inserted direction
Plug side
①
Receptacle side
Please hold the wire at a 10mm distance from the crimped section.
10mm
(Reference)
NOTE
※ When you hold the wire at a further position, the wire would bend easily, making it difficult
to insert the terminal.
※ The value (10mm) is a reference. It changes regards to the wire size and material. Please
confirm the best position before starting the insertion.
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②
Insert the terminal straight into the housing until hits the inner wall.
NOTE
※ When the terminal in not loaded fully, the terminal would fall out of the housing.
※ Please crimp the terminal using the specified height and width.
(For details, please refer to the crimp specification, CS-503196-001.)
※ When insertion cannot be done smoothly, do not force the terminal to mate the
connector. Please reconfirm if there is no deformation in the plastic or the terminal
and re-insert.
③
Confirm if the terminal is inserted correctly by pulling the terminals with little force.
Do not pull hard.
④
Use an exclusive terminal extraction tool (578056-6000) in case of irregular insertion or
damaged terminals and change them to new ones.
Refer to the manual as to exclusive extraction tool.（IS-578056-6000JE）
NOTE
※ When you need to remove the terminal which was once inserted, the mold lance strength declines
extremely by the occurrence of wound and transformation of housing. Therefore, when you
re-insert the terminal, may fall out easily. To prevent this condition, please use a new housing.
※
Do not pull the wire with too much force.
※ When repairing the connection, please be careful not to deform the lance on the terminal.
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⑤
Please be careful on the direction of the terminal insertion. When the terminal is inserted
in the wrong direction, it could lead to terminal deformation or housing breakage.
Correct mating direction
Lance
Plug side
side
Plug
Insertion direction
Receptacle
Receptacle
side
side
Wrong direction
Lance
＜１．Terminal upside down＞
Plug
Plug side
side
Insertion direction
Receptacle
Receptacle
side
side
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＜２．Tilted＞
Plug side
Receptacle side
Insertion direction
Insertion direction
＜３．90degrees rotated＞
Receptacle side
side
Receptacle
Plug
Plug side
side
Insertion direction
Insertion direction
⑥
When checking after terminal insertion, do not pull or bend the wire too much.
The unanticipated force to the connector may lead to contact failure.
⑦
Please use the defined mating connector when you check the continuity. Mating with the
wrong connector may lead to terminal deformation and contact failure.
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TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO
MOLEX INC. AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
FILE NAME
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● Housing insertion to the shell
NOTE
Install the housing surely until the lock sound is heard.
Plug shell ass’y
(Reverse side)
Block number
Plug shell ass’y
58687-00＊0
Plug housing
503193-0600
Receptacle housing
503194-0600
Receptacle shell ass’y
(Reverse side)
Block number
Receptacle shell ass’y
50691-00＊0
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TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO
MOLEX INC. AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
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4-5．Installation of plug shell ass’y
Plug cover ass’y
58696-0010 / 58696-1010
Plug shell ass’y
58687-00＊0
NOTE
※When the cover is installed in the plug shell ass’y the tightening torque of the M2.5 screw is
assumed to be 4~5kgf.
4-6．Installation of end bell cap set
Install the end bell bush (58459-000＊) and the end bell cap (58457-0000).
NOTE
※Tighten the end bell cap surely.
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RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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4-7．Installation to the panel
The following are recommended panel opening dimension of receptacle shell ass’y.
NOTE
The installation of the connector is installed so that
the undermentioned seal may come to the upper
part of the panel.
Mating polarization key indication label
Panel opening dimension
4-8．Installation of receptacle cover (for conjunction)
① The installation of the cover is passed
through the cable witch peels off
the sheath in order of the end bell cap, bush,
and the receptacle cover for conjunction.
② Crimp wires to terminal with exclusive
crimping tools based upon crimping
specification.
(Please refer to paragraph 4-3.)
End bell bush
58459-000＊
Cable
End bell cap
58457-0000
Receptacle cover for conjunction
56386-0000
① cover is passed through cable
③ Terminal insertion to the housing and
housing install in receptacle shell ass’y.
(Please refer to paragraph 4-4.)
④ Receptacle cover for conjunction
install in receptacle shell ass’y.
⑤ Install the end bell cap set.
(Please refer to paragraph 4-6.)
Receptacle shell ass’y
58691-00＊0
④ installation receptacle cover for conjunction
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RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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【5. Instruction on mating connector】
5-1．Mating
The plug shell ass’y and the plug cover ass’y are locked and to engage with the receptacle shell ass’y,
the lever is locked surely.
Plug shell ass’y
58687-00＊0
Plug cover ass’y
58696-0010 / 58696-1010
Housing
503193-0600 / 503194-0600
Cable
Receptacle shell ass’y
58691-00＊0
Housing
503193-0600 / 503194-0600
End bell cap set
58550-000＊
Lever lock
NOTE
① It is not lock at imperfect engagement.
② Lever operation force：20Kg MAX．
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RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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5-2．Un-mating
The lever is surely released, and the plug cover ass’y and the plug shell ass’y are pulled out.
Plug shell ass’y
58687-00＊0
Lever unlock
Housing
503193-0600 / 503194-0600
Cable
Receptacle shell ass’y
58691-00＊0
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Plug cover ass’y
58696-0010 / 58696-1010
Housing
503193-0600 / 503194-0600
TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO
MOLEX INC. AND SHOULD NOT BE USED WITHOUT WRITTEN PERMISSION
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5-3．Mating dimension
Panel
Straight type
Straight type
（Receptacle cover for conjunction assembly condition）
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RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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Right-angle type
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RECTANGULAR CONNECTOR
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【6. Other】
● Tools and wire to use
1．In case you would like to use different size wire, please let us know in advance since they
would not be covered under warranty.
2．For rejects that occurred by using different tools other than specified in the spec, they would
not be covered under warranty.
3．Please confirm this product beforehand when you select the cable because there is what to coming
and it is not easy to assemble, and there is what to protection structure(IP67) cannot be kept with
the composition cable.
4．Please confirm the waterproof which suits the used environment beforehand with the selected cable.
● Rating & performance spec
1．Please use this product within the spec.（PS-58691-005）
2．Do not mate/unmated while electricity is flowing.
3．Please use the connector after confirming that it meets the required spec for your product.
4．In order to avoid short circuits, please be careful so no metal panels and metal pieces
interfere with the connector.
● Application
1．This is not designed to meet applications which are used under conditions where a person’s
life could be put under danger. Please do not use this product for applications in the medical,
aircraft, atomic power, etc without notifying us.
2．In case you were to use this connector for automotive/boat applications, please notify us in advance.
(We would test to see toward your spec.)
3．Do not use the product outside or any other atmosphere which is equivalent to this.
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TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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REV.
REV. RECORD
DATE
EC NO.
WRTTN:
CH'K:
A
RELEASED
'09/01/19
J2009-1719
H.KOBAYASHI
S.SATO
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TITLE:
36CKT. PROTECTED SPLASHING WATER
RECTANGULAR CONNECTOR
APPLICATION SPECIFICATION
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