APPLICATION SPECIFICATION
APPLICATION SPECIFICATIONML-XT SEALED CONNECTOR SYSTEMREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide1 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION1.0 SCOPEThis document describes the correct procedure for the assembly of the ML-XT connector system,including contact insertion, wedgelock insertion/withdrawal, contact removal and connectormating/unmating.2.0 PRODUCT INFORMATIONDESIGN CHARACTERISTICSPERFORMANCE CHARACTERISTICSOne-piece plug housing and sealdesign, permanently bonded by twoshot LSR (liquid silicone rubber)molding technologyPrevents fluid ingress; system is IP68-ratedand J2030 power-wash test capable Preventsloss/ misalignment of seal; ensuresrepeatable retention during unmating andmating of plug and receptacleAchieves superior reliability without the needfor costly re-designProvides greater tear-resistance over LSRmaterial; prevents damage to rear seal duringterminal insertion/ extractionLocks in rear HCR seals Allows for flexiblecable exits and cable movement whilstmaintaining optimum seal position to preventleak pathsReduces inventory, assembly time and costsfor harness manufacturers and prevents lossof rear seals for a cost-competitive matedsystemSupports tooling widely used at harnessmakersWithstands high axial pull-out forces perJ2030 specificationDrop in replacement for de-factoindustry standard connectorsRear seals made from HCR (highconsistency rubber)Latched rear coversPlug and receptacle housings aresupplied pre-assembled with internalHCR rear seals locked-in by rearcoversUtilises Molex proven XRC terminalswith current ratings up to 13.0AHigh terminal retention force; exceeds111N (Subject to use of cable withsufficient tensile strength to sustain111N load)Wedgelock / TPA (Terminal PositionAssurance) loaded after terminalsPlug housing features integral lockinglatch9 colour-coded housings availableLocks terminals in position for secureelectrical contactEnsures secure mating of plug and receptacleEnables easy visual mating of harnesses toprevent mis-matingPrevents mis-mating of different circuitsKeying options available acrossmultiple circuit sizesUnmating features present on terminalretention fingersREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS AEnables easy extraction of terminalsTITLE:SHEET No.ML-XT Assembly Guide2 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION3.0 REFERENCE DOCUMENTSThis instructions manual contains supplemental information pertaining to the Molex ML-XT sealedconnector system. Additional information such as keying, colours etc can be found on the Sales &Assembly drawings:93443**** PSD (multiple documents)84525**** PSD (multiple documents)84524**** PSD (multiple documents)ATS-63824-5300 (ML-XT Removal Tool Specification)4.0 PRODUCT SUMMARY4.1 CONNECTOR ASSEMBLYFigure 1: 2cct Plug ConnectorREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide3 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATIONFigure 2: 2cct Receptacle ConnectorREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide4 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION4.2 PIN/SOCKET TERMINALTerminal FeaturesBase Material - Copper AlloyPlating Options - Nickel, GoldWire Sizes: 14, 16, 18 AWG1.5, 1.0, 0.8, 0.75mm2Figure 3: Pin TerminalFigure 4: Socket TerminalREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide5 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION4.3 PRODUCT IDENTIFICATIONAll parts are laser etched with: Date Code (D WW YY)o D DAY of the week (1 To 7)o WW Week of the year (01 to 52)o YY Last two digits of the Year (01 – 99)Note – Location for Date Codes can be found on Customer DrawingsMOLEX DATE CODEREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide6 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION4.4 CONNECTOR ASSEMBLY4.4.1 TERMINAL INSTALLATIONGrip the wire no less than 10mm for smaller diameter cable (1.4mm to 2.4mm) & no less than20mm for larger diameter cable (2.4mm to 3.6mm) from the terminal insulation crimp align terminalon centre with the appropriate opening in the back cover and insert through the circuit opening inthe back seal. 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 connector is fully populated insert the wedgelock/TPA. The wedgelock should ‘click’ intoposition. Plug Connector/Socket Terminal shown – use same method for Receptacle/Pin.OKOK!!!!!!!DO NOT INSTALL THE TERMINATED CABLES AT AN ANGLE!!!!!!!NONOREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide7 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATIONTo ensure secure terminal insertion:Follow the Push, Click, Pull Methodof terminal insertionNever try insert the terminal whenwedgelock (TPA) is already /ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide8 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION4.4.2 TERMINAL EXTRACTION1. Lever the Wedgelock from the housing using the flathead screwdriver end of the removal tool(63824-5300) – Take care not to damage the 2-shot seal (For Receptacle wedgelock usehooked end of tool).2. To remove the contacts, gently pull the cable backwards while at the same time releasing thelocking finger by moving it away from the terminal/contact with the flathead screwdriver end ofthe removal tool. (For 3cct Receptacle wedgelock removal use needle nose pliers)3. Simply pull out the terminated cable slowly and on centre.DO NOT PULL OUT CABLES AT AN ANGLE – ONLY EXTRACT ONE CABLE AT A TIME!11223NO!!REVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide9 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION4.5 CONNECTOR MATINGNote and align both plug and receptacle connectors and keying features (if present). Begin matingprocedure by sliding the two connectors together, press firmly until you hear an audible click from theprimary latch.Primary LatchOKNOREVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ANOTITLE:SHEET No.ML-XT Assembly Guide10 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
APPLICATION SPECIFICATION4.6 CONNECTOR UNMATINGDepress the primary latch on the plug connector to fully disengage locking mechanism and then pullthe plug connector out from the receptacle connector while keeping the primary latch depressed.4.7 HARNESS ROUTINGThe cable shall exit 1.0mm beyond the connector housing, co-axial with the grommet sealing lips.Bending of the cable shall be performed beyond this point to the recommended cable manufacturer’sbend radius.REVISION:A2ECR/ECN INFORMATION:EC No: 103069DATE: 2016/03/112016/03/112016/03/112016/03/11DOCUMENT NUMBER:934430010 PS ATITLE:SHEET No.ML-XT Assembly Guide11 of 11CREATED / REVISED BY:CHECKED BY:APPROVED BY:JFLETCHER/FDUGGANFDUGGANJDWALLACETEMPLATE FILENAME: APPLICATION SPEC[SIZE A](V.2).DOC
application specification revision: ecr/ecn information: title: ml-xt assembly guide sheet no. a2 ec no: 103069 1 of 11 date: 2016/03/112016/0 3/112016/03/1120 document number: 16/03/11 created / revised by: checked by: approved by:
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