Custom 1–40 Pin JST Wire Harness Cable Assembly

This configurable cable assembly is intended for applications where connector pitch, cavity count and pinout matter more than a generic “JST cable” description. It supports compact JST-style SH, ZH, PH and XH families across the 0.8 to 2.54 mm pitch range, with configurations from a single circuit up to 40 positions.

Each harness is made against an approved pinout or sample. Wire length, conductor size, color sequence, connector orientation, terminal processing and packaging can be adjusted to match the equipment. The result is a production-ready interconnect for PCB assemblies, control equipment, machines and electronic products.

Connector pitch and series must be confirmed together

SH, ZH, PH and XH housings may look similar in photographs, but they are not interchangeable. Pitch, terminal design, latch geometry, housing polarization and mating height all affect compatibility. For a reliable quotation, provide the exact connector series and PCB-side mating part whenever possible.

If the part number is unknown, send a clear photograph, the measured pitch, pin count and mating-board details. A physical sample is the most reliable reference for uncommon or cross-brand connectors.

From 1 to 40 circuits

The broad pin-count range makes this harness suitable for simple two-wire power leads as well as multi-signal equipment interconnects. Higher cavity counts require more control than a basic continuity check. Pin numbering, row orientation and the viewing direction of the drawing must be unambiguous before production starts.

• 1–6 pins: common for power, motors, fans, sensors and simple controls.

• 7–20 pins: useful for combined power and signal connections in PCB assemblies and control panels.

• 21–40 pins: suited to denser equipment interconnects where wire identification and pinout documentation are essential.

For double-row housings, specify whether numbering is viewed from the wire side or the mating face. This single detail prevents many otherwise avoidable wiring errors.

Configurable wire construction

• Connector families: JST SH, ZH, PH, XH and compatible alternatives.

• Pitch range: 0.8, 1.0, 1.25, 1.5, 2.0 and 2.54 mm options subject to connector selection.

• Conductor: copper-core wire sized for the required current, flexibility and terminal.

• Insulation: nylon, PVC and PET options.

• Jacket and protection: PVC, silicone, rubber, sleeving or bundling can be evaluated for the installation.

• Length: standard examples include 100, 120 and 150 mm; custom finished lengths are available.

• Identification: custom wire colors, numbered markers and labels can support assembly and service.

Voltage options shown for the product range include 36, 110, 220, 240 and 380 V. The permitted rating of a finished harness is determined by the complete connector and wire construction, not by voltage alone. Creepage, clearance, current, temperature, insulation and destination-market requirements must be reviewed for mains or industrial applications.

Typical applications

These assemblies are used between PCBs, sensors, displays, control boards, power modules and equipment wiring. Common projects include industrial controllers, RF control products, machines, test equipment, small appliances and electronic assemblies that need a plug-in connection instead of point-to-point wiring.

For moving assemblies or high-vibration equipment, specify the bend location, flex frequency and retention method. A small-pitch connector should not be used as the cable strain relief. The harness should be mechanically supported so repeated movement is not transferred directly into the crimp terminals.

Sample approval and production control

Samples are available before mass production. The first article should be checked in the actual mating connector and enclosure, not only with a continuity meter. Confirm insertion, latch engagement, wire exit direction, bend clearance and service access.

Production inspection normally covers wire cutting, stripping, terminal crimping, housing insertion, pin sequence, appearance and electrical continuity. For multi-pin assemblies, a controlled wiring table or test fixture is strongly recommended. The approved drawing and sample then become the reference for repeat batches.

Information needed for an accurate quotation

• connector series, manufacturer and pitch;

• pin count, row arrangement and mating-part number;

• pin-to-pin wiring table or schematic;

• wire gauge, insulation, color sequence and finished length;

• working voltage, current and environmental conditions;

• single-ended, double-ended or branched construction;

• labels, sleeving, tie points and packaging requirements;

• sample quantity and expected order volume.

If you only have an existing cable, send the sample for evaluation. ANRIVERS can help turn the sample into a controlled production drawing, identify the connector family and confirm the details that affect fit, reliability and cost before tooling or volume production.

OEM and ODM manufacturing

Connector combinations, pinout, wire length, wire color, terminal type, housing, labels and packaging can be customized. Small sample quantities are supported for engineering verification, while production MOQ and lead time depend on connector availability, wire construction and inspection requirements.

Contact us with your drawing, sample or application description for a project-specific harness recommendation and quotation.