9 pin connector on the 520-H

[boovuc 1,090]

Electrical gurus.....................any advice removing the pins from a bad main engine connector on an Onan P220/520-H? They are really in there! Really really in there!

I have a crimper, and a Molex .093" connector kit with the 9 pin connectors I need. The extractor won't budge them. The red wire on the male connector melted away and or snapped off. This will hold me up swapping engines. Or at least trying! 

[Save Old Iron 1,566]

Due to the excessive heat, you may find the wires corroded at the male pins and unsuitable for crimping to the new connectors.

 

Trimming off an inch or more of wiring may be required  At best, snip the wiring at the housing, strip the insulation and inspect the wire strands.

[zieg72 209]

On a couple of previous 520's that I replaced that connector, I took it one step forward and got a extra HD 2 prong for those 2 wires that overheat the connection and wire it besides the new 9-pin, 2 pins I don't use.  My $.02

[Cable 179]

I use an AMP extractor.  Push the extractor fully into the slot and rotate it a few degrees in both directions.  If you don't feel the pin release try pushing the pin back into position.  Often dirt gets under the tangs that hold the pins in place. Serious force is not needed.  If you hurt yourself you are using more force than is needed.

 

As for the burnt red wire, you need to clean the individual conductors (strands) until you have bright copper.  Action of the corrosion and heat creates a less than ideal mating surface.  Be sure to get a good solid crimp.  If you can pull the wire out of the new crimp it was not good enough. I will solder this pin if I can't get clean bright copper.  Also I favor using gold plated pins for the two red wires, one from the starter and the other from the regulator. Gold pretty much puts a stop to the corrosion.

 

Before reinserting any pins that are being reused return the compressed tang back out sightly until it is the same as a new pin.  It is only necessary to replace pings that are damage. 

[Shuboxlover 478]

If you have a dremel tool, you can cut away at the plastic (make sure you don't knick the wires or pin) and take them out one by one.

[AMC RULES 37,130]

What did the squirrel say?    

[boovuc 1,090]

Everything taken in advisement. Good ideas and thanks for the input. Took the night off tonight!