912Is Terminal Position Assurance?

[ejoern]

For you 912Is guys out there. I am starting to wire my HIC connectors using the Faston connectors. The Rotax manual says as part of connecting the pins to "Press down white integral terminal position assurance (TPA) with needle nose pliers until audible click is heard". This is step 3 before the pin is inserted into the HIC receptacle. I don't know what this is. I did get some white pins that will fit into any of the slots, but I don't know what it does or how its used to insert the pins. Any help would be appreciated. Unfortunately, I did slide one of the white pins into a slot and now its locked in there.

Thanks!

Eric

[efwd]

If Im not mistaken, the terminal connector is a black plug with a white inner part that slides out. I thought that after the pins are inserted this white part is pushed back inside the black housing and it clicks into position and locks the pins in. I could be wrong as I read the instructions a month ago and haven't done this yet myself. There are YouTube videos that demonstrate this. Not real sure why needle nose would be needed. In the video its just pushed in by hand.
Eddie

[ejoern]

Thanks Eddie. I did notice the white part of the connector does slide in and out just a bit. The odd thing here is that they put this step before the pin is inserted. or at least that is the way I am reading it. If it was to lock the pin in place, one would think that step would be after all the pins were inserted. What do you think?

Eric

[neville]

Inserted pins can be removed with a pin extractor. The extractor costs $20,+.
it can be purchased from Allied electronics, however it is nothing more than a 7/8th in long stainless pin .038 dia mounted in a 1-3/4th plastic handle. Molex P/N is 63813-1500. It is used with MX-150 and MX-150L connectors.

[ejoern]

Forgot to ask. Can you post the link to the youtube video you found?

Eric

[neville]

Also, there are two sizes of pins in the connector kit. One must be careful to install them in the correct sockets. The crimping tool has separate anvils for the two sizes.

[efwd]

Good morning Eric.
I apologize if I have lead you astray but It was my Vertical Power connector that I saw being employed in the video. It is a very similar connector and I believe its the same type. So, If its any help you can see what it is I saw at
http://verticalpower.com/vp-x/. You will find the second Vimeo video titled Wiring your vertical power. The connector pinning will be found at 3min 10sec.
Eddie

[ejoern]

Thanks Eddie. I now see what you mean. I was able to remove the white filler pin and I actually pulled the white part of the connector up just a little, then inserted the pin. There is only one way the pin should go in & if done right will snap into place. Thanks for the help!

Neville, I checked all the pins that came with the HIC A and HIC B connectors and they are all the same. I understand that the X3 connector is completely different. Is that what you were referring to?

Eric

[neville]

The end of the pin which will be crimped to a wire comes in two sizes in order to accept different wire sizes. Refer to installation manual on page 26 of 24-00-00, electrical section. Some wires are AWG 16 and others are AWG 18. The crimper is also available at Allied for +/- $ 70.00. It has two sets of anvils for the different size pins. PS. My reference to the manual page location is from a page of Edition 1/Rev1 of 07/01.2014. The page may be different in the latest revision

[ejoern]

Neville, I now see what your talking about. Very subtle for sure. My manual is a few months older than yours and does not mention it, so I will try to see if I can find a later edition. I do have the tool required so I should be set. Thanks for letting me know about that, I don't think I would have noticed it otherwise.

Eric

[neville]

One last thing, Arrow electronics sells pins by the piece and Molex sells connectors by the piece. I know this due to a mistake I made.

[dcsfoto]

got a part# for the pins? I want extras

any tips for installing pins?

I will be starting soon

David Kelm

[neville]

google arrow electronics, at top of home page enter P/N in search field and you will get all info, price. and link to order.

P/N 019420002 female 10 for about 15 cents each

P/N 194170024 male 10 for about 12 cents each

install instructions are in Rotax install manual. In the Rotax box of pins and connectors you will find two sizes of pins. The difference is at the end where the conductor is crimped on as there are two sizes of wire to be used. The crimp tool has dies for each size.

[dcsfoto]

thanks

what are the 4 round metal threaded parts for ?

[dcsfoto]

not able to find those part numbers

David Kelm

[neville]

Very strange. Here are the steps I used to arrive at the proper page on Arrow. 1, google arrow electronics. 2. select Arrow Denver from selections. 3. type in p/n at top of home page. 4, a picture and description of part shows up. I was using google chrome.

[dcsfoto]

got my stuff.

not able to find the larger gauge pins

thanks

David Kelm

[dcsfoto]

question

do I pull the white inner part out, insert pins, then push back in place?

ready to start that part


Thanks
David Kelm

[neville]

The installation manual in effect in 2013 when I did my engine stated;

1. push white block out (towards the face which mates with the engine side connector) . It will go a short distance and stop.

2. set all pins with crimped wires into proper numbered slots.

3.Hold all pins from backing out and push white block back in. Test that they are all locked in.

The revised manual now in effect (rev 3 Nov 2015) has the following instructions:

1. press in white block and hold with point of needle nose pliers.

2. push pin with crimped wire into proper position until it locks into place. continue with remaining pins.

The new instructions sound easier to do. If you look at the wire side of the connector you will see a grove. orientate the pin so that the proper side of the pin mates with the grove. Other wise it will not lock in place properly and may not be removable. That's when you get to buy a new connector. I speak from experience.

[dcsfoto]

well the HIC A and B connectors kicked my butt for two days.
but done now.

was not able to get the pins to lock in using the current instructions

tapped the connector on the table to slide the TPA out a bit