You're right, buying a whole kit just for a couple of D-sub pins is frustrating. Unfortunately, Generac rarely publishes the exact component part numbers for individual pieces of their kits. They want you to buy the whole kit.However, with a little detective work, we can figure out the likely D-sub pin type and find alternatives. Here's how to proceed

1. Identify the D-sub Connector Type Used in the Generac 7109 Kit:
Look at the Mating Connector

If you have a Generac controller with the mating D-sub connector, carefully examine it. Does it have 9 pins, 15 pins, 25 pins, or some other number? This tells you the D-sub size. Most two-wire start controllers use a 9-pin D-sub.

Examine the Pin Gender

Are the pins male (protruding) or female (recessed)? The kit you are talking about are female if they are going into the cable to connect to the controller.

Take Measurements

Measure the diameter of the pins. This will help determine if they are standard or high-density.

2. Determine the Wire Gauge Range

You mentioned using #18 stranded wire. This is crucial. The D-sub pins must be designed to crimp onto #18 wire securely.

3. Identify Crimp Type

Are the pins crimped using a manual crimper, or are they supposed to be automatically crimped?

4. Likely D-sub Pin Type

Based on common usage in control systems and the use of #18 wire, the pins are almost certainly:

Standard Density D-sub Connector Pins

This is the most common type.

Female Pins

For terminating the cable to connect to the controller.

Crimp Type

Designed to be crimped onto the wire using a suitable crimping tool.

Wire Gauge Range

Designed to accept 18 AWG stranded wire.

5. Finding Alternative Pins

Now that you have a good idea of the pin type, here's where to find alternatives:

Major Electronics Distributors

Companies like Digi-Key, Mouser Electronics, Newark/Element14, and Allied Electronics are your best bet. Go to their websites and search for: "D-sub crimp pins" "D-sub female crimp contacts" Filter the results by:

Wire Gauge

#18 AWG

Connector Gender

Female

Connector Series

Standard Density

Contact Plating

Gold or Tin (Gold is more corrosion-resistant)

Amazon/eBay (Proceed with Caution)

You can find D-sub pins on these sites, but be very careful about the quality. Make sure the seller is reputable and the product descriptions are accurate.

Example Search Terms (Digi-Key/Mouser)

"D-Sub Connector Contacts - Socket, Crimp, 18 AWG" "D-Sub Standard Density Female Crimp Contact"

Important Considerations



Crimping Tool

You'll need a good quality crimping tool designed for D-sub pins. Using the wrong tool will result in unreliable connections. Make sure the crimping tool matches the style of pin you purchased.

Pin Material and Plating

Gold plating is more expensive but offers better corrosion resistance and long-term reliability, especially in harsh environments.

Test and Verify

After crimping the pins, always pull-test them to ensure they are securely attached to the wire. Use a multimeter to verify continuity.

In summary: You likely need standard density D-sub female* crimp pins designed for 18 AWG wire. Check the major electronics distributors and use the search terms above. Be sure to get the correct crimping tool and test your connections. Good luck! Let me know if you have any other questions. Flag for review