Tata Motors Spare Parts Pricelist

[IndigoXLGrandDi]

The Picture of the "Lug" which I wanted to ask you is as below--

Blue 16-14 AWG .187 Female Disconnects | 28-6011 (286011) | Distributed By MCM


If I fit buy the Lug (from Local Market) such that it can bear the 15A Current (the Fuses in the Fuse & Relay Box are of 15A Rating) and small enough so that it does not touch the adjacent lugs, how long will the solution last (as per your assumption)?

[condor]

1. You will have to get specifications of the particular unit you want to buy. I am not sure you will get it.

2. Even if you do get it, you will not be able ot use it directly into the fuse/relay box. That's the reason I would try the other connector I had referred to.

What you can explore is using a series of 2 pin-connectors instead (check either #28-6060 or #28-6062) (one for top pin, one for bottom pin).

(looks like this will become messy)

[condor]

@IndigoXL, the root cause of this problem is possibly in the material used for the connectors. They seem to heat up when current flows through them, and hence damage the wires.

There are reasons why I suspect the material of the connectors in the fuse-relay box. One - the problem does not happen anywhere else in the car. Two, the problem is not with the wires. If it was with the wires, then it could have again happened anywhere in the car.

If this is correct, then using the lug will not help completely because the other end of the connector is still the original one. (Heat generated will reduce, but not be elimated completely)

What I suggest is:
1. use Anderson power connectors.
Anderson Power Products Powerpole Modular Connectors | 113854G1 | Anderson Power Products

These are rated 30A, 600V. But you will have to use a series of connectors in a matrix, with proper labelling of the wires.

2. Use the 2-pin connectors like this:
2 Conductor 16-22 AWG Solderless Connectors | 28-2175 (282175) | Distributed By MCM

The fuse/relay box has series of connectors one at the top, and one below. You can use the required number of these connectors in parallel. Tie up the entire bundle of connectors after that.


(red line is to show that these are tied up in a bunch)

[IndigoXLGrandDi]

Thanks Condor for suggesting so many solutions.

Today I asked our Dad's friend who is a D.E.E about this problem and showed the burnt connector to him. I asked him whether I can get the "Lug" which can tolerate 16A Current yet should be small so that any two of the lugs not touch each other.
He said that no lug that will be able to tolerate 16A current yet be of such small size is available.

He took me to his regular Electrician (who does the electrical-related jobs in cars/bikes).
The Electrician told me to fit an Electronic Relay to that connector so that the Current Flow will not be more to melt the plastic connector.

I told him that I had fitted a Relay to our another Indigo (Indigo LS IDI May 2004) and the Relay got short circuit because water entered due to rust and corrosion.
He told me that Electronic Relay is unlike ordinary one and will not give any problem (soon).
The cost of the Electronic Relay is @Rs.450/- and his Labour Rs.200/- and it will take @2hours to complete the job.

Lets see what happens.

Condor, I will keep you informed on this front.

I am very thankful to you for your help.

As for Rear AC Switch Assembly, I will PM you tomorrow.

[ap.meena]

Hi,

Have you finally solved the issue and mind sharing the results of the relay introduction exercise?

I am having a 2006 Turbo DLG Indica and am having a similar problem wherein the plastic coupler (I think you have called it the lug) has started melting leading to unreliable functioning of most electrical systems such as headlights, horn, central locking, internal lights and air conditioning. Few days back I was left without all this on the Delhi Jaipur NH8 for intermittent periods of time.

Solution suggested and done as well was very crude removal of 2 wires which had melt (out of 4 in the connector) and a simple twist wrapped up in tape.

I tried at many shops and could not source the part and have also been told that harness needs to be changed. Wondering if the relay solution could solve the issue permanently.

cheers
apm

Originally Posted by IndigoXLGrandDi

Thanks Condor for suggesting so many solutions.

Today I asked our Dad's friend who is a D.E.E about this problem and showed the burnt connector to him. I asked him whether I can get the "Lug" which can tolerate 16A Current yet should be small so that any two of the lugs not touch each other.
He said that no lug that will be able to tolerate 16A current yet be of such small size is available.

He took me to his regular Electrician (who does the electrical-related jobs in cars/bikes).
The Electrician told me to fit an Electronic Relay to that connector so that the Current Flow will not be more to melt the plastic connector.

I told him that I had fitted a Relay to our another Indigo (Indigo LS IDI May 2004) and the Relay got short circuit because water entered due to rust and corrosion.
He told me that Electronic Relay is unlike ordinary one and will not give any problem (soon).
The cost of the Electronic Relay is @Rs.450/- and his Labour Rs.200/- and it will take @2hours to complete the job.

Lets see what happens.

Condor, I will keep you informed on this front.

I am very thankful to you for your help.

As for Rear AC Switch Assembly, I will PM you tomorrow.

[IndigoXLGrandDi]

Can you please post a photo of the connector?

Have you upgraded the Head light Bulbs to >60/55W?

Our Indigo XL runs on OEM 55W H1 and H7 Bulbs. But still the connector in BCM under Bonnet got melted due to loose connection (My Fault) last year (Oct 2011).

The Connector had been fitted using M-Seal last year.

But the Mechanic in Achal Automobiles Pvt Ltd., Solapur (TASC) tried to remove the connector (for what reason he knows) and broke it. Due to this, the car would die whenever the connector was shaken. The car was given for Overheating Issue. That TASC billed me for Rs. 54K+. I will post that in the relevant section shortly.