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The pin size on these connectors is .062". I've been using the shank end of a .060" drill bit to check the sockets for tightness. If I don't feel the resistance when inserting or removing the drill bit then I'm going to replace that socket. I'm not seeing any problems with the pins, only the...

Just a thought here. I've been working on an 804A unit which has some high resistance issues in the J5/P5 and J6/P6 AMP connectors. I've ordered some socket pins to repair the 24-pin connector. These problems have been affecting the 24vdc power up to the main control panel, the start circuit and...

That’s very interesting. With no moving parts, it makes one wonder what could cause an intermittent open? Maybe loosen all 6 of the studs, clean and tighten? Treat the studs with some corrosion prevention like WD-40?

This is a very detailed explanation of what you found. It’s what helps to make this an awesome forum. Great job!

Man, it's so much more pleasurable to trouble-shoot these machines inside of a heated shop that's well-lit with a cup of coffee and a little music. With your determination, you'll find the problem.