ME 2011 Battery Assemble Instructions
Objective: Instructions on how to assemble a battery pack harness from raw material.
Part Number / In Image / Description1 / 2 / Black wire: ground connection
2 / 2 / Red Wire: positive connection
3 / 2 / 12V Battery pack
4 / 3 / Wire stripper: removes outer plastic coating on black and red wire
5 / 3 / Wire crimper: compresses connectors (P# 7) onto wires
6 / 3 / Molex wire crimper: compresses connectors (P# 8) onto wires
7 / 4 / Female quick disconnect terminal: connects wire to battery
8 / 4 / Female Molex connector: connectors wire to male terminal connector
9 / 4 / Male terminal connector: connects black/red wire to female bunny tail
Procedure
Step 1: Cut about eight inches of both the black and red wire (P#’s 1 & 2) and strip about 0.5cm of the plastic covering off both ends of both wires with the wire stripper (P# 4)
Step 2: Crimp on one Female quick disconnect (P# 7) on each wire using the wire crimper (P# 5)
Step 3: Crimp on one female Molex connector (P# 8) on the other end of each wire using the Molex crimper (P# 6). It is important that the wire is on the “wire side” of the tool as labeled on the tool and shown in image 5. Image 6 shows the current progress.
Step 4:Push the end of the black wire that has the Molex female connector (P# 8) crimped onto it into the female hole that contains the flat bottom (this is important the wrong side would mean reversed electrical flow). Push the end of the red wire that has the Molex female connector (P# 9) into the female hole that contains the tapered edges on the front. See Image 7.
Step 5: Slide the end of both wires that contain the female quick discounters onto the appropriate battery terminal (P# 3) paying close attention that the red wire connects to the red terminal and the black wire is connected to the black terminal.
Step 6: Flatten wires out over batter surface and tightly wrap electrical tape around and over the battery pack and over the wires. See Image 1.
Step 7: The final step is to test the battery to make sure all the connections have been made and the current is able to flow freely. Grab a motor and a female bunny ears and connect them to the through the male terminal connector (P# 9) of the battery to see if the motor runs. If it does not run make sure battery is charged, or re-check all connections that you made.
Page 1