Battery Cable Work Instruction - Team537/RobotCode2024 GitHub Wiki

Material:

Qty Materials
8.75in+ 4AWG RED flexible battery cable
8.75in+ 4AWG BLACK flexible battery cable
2 4AWG SB120 terminals
2 4AWG 90deg Ring Terminals
1 SB120 RED connector
3in+ Red 3/4in dual wall heat shrink tubing
3in+ Black 3/4in dual wall heat shrink tubing
2 Grasshopper battery nuts pack
2 3/4in 10-32 SHCS
1 SB120 T-Handle
2 1in 10-32 SHCS
2 10-32 Low Profile Nyloc Nut
1 Black Terminal Cover
1 Red Terminal Cover

Tools:

Tool Image
Jonard Large Gauge Wire Stripper
TEMCO 5Ton Hydraulic Crimper
Scissors
Flush Cutters
Heat Gun or Micro Torch
Small Flat Blade Screwdriver
5/32 ball end Hex Wrench
Large Gauge Wire Cutter

Instructions:

Mies-en-plas (prep):

  1. Cut an 8.75in length of 4AWG red and 4AWG black flexible battery cable using the Large Gauge Wire Cutter.
  2. Strip one end of each of the above cables with the Jonard Large Gauge Wire Stripper to a depth of 0.75in from the end.
  3. Strip the opposite end of each cable with the Jonard Large Gauge Wire Stripper to a depth of 0.5in from the end.
  4. Using the Scissors cut qty: 2 Red dual wall heat shrink 1.5in long each.
  5. Using the Scissors cut qty: 2 Black dual wall heat shrink 1.5in long each.
  6. Install the 4AWG+ dies into the TEMCO 5TON Hydraulic Crimper

Cable Fabrication:

  1. Slide the 2 pieces of 1.5in Red or Black Dual Wall Heat Shrink onto the middle of the matching color battery cable.

  2. Place the SB120 4AWG terminal onto the 0.75in stripped end of either the red or black battery cable.

  3. Use the TEMCO 5TON Hydraulic Crimper with 4AWG+ dies to crimp the SB120 terminal onto the 4AWG wire. Crimp in 2 locations on the terminal barrel, one near the terminal entrance and one higher up the barrel but barley overlapping the first.

  4. Place the 4AWG 90deg Ring Terminal on the 0.5in stripped side of the battery cable. Orient the 90deg ring terminal such that the “flag” or bent flat points down in the same direction as the bottom side or locking side of the SB120 terminal.

  5. Use the TEMCO 5TON Hydraulic Crimper with 4AWG+ dies to crimp the 4AWG 90deg Ring Terminal barrel onto the 4AWG wire. Crimp in 1 location centered on the barrel.

  6. If flashing of the barrel material is present and sharp enough on the 90deg Ring Terminal to cut the dual walled heat shrink, use a Flush Cutter or Side Cutter to trim off flashing of the barrel material.

  7. Use a metal file to clean up/round off any further sharp edges

  8. If flashing of the barrel material is present and wide enough that the SB120 terminal will not insert into the SB120 housing, use a metal file to reduce the barrel flashing width equally on both sides such that the SB120 terminal fits into the SB120 housing with 1/8in+ clearance, PAUSE. Have a second person or a mentor with electrical knowledge check the crimps before proceeding to the next step.

  9. Slide 1 Dual Wall Heat Shrink 1.5in section over the SB120 terminal barrel such that 0.75in covers the barrel and 0.75in extends over the battery cable. (i.e. place the MIDDLE of the 1.5 heat shrink section at the junction where the battery cable becomes connector terminal).

  10. Use a Heat Gun on the HIGH setting or a Micro Torch with a minimal sized flame to heat the Dual Wall Heat Shrink and secure/insulate the SB120 terminal joint. The Heat Shrink should not only shrink – but hot glue should melt and secure the heat shrink to the terminal and the wire each. Each end of the Heat Shrink should have hot glue visible attaching it to the battery cable and terminal.

  11. Slide 1 Dual Wall Heat Shrink 1.5in section over the 4AWG 90deg Ring Terminal barrel such that 1 end of the Heat Shrink Tube is flush with the 90deg Ring Terminal bent Flag. (i.e. the Heat Shrink should be “bottomed out” on the ring terminal barrel completely covering the barrel).

  12. Use a Heat Gun on the HIGH setting or a Micro Torch with a minimal sized flame to heat the Dual Wall Heat Shrink and secure/insulate the 4AWG 90deg Ring Terminal joint. The Heat Shrink should not only shrink – but hot glue should melt and secure the heat shrink to the terminal and the wire each. Each end of the Heat Shrink should have hot glue visible attaching it to the battery cable and terminal.

  13. Install a Red or Black Battery Terminal Cover on the same colored cable on the 90deg. End.

SB120 Assembly:

  1. Fully insert the BLACK Battery Cable SB120 terminal into the SB120 NEGATIVE (-) side of the SB120 Housing.
  2. Perform a tug test to verify the terminal if fully seated in the SB120 housing.
  3. Fully insert the RED Battery Cable SB120 terminal into the SB120 POSITIVE (+) side of the SB120 Housing.
  4. Perform a tug test to verify the terminal if fully seated in the SB120 housing.
  5. Use the 5/32 ball end Hex Wrench, Qty: Two (2) 1in 10-32 SHCS and Qty: Two (2) 1in 10-32 Low Profile Nyloc Nuts to secure the SB120 T-Handle to the SB120 Housing.
  6. Perform this procedure by hand or with a drill set to the LOWEST (1) torque setting in torque/driver mode Battery Installation:
  7. Use Qty: 1 Grashoppper Nut and Qty: One (1) 0.75in 10-32 SHCS to connect the Black Battery Cable as shown in Figure aaaaaa.
  8. Use the 5/32 ball end Hex Wrench by hand or in a drill set to 4 in the Torque/Driver mode to fully tighten the Grashopper Nut.
  9. Slide the Black Battery Terminal Cover over the Battery Terminal and Battery Cable joint.
  10. Secure the Battery Terminal Cover to the Cable with electrical tape if necessary.

Repeat the above procedure for the Red Battery Cable to the Positive Battery Terminal referencing Figure bbbbb.