How to crimp a Spade Connector
Step One: Preparation
> Female spade connectors FOR the C batteries
> Stripped wires
> Example of how the wire is inserted into terminal
(this is not a real step in the process)
> Example of how the wire is inserted into terminal
(this is not a real step in the process)
> Hand crimp tool (crimper)
> Close-up of crimper
Step Two: Time to Begin
> Inserting terminal into crimper
> Inserting terminal into crimper
> Inserting terminal into crimper
> Wire inserted into conductor crimp with terminal in crimper
> Squeezing the crimper - conductor crimp begins to bend
> Squeezing the crimper - conductor crimp closes down on the wire
> Crimper fully squeezed - conductor crimp is complete
> Release the crimper
> Examine the crimp - in this case the spade was damaged slightly
Step Three: Now it's time for the insulation crimp
> If the insulation crimp is too wide for the crimper, close the Bell Mouth (Flare) by bending it slightly with the crimper
> If the insulation crimp is too wide for the crimper, close the Bell Mouth (Flare) by bending it slightly with the crimper
> Not the insulation crimp side of the terminal can fir into the crimper
> Inserting insulation crimp side of the terminal into crimper
> Squeezing the crimper - insulation crimp begins to bend
> Crimp - fully squeezed - insulation crimp is complete
> Examine the crimp
How to Attach an Internal Battery Connector
The JWIN Boombox is designed for use with disposable batteries, although it can be used with rechargeable batteries. Most people that use rechargables remove them from the unit and place them into a battery charger. Many of the teachers that will be using the JWIN for education are not familiar with consumer electronics, so we want to simplify the recharging process. We have devised a method of recharging the batteries without removing them from the JWIN unit. This method recharges the batteries while they are within the battery compartment.
The JWIN requires 8 C batteries. 6 of these will be traditional button top batteries, however 2 of these batteries will be tabbed.
These instructions will help the reader to create a cable to facilitate the recharging of the batteries while inside of the battery compartment.
Slide the wired connector onto the spade (or tab) on the battery.
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Be sure that that the spade connectors are attached to the proper side of the C batteries. One of the tabbed batteries needs to be attached to the positive spade connector and the other tabbed battery needs to be attached to the negative spade connector.
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The spade connectors are crimped onto the wires of the male cigarette automotive DC plug.
The positive wire runs from the tip of the male automotive DC plug.
The negative wire runs from the side of the male automotive DC plug.
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o recharge the batteries, shut off the radio and insert the male automotive DC plug into a solar panel with a female automotive DC jack/socket for a few hours. The solar panel should have a battery voltage regulator and a meter to indicate when the batteries are fully charged.
There are 8 potential spaces for the batteries to be inserted into the JWIN. There are 2 rows of 2 batteries on two levels. In order to access the battery compartment the JWIN must be placed upside down on a flat surface.
The 2 tabbed batteries MUST BE placed in the battery compartment in a very specific location, they MUST BE inserted into the spaces where the power is delivered to the JWIN (power spaces). When looking at the battery compartment with the JWIN upside down, these power spaces are on the bottom level. These power spaces are not in the same row. They are closest to the headphone jack (14)
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The battery door can be replaced with the wire exiting the battery compartment. Thread the wire next to one of the tabs that holds the battery door in place.
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