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To assemble U-Shaped Stamping/Wire Kit
No. 23-94-2120:
1.
Trim any excess wire stranding from 115mm
wire. Place wire through hole in small tab of
stamping. Twist metal strands to temporarily
hold wire to stamping. Trim any excess wire
stranding. Be sure to position wire straight
down at the 6:00 position. Secure with minimal
solder to the strands.
2. Feed heat shrink tubing over the wire and slide up
over soldered
tab. Use a heat gun to heat
the tubing to
soldered tab.
1
2
Route wire
around PCBA
and fwd./rev.
shuttle (See
below). Solder this
end of wire to rear left
terminal on battery
connector block.
NOTE: Switch and connector
block are shown without wires
for clarity.
Kit consists of:
1 U-Shaped
Stamping
1 115mm Wire
1 Shrink Tube
tighten/shrink around
3. Remove Electronic/Gearcase Assemblies from
housing halves.
4. Place U-Shaped Stamping onto groove of gearcase
end cap with small tab/wire positioned at the bottom.
Route the wire to the left side (behind) the PCBA.
5. Loosly install the Electronic/Gearcase Assembly (with
the U-Shaped Stamping/Wire Assembly in place) into
the Left Housing Halve. Wire is to be positioned
behind the fwd./rev. shuttle. Be sure the U-Shaped
Stamping is properly seated in the recess of the housing. (See detail above).
6. Take the loose end of the kit wire and place metal wire strands onto negative terminal of the battery terminal block
(rear left side with black wire attached to it). Secure that end with a minimal amount of solder.
7. Press all electronic components in place and route all wires in the left handle halve according to the wiring
diagram on page two. Be sure all mechanical and electrical components are firmly seated. Be sure all wires are
pressed firmly down in traps. Be sure that the fwd./rev. shuttle and spring are reinstalled and function properly.
8. Carefully install Right Housing Halve being sure that there are no interferences. Secure with existing screws.
Recess in left handle halve for
U-Shaped Stamping
U-Shaped Stamping
(Grounding Plate)
Gearcase End Cap
Gearcase End Cap groove for
U-Shaped Stamping
Black wire soldered to
negative terminal & PCBA
Long HV wire to
U-Shaped Stamping
Closed End Connector
Short HV wire soldered
to negative terminal
PRODUCTION WIRING- For ease in production, the
Electronics Assembly (Switch, Stator, PCBA and
BatteryTerminal Block) has a short HV wire pre-
soldered to the negative terminal. During production
a longer HV wire (with a U-Shaped Stamping) is
joined to short wire with an closed end connector.
Black wire soldered to
negative terminal & PCBA
23-94-2120 U-Shaped
Stamping/Wire Kit
(Kit must be assembled,
see steps 1 and 2 above)
Snip short production
HV wire at terminal here
SERVICE WIRING- When installing a service re-
placement U-Shaped Stamping/Wire Kit (23-94-2120)
it is recommended to snip old HV wire system at
battery terminal. Remove and discard that short wire,
closed end connector and longer wire with U-Shaped
Stamping. Follow instructions to install new wire kit.
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