Chassis Assembly Instructions Pt2

Step 14: Assemble and install air tank mounts and accessories

You will need:

3/32” Hex Driver / Allen Key

1/8” Hex Driver / Allen Key

#4 Washer Qty 2

MRC-ATM-REG (3D Printed Part)

MRC-ATM-711 (3D Printed Part)

• Attach part REG to part MRC-ATM-REG using the 4-40×7/8” screws and #4 washers as shown. Snug enough that it doesn’t move but do not overtighten as you may strip the plastic threads.
• 
• Wrap the threads of the 711 valve in Teflon tape. Slide part ATM-711-1 over the threads then insert valve into the 1/4” Female PTC using the 7/16” socket to tighten the assembly. You can use the cavity in part ATM-711 to grip as needed. Do not overtighten.
• Fully seat the valve assembly into part ATM-711 so that ATM-711-1 is flush with the bottom. This is a friction fit.

• Insert the 10-32 x 1” screws through the holes in BP as shown one at a time.

• Tighten the screws until both air tank mounts (ATM) are snug against panel BP. Do not overtighten.

Step 15: Assemble air valve assembly

You will need:

1/2” Wrench

9/16” Wrench

5-Way Air Valve Qty 1

THE PTC CONNECTORS INCLUDED WITH THE VALVE ARE 6MM – NOT 1/4 INCH. There are 1/4 inch connectors included with your kit that you should use instead. We made this change for better integration with other components and availability of supplies.

• Wrap each threaded part with Teflon tape before threading it into the valve.
• The knurled wheel on top of the valve can be loosened to rotate the solenoid so that the wires exit in the correct direction for our installation. Make sure to re-tighten this wheel after rotating the solenoid.
• 
• Using the 9/16” wrench thread the 90-degree PTC connectors into the holes shown. Tighten until snug then turn no more than 1/8-1/4 turn more to seat.

• Using the 1/2” wrench thread the air filters into place. These are made of soft brass and should not be tightened vigorously.

Step 16: Assemble and install pressure safety switch with valve assembly

You will need:

3/32” Hex Driver / Allen Key

5/64” Hex Driver / Allen Key

9/16” Wrench

PS120 – Pressure Switch

PTC Connector Straight 1/4” OD 1/8” NPT Thread

• Wrap the threaded part of the pressure switch with Teflon tape before threading it into the PTC connector.
• Use the 9/16” wrench to tighten the PTC connector. Turn 1/8 to 1/4 turn after it gets snug.

• Insert the assembled pressure switch into part PSM.
• 
• Finish the PSM assembly using a 4-40 x 5/8” socket cap screw.
• Slide the PSMC cover in place. It should click under the tab. A small mallet may help get this locked in.

Insert the 6-32 Nylon Insert Locknuts into the recesses shown.

• Place the PSM and Valve assemblies together. Insert the 6-32 screws through the valve assembly and thread into the locknuts in part PSM. Tighten until fully seated but do not overtighten.
• Insert the 6-32 x 1.75” flat head socket cap screws through the holes shown in panel BP.
• 

Step 17: Assemble and install wheels. Repeat steps for both wheels.

You will need:

5/32” Hex Driver / Allen Key

7/16” Wrench (or socket)

DW478 – Drive Wheel Qty 2

DWP478-60 – Drive Wheel Pulley 60T Qty 2

DB350 – Drive Belt Qty 2

Wheel Bearings Qty 2

Soft Mallet

• Insert the drive wheel pulley into the wheel noting the molded socket and key to orient them properly.
• 
• Insert the 4 x 1/4-20 x 1.25” flat head screws as shown.
• 
• Insert washers and THIN 1/4-20 locknuts onto the 1/4-20 screws and tighten in a star pattern until the screws are flush with the back of the THIN locknuts.
• 
• Press the bearings into place as shown.

• Slide the drive belt over the pulley and insert the WIT to hold the spacer in place while you slide the assembly into the chassis. This will be removed in a later step.
• The drive belt should stay on the pulley throughout the remaining assembly even if not shown.

• Use the 1/4-20 x 3.25” flat socket cap screw and the WSIT to tap an aluminum spacer into the desired mounting hole. The standard 350mm belt uses the furthest forward position. The remaning holes are for (in order) 375mm, 400mm and 425mm belts. (Shown transparent for clarity)
• If you need to remove this spacer you can use the WSRT by tapping from the opposite side to pop it out.
• 
• Slide the wheel assembly (including the drive belt) into the chassis as shown. The spacers should be lined up with the appropriate hole. Use the 1/4-20 x 3.25” flat socket cap screw to press out the WIT.
• 

• Line up the 1/4-20 locknut as shown and tighten until snug. Do not overitghten. The recess in the chassis is the proper width so that no wrench or socket should be needed to keep the nut from turning.

Step 18: Mate panel BP to the rest of the chassis.

You will need:

7/32” Hex Driver / Allen Key

3/8-16 x 1.5” Flat Socket Cap Screws Qty 6

• Line up panel BP with the mounting points on the bottom of the chassis and lay it in place. Make sure no wires or other attachments are getting pinched.
• Thread and tighten all 3/8-16×1.5” screws until they are snug. Do not overtighten. Turn only 1/4 turn past the first feeling of bottoming out.

Step 19: Drive motor installation. Repeat steps for each side.

You will need:

3/32” Hex Driver / Allen Key

5/32” Hex Driver / Allen Key

Neo Brushless Motor Qty 2

2mm Drive Key Qty 2

• Slide the motor spacer over the shaft and rest it on the bearing. This will help line up the mounting screws in a later step.
• 
• Insert the 2mm drive key into the slot on the shaft of the motor then slide the HTD-5M-12 pulley over the shaft and key.
• 

• Insert and the motor into the chassis and slide the drive belt over the pulley as shown. Align the assembly so that the drive belt is straight. Once in place tighten the set screw.
• 
• Rotate the motor so that the power wires are oriented as shown toward the rear of the chassis.
• 
• Assemble the 10-32 x 7/8” socket cap screw, split lock washer and general purpose washer as shown and thread into the motor. Tighten until snug and add about 1/4 turn. Do not overtighten.

Step 20: Install Pinion Stops – Repeat steps for both sides

You will need:

5/32” Hex Driver / Allen Key

Small Adjustable Wrench

• Insert the 1/4-20 flat socket cap screw through the hole shown.
• 
• Use the adjustable wrench against the flat areas of the pinion stop to prevent it from turning while you tighten the screw with the allen key. Tighten until snug. Do not overtighten.
• 

Step 21: Install Battery Mounts – Repeat steps for both sides

You will need:

5/32” Hex Driver / Allen Key

1/4-20 x 1.25” Flat Socket Cap Screws Qty 2

1/4-20 Nylon Insert Locknuts Qty 2

MRC-BM (3D Printed Part) Qty 2

• Slide the BM under the motor as shown.
• 
• Insert the locknuts from the top. Push all the way to the bottom taking care that they stay straight. It may be helpful to use a long 1/4-20 screw threaded in a couple turns to guide them.

• Insert the 1/4-20 x 1.25” screws as shown and use the allen key to thread into the nuts for a snug fit. Do not overtighten.

Step 22: Install Battery

You will need:

3S 9000mah Lipo Battery

Velcro Straps Qty 2

• Slide the battery into the mount as shown. Make sure the connector is oriented in a way that doesn’t pinch and is easy to connect/disconnect from your power input.

• Wrap the Velcro strap around the mount using the built-in groove and channel. Pull the strap tight and press them together to lock the battery in place.

Step 23: Install Air Tank

You will need:

Air Tank

Velcro Straps Qty 2

• Using the same technique as in the battery mounting slide the tank into the mounts and tighten the Velcro strap around to hold it in place.

Step 24: Install Magstop

You will need:

5/32” Hex Driver / Allen Key

3/8 Wrench

MRC-MGB (3D Printed Part)

MRC-MGW (3D Printed Part

• Insert the wire and connector of MRC-MGB through the larger hole on the Top Plate (not shown) and insert the 10-32 screws into the 2 holes shown.

• Using the allen key and wrench tighten the washers and nuts on the 10-32 screws from the bottom of the panel as shown.

• Insert the MRC-MGW pins into the sockets shown to activate full controls. This can be removed during service when full mobility is not needed.
• 

Step 25: Install the top plate on the chassis.

You will need:

7/32” Hex Driver / Allen Key

3/8-16 x 1.5” Flat Socket Cap Screws Qty

• Insert the 3/8-16 x 1/5” screws in the holes as shown and tighten for a snug fit. You should pay careful attention during your battle system design to make sure you can reach these fasteners with it installed. This is how you will access the inside of the chassis for operation and maintenance.

This concludes the major chassis assembly

Take a moment to inspect your robot for proper operation:

Drive belts should be tight but not restrict the movement of the wheels

Wheels should turn relatively easily

All components should be securely fastened in place

The next section of instructions will detail electrical and air system connections