Johnny 5 Chassis Assembly Instructions v1.0

For further information on lexan, see <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/support/polycarbonate-info-page/" target="_blank">this page</a>.</td>

26

27

Lexan Preparation.</td>

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<td valign="top" align="left">Step 1.

34

Attach four 3" aluminum bars to the inside pair of lexan panels as shown. Use 4-40 x

.375" hex screws.

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Figure 1.</td>

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<td valign="top" align="left">Step 2.

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Attach 1.5" hex standoffs to the lexan panels as shown. Use 4-40 x

.375" screws.

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Figure 2.</td>

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</td>

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<td valign="top" align="left">Step 3.

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Attach the motors as shown, using four 3mm x 8mm screws. Make sure the

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motor shafts and the hex standoffs are on the same side of the lexan panels.

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Figure 3.</td>

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<td valign="top" align="left">Step 4.

101

Install the hubs onto the motor shafts as shown. Align the hub to be flush

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with the end of the motor shaft. Tighten the set screw down firmly.</td>

Figure 4.</td>

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<td valign="top" align="left">Step 5.

111

Install the sprockets onto the hubs as shown. Take care to make the teeth on the sprockets line up as shown! Use two 4-40 x .625"

screws per side.

<td >Sprocket Alignment:</td>

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Figure 5.</td>

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<td valign="top" align="left">Step 6.

134

Prepare the idler sprockets. Install the two sprocket halves back-to-back

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on the long end of the idler hub. Take care to make the teeth on the sprockets line up as shown!

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Attach them with two 3mm x 8mm screws. Make four idler sprocket assemblies.

Figure 6-1.</td>

Figure 6-2.</td>

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<td valign="top" align="left">Step 7.

147

Attach ball bearings to the idler sprockets as directed in either Figure 7-1A or

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Figure 7-1B, depending on which version of the idler hub you have. Install the idler sprockets into the

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side panel as shown in Figure 7-2. Slide twelve nylon bushings over the nylon standoffs.

Figure 7-1A.</td>

Figure 7-1B.</td>

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Figure 7-2.</td>

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<td valign="top" align="left">Step 8.

168

Install the outer lexan panels as shown to close up the assemblies. Use twelve 4-40 x .375" screws.

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Figure 8.</td>

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<td valign="top" align="left">Step 9.

190

Wrap the 21-segment track assembly around the sprockets, push the axel in and secure with two nylon snap rivet fasteners. These parts are

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included with the track kit, not the chassis kit.

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Figure 9.</td>

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<td valign="top" align="left">Step 10.

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You should now have two assemblies that look something like this.</td>

Figure 10.</td>

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<td valign="top" align="left">Step 11.

221

Attach 1.5" hex standoffs to the bottom panel as shown. Use 4-40 x

.375" screws.

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Figure 11.</td>

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</td>

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<td valign="top" align="left">Step 12.

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Attach the top panel as shown. Use six 4-40 x .375" screws.

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Figure 12.</td>

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<td valign="top" align="left">Step 15.

265

Attach the track assemblies to the chassis as shown. Use eight 4-40 x .375"

screws.

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Figure 15.</td>

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<td valign="top" align="left">Step

287

16.

288

Push the capacitor legs through the holes in the motor terminals. Bend the capacitor legs down onto the terminals as shown.</td>

Figure 16.</td>

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<td valign="top" align="left">Step

298

17.

299

Push the motor wire connectors onto the motor terminals. Make sure to put the red wires on (+) and the

300

yellow wires on (-).</td>

Figure 17.</td>

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<td valign="top" align="left">Step

309

18.

310

Install the wiring harness as shown. This switch will be for the 7.2vdc battery that powers the Sabertooth motor controller. Additional

311

mounting holes allow adding separate power switches for accessories you add to the mobile platform, such as an arm, Johnny 5 torso, etc.</td>

Figure 18.</td>

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<td valign="top" align="left">Step

320

19.

321

Refer to Table 19 for Sabertooth connection information. We've included the switch settings we used for Johnny 5 - you may need to use

322

different settings for your application. You can find which direction to flip the switches on the card included with the Sabertooth. Route the

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motor wires through the holes in the chassis as shown! When the Sabertooth is properly connected and set up, use some double-sided foam tape to

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secure it inside the chassis.

<td >

<td align="center" bordercolor="#808080" bgcolor="#C0C0C0" colspan="2">Sabertooth

335

Connections</td>

336

<td align="center" bordercolor="#808080" bgcolor="#C0C0C0" colspan="2">Sabertooth Switch

Settings</td>

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<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Robot's right motor,

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red wire</td>

343

344

<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Independent Control</td>

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<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Robot's right motor,

349

yellow wire</td>

350

351

<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Disable Exponential</td>

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<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Robot's left motor,

356

red wire</td>

357

358

<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Non-lithium mode</td>

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<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Robot's left motor,

yellow wire</td>

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<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Battery (+), red wire</td>

370

371

<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Enable Auto-Calibrate</td>

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<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Battery (-), black wire</td>

376

377

<td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF">Disable Timeout</td>

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<td >

Table 19

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Figure 19.</td>

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<td valign="top" align="left">Step

401

20.

402

The Sabertooth has a battery elimination feature (BEC). This is useful when connecting the Sabertooth to an R/C receiver as it provides 5vdc at

403

500mA. This BEC can power the receiver itself and a couple of servos in low power applications, such as a pan-and-tilt. However, when more

404

powerful servos are connected to the R/C receiver, you must disable the BEC and provide a separate battery to the R/C receiver and its servos.

405

It is also necessary to disable the BEC if you are connecting the Sabertooth to an SSC-32.

406

To disable the BEC, pull the red wire out of the black housings of the CH1 and CH2 wires as shown in

407

Figure 21. Be sure to cover the exposed wire with heat shrink to prevent accidental short circuits!

</td>

Figure 20.</td>

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<td valign="top" align="left">Step

417

21.

418

This wiring harness is not included in the Tri-Track Chassis kit. We are illustrating what is necessary to install an SSC-32 to control an

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arm, Johnny 5 torso, or other servo-based addition. This switch will be used for a 6vdc battery.</td>

Figure 21.</td>

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<td valign="top" align="left">Step

428

22.

429

If you are using both an SSC-32 and a Bot Board, you will install them as shown in Figure

430

22. If you are only using the SSC-32, you will secure

431

it with the four screws and standoffs.</td>

Figure 22.</td>

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<td valign="top" >Step 23.

441

Now it's time to build the base rotate. Insert the stainless steel pins into the plastic bearings as shown.

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Figure 23.</td>

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<td valign="top" >Step 24.

462

Install the bearings into the base as shown. They will fit snugly.

463

Note, the notch in the bottom edge of the base indicates the back.

</td>

Figure 24.</td>

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<td valign="top" >Step 25.

473

Lay a piece of 400 grit sandpaper on a flat surface and move the base (upside down) in small circles on it. This will remove any imperfections

474

on the bearings.</td>

Figure 25.</td>

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<td valign="top" >Step 26.

484

Figure 26 shows the circle pattern on the sandpaper and the inset shows the bearings after any imperfections have been removed.</td>

Figure 26.</td>

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<td valign="top" >Step 27.

493

Figure 27 illustrates a typical standard-size servo with its output horn (the round white part) at center position. Make sure your servo

494

looks like the image, and then carefully remove the servo horn screw and pull the horn straight off of the servo.

495

The Johnny 5 kit includes either an HS-475 or HS-485.

496

Make sure you do not lose the servo horn

497

screw! You will need it later.

</td>

Figure 27.</td>

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<td valign="top" >Step 28.

507

Place the servo in the base as shown and screw it in tightly using four #4 tapping screws.

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Figure 28.</td>

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<td valign="top" >Step 29.

529

Add a drop of 3-in-1 oil to each bearing.</td>

Figure 29.</td>

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<td valign="top" >Step 30.

538

Route the base servo's cable through the hole in the back of the base. This will keep the base level to the mounting surface.</td>

Figure 30.</td>

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<td valign="top" align="left">Step

547

31.

548

Install the base rotate using the top screws from the standoffs as

549

shown.

550

Now move on to the Johnny 5 Torso

assembly.

</td>

Figure 31.</td>

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