Tri-Track 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>

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Lexan Preparation.</td>

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

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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 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.

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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.

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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.

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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.

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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.

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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.

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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.

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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 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.

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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

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16.

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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

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17.

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

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yellow wires on (-).</td>

Figure 17.</td>

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

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18.

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

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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

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19.

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

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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

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Connections</td>

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<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>

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<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,

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yellow wire</td>

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<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,

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red wire</td>

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<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>

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<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>

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<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

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20.

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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

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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

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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.

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

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

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

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Figure 20.</td>

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

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21.

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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

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22.

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

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

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

Figure 22.</td>

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

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23.

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You can install the optional base rotate using the top screws from the standoffs.</td>

Figure 23.</td>

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