This section describes the assembly of a vehicle. Firstly, lists with necessary materials and useful tools are given. Afterwards, the assembly is described step by step devided into the following 7 parts:

These instructions do not include PCB soldering. For instructions on PCB assemly, see PCB Assembly.

For questions regarding assembly, please contact:

Patrick Scheffe

Contents

0. Bill of Materials

The following tables show the quantities of the components needed for one vehicle. Note: The elements needed for PCB-Assembly are not given here.

Mechanical Components		Quantity
XRAY M18 Pro LiPo Kit		1
NF113LG-011 DC motor		1
Motor Magnet (6x2.5 mm, diametrically magnetised)		1
Battery Holder (.stl file for 3D printing)		1
LED Holder (.stl file for 3D printing)		1
Screws	M2x6mm	2
	M2x5mm	2
	M2x10mm Countersink	2
	M2.5x6mm	3
	M3x10mm	2
Nuts	M2	6
	M2.5	5
	M3	4
Washers	M2.5	2
	inner diameter: 2.2mm outer diameter: max. 4.5mm	2

Electrical Components			Quantity
Vehicle Main Board			1
Odometer Board			1
Female DSUB 9 connector			1
HiTEC D89MW servo			1
Banana connector 4mm			2
Banana connector 2mm			1
100nF capacitor			2
Fuse holder 0031.8201.G			1
Fuse 521,027			1
Red 1.0 wire end ferrule			4
4-Pole connector			1
LED NSDW570GS-K1			4
IDC Ribbon cable 10 POL (AWG 28-10G 10M)			11 cm
IDC Socket 10 POL			2
Heat shrinks
Silver wire
	Color	Gauge
Wires	Red	1mm2	31 cm
	Black	1mm2	25.5 cm
	Blue	0.5mm2	8.2 cm
	Red	0.14mm2	35 cm
	Black	0.14mm2	35 cm

Tools
2-Part epoxy adhesive
HiTEC DPC-11 Software
Servo Programmer incl. necessary harnesses
Soldering iron
Crimper
3D-Printer
Diverse drills, screwdrivers and allen keys

Contents

1. Underframe Preparation

The CPM Lab's vehicles are based on the XRAY M18 Pro LiPo Kit. However, for using it in the Lab, several adaptations have to be applied to it.

In this step, additional holes will be added to the underframe of the M18 to provide mounts for the charging connection, the fuse, and the switch. For this, a wooden template is used onto which even multiple underframes can be attached.

Contents

2. Adhesive Preparation

Since the adhesive needs some time for drying, this step is done now. On the one hand, the magnet must be adhered to the cog to allow distance measuring by the odometer. On the other hand, two nuts fixed to the Flex Piece will allow an easier fastening of the Main Board in the end.

Contents

3. XRAY M18 PRO Assembly

In the next part, the M18 Pro is built according to its manual, mostly. Consequently, this section focuses on tips and indicates deviations from the original.

Contents

4. Servo Configuration

The assembly of the M18 Pro ends with the configuration of the servo and the wheels. In order to configure the HiTEC D89MW Servo, the HiTEC DPC-11 software is used. For the current configuration of all vehicle's servos look here.

Contents

5. Soldering

This section describes the mounting of most electrical components, i.e., the soldering and mounting of

the motor,
the fuse,
the switch,
the charging connection (DSUB), and
the battery.

Contents

6. LED Holder

This section now describes the soldering and mounting of the LED Holder, which is needed for the IPS. For the assembly of the odometer board, look here.