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Task 1: Wheel assembly

Preparation​

Assembly time​

20 min per wheel / 80 min total

Tools needed​

  • cross-head screwdriver
  • 2.5mm hex key (metric)
  • 3mm hex key (metric)
  • lithium grease
  • Loctite glue (anaerobic, low-strength)
Box of parts used to assemble Leo Rover wheels
Opened box containing parts used to assemble Leo Rover wheels

Step 1: Motor assembly​

Prepare:

  • 1x DC motor with wheel cap and cable
  • 1x wheel tube with bearings
  • 4x 2.5x9.5 self tapping cross-head screws
  • cross-head Phillips screwdriver
Parts used to assemble motor of the Leo Rover, laying on the table
Hands holding motor tube and DC motor
Insert the motor to the motor tube.
Motor tube with inserted motor, screwdriver tightening the screw
Secure the motor using 4x 2.9x9.5 screws.
Rear side of the motor tube with opened wheel cap
Push the motor cap to the tube to close the assembly.
Rear side of the motor tube with closed wheel cap
Wheel cap without inserted rubber seals
Press the cable rubbers into their housings.
Wheel cap with inserted rubber seals

Step 2: Wheel mounts​

Prepare:

  • step 1 assembly
  • 1x lower wheel mounting
  • 1x upper wheel mounting
  • 4x m4x12 hex screw
  • 3mm hex-head key
Required parts used to assemble wheels mounts
step 1 assembly with both mountings
Place the upper wheel mounting and the lower wheel mounting on the wheel tube (according to the photo).
Screwing together both mountings on motor tube
Assemble the wheel mountings together using 4x m4x12 hex screws. Tighten the connection just enough so that the mountings don't slide or rotate on the tube.
Rear view of assembled component, cable going in direction of upper mounting
Make sure the wheel mountings pair is aligned with the wheel cap as in the photo.

Step 3: Shaft seal​

Prepare:

  • step 2 assembly
  • 1x rubber radial shaft seal
  • lithium grease
Parts used to assembly shaft seal
Inserting seal into front of motor tube
Press the shaft seal in the corresponding housing in the wheel tub. The seal needs to be pressed on the motor shaft side, with a groove facing outwards.
Inserting seal with use of hands
Motor tube with properly inserted shaft seal
The seal needs to be evenly housed in the tube.
Applying lithium grease between motor housing and shaft seal
Applied grease on motor housing
Press a decent amount of lithium grease between the shaft seal and the motor housing.

Step 4: Shaft adapter​

Prepare:

  • 1x shaft adapter(stainless steel)
  • 1x m4x10 torque screw
  • 2mm hex key
  • Loctite glue
Loctite, shaft adapter, torque screw and imbus screwdriver laying on the table
Applying loctite on torque screw
Press a drop of Loctite glue on the torque screw thread.
Inserting torque screw into shaft adapter
Insert the torque screw to the shaft adapter radial hole. Don't tighten it yet.
Putting shaft adapter on motor shaft
Attach the adapter to the motor shaft. Make sure the radial hole is in the normal axis of the motor shaft plain side.
Correctly positioned shaft adapter
Press the adapter until there's only 0.5-1mm clearance between the adapter and the wheel tube. Some force may be needed, depending on how much grease needs to be pushed out to make space for the shaft.
Correctly positioned shaft adapter
Tighten rhe radial torque screw.

Step 5: Wheel rim​

Prepare:

  • step 4 assembly
  • 1x wheel rim (3D-printed)
  • 1x torque plate (3D-printed)
  • 5x m4x8 round head screw
  • 2mm hex-head key
Parts needed to assemble wheel rim
Putting wheel rim on step 4 assembly
Push the wheel rim on the assembly bearings, some force may be needed.
Pressing wheel rim on top of bearings
Correctly positioned wheel rim
Push until the front bearing touches the wheel rim internal step and the rear bearing ends plain with the wheel rim surface.
Correctly positioned wheel rim, rear side of the wheel rim touching bearing
Assembly and torque plate held in hands
Assemble the torque plate so the plate 'teeth' match the rim openings.
Torque plate mounted on the wheel rim, holes aligned with shaft adapter
Align the torque plate holes with the shaft adapter threaded holes and screw them together using 5x m4x8 screws.
Assembled wheel rim

Step 6: Tire​

Prepare:

  • step 5 assembly
  • 1 x tire
Step 5 assembly and tire laying on the table
There will be 2x step 5 assemblies with a shorter cable and 2x step 5 assemblies with a longer cable. Assemble the tires to end up with 1x short cable assembly with the tire thread facing left, 1x short cable assembly with the tire thread facing right, 1x long cable assembly with the tire thread facing left and 1x long cable assembly with the tire thread facing right.
Assembling tire on the wheel rim
Each tire needs to fit on the wheel rim grooves, some force is needed to push and align them properly. Make sure the front and read lip of the tire are in the corresponding grooves.
Assembling tire on the wheel rim
Each tire needs to fit on the wheel rim grooves, some force is needed to push and align them properly. Make sure the front and read lip of the tire are in the corresponding grooves.
Tire assembled on the wheel rim
Overview of assembled wheel module

Good job! Now 3 more to go.​

Screw used to mount wheel module with rocker
After the assembly step you'll end up with 2x m5x10 hex screws that will be used later to mount the wheel to the suspension. Store them in the plastic tray.