AndyMark Rover am-4100 PN8 Series User manual

User Guide
Rover 8” Pneumatic Drive (am-4100_PN8)
Variants:
am-4100k_PN8
am-4100m_PN8
am-4100mk_PN8

2
Additional Instructions Available
We encourage customers to seek product information at AndyMark.com, contact us via e-mail at
[e-mail], or call Toll-Free 877-868-4770 with questions about any of our products.
2019 Updates
10-04-19: Initial Release
12-27-19: Revised Electrical Layout
Rover Chassis Recommended Hand Tool List (not included)
Component
Part Number
QTY
Part Photo
1/8” Allen Driver
am-2750
1
3/32” Allen Driver
am-3173
1
5/32" Allen Driver
am-2751
1
3mm Allen Driver
am-3688
1
2.5mm Allen Driver
am-3724
1
5.5mm Nut Driver
am-1287
1
3/8 in Nut Driver
am-3877
1
7mm Combination Wrench
am-4140
1
3/8"-7/16" Open End Wrench
am-2745
1
DarkSoul #25 Chain Break
am-4024
1
Retaining Ring Pliers
am-4013
1
TRIcrimp PowerPle Crimper
am-2554
1
Hand Rivet Tool
am-2834
1
Ferrule Crimp Tool
am-3739
1
¼ Inch Drill Bit
am-4048
1

3
Gearbox Assembly Bill of Materials
Component
Part Number
QTY
Part Photo
RedLine Motor with 16 Tooth Pinion
Gear Installed
am-3775a_16t
4
Sport Two Motor Gearbox With No
Shaft
am-3984
2
57 Sport 3 Inch Shaft
am-3791
2
57 Sport Gearbox, 16:1, SD
am-3972_016
2
2 Motor Sport Gearbox Pinion Shaft
am-3988
2
57 Sport Flange Mount
am-4132
2
10-32 x 0.5 Inch Button Head Cap
Screw
am-1512
4
Red Tacky Grease, 14.2 gram
am-2768
1
8” Pneumatic Wheel Assembly Bill of Materials
Component
Part Number
QTY
Part Photo
Hub Half for 8”Pneumatic Wheel
am-0971_half
8
4-40 x 1.0 Inch Pan Phillips Self-
Tapping Screw, qty 6
am-1250
4
Tire for 8 inch Pneumatic Wheel
am-0972
4
Inner Tube for 8 inch Pneumatic
Wheel
am-0973
4
1/2 Inch Hex Hub
am-0096a
4
10-32 x 2.0 Inch Socket Head Cap
Screw
am-1049
24
10-32 Nylock Jam Nut
am-1063
24

4
Chassis Assembly Bill of Materials
Component
Part Number
QTY
Part Photo
Rover Drive Rail
am-4094
2
1/2 Inch Hex Bore Bearing, Flanged
am-2986
10
1/2 Inch E-Clip
am-0206
2
#25 Single Strand Riveted Roller
Chain, 10 Feet
am-0370
1
17T Double Sprocket
am-3999
6
Rover Wheel Shaft
am-4133
2
Rover Idler Shaft
am-4126
2
1/4-20 x 0.5 Inch Button Head Cap
Screw
am-1039
6
1/4 Inch Flat Washer
am-1027
6
1/2 Inch Hex Spacer x 0.25 Inch
am-3948-250
6
10-32 x 0.625 Inch Socket Head Cap
Screw
am-1007
4
10-32 Nylock Jam Nut
am-1063
4
Rover End Rail
am-4131
2
1/4-20 x 1.75 Inch Self Tapping
Screw
am-1372
24
0.375 in. OD x 0.257 in. ID x 0.875 in.
Aluminum Spacer
am-1513
16
1/2 Inch Hex Spacer x 0.5 Inch
am-3948-500
2
1/2 Inch Hex Spacer x 0.188 Inch
am-3948-188
2

5
10-32 x 0.375 Inch Socket Head Cap
Screw
am-1359
2
#10 x 0.75 Inch Fender Washer
am-1523
2
Rover Chassis Bottom Plate,
Polycarbonate
am-4100_bottom
1
3/16 Inch Rivet, 0.376-0.5 Inch
Range
am-1340
8
Electronics Assembly Bill of Materials
Component
Part Number
QTY
Part Photo
M3 x 14mm Socket Head Cap Screw
am-1367
8
M3 Nylock Nut
am-1023
8
S3 Corner Gusset
am-3606
2
PowerPole Distribution Board
am-3699
1
CAN connector
am-4130
1
Victor SPX Motor Controller
am-3748
4
M4 Nylock Nut
am-1435
6
M4 x 50mm Socket Head Cap Screw
am-1401
4
1/4-20 x 1.0 Inch Socket Head Cap
Screw
am-1341
2
1/4-20 Nylock Nut
am-1015
2

6
120A Circuit Breaker
am-0282
1
6mm Standoff
ip-3749_standoff
4
M3 x 10mm Socket Head Cap Screw
am-1021
8
Hero Development Board
am-3206
1
20 AWG White Ferrule Crimp
am-3738_20
4
120 Ohm Resistor
am-4111
1
Hero Power Cable
am-4114
1
30 Amp Resetable Fuses
am-4112
5
Rover Chassis Power Cable
am-4113
1
12 Guage Red Black Bonded Wire
am-0904_5
5 ft
Powerpole Kit, 8 Pack
am-2198
2
Female Spade Connector, 12-10
AWG, Yellow, 10 Pack
am-2211
1

7
Rover Chassis Top Plate,
Polycarbonate
am-4100_top
1
10-32 x 1.375 Inch Socket Head Cap
Screw
am-1154
8
Nylon Spacer ¾ Inch Long
am-4107
8
10-32 Nylock Jam Nut
am-1063
8
AM14U Family Horizontal Battery
Mount Strap Plate
am-2940
2
10-32 x 2.75 Inch Socket Head Cap
Screw
am-1397
6
10-32 Wing Nut
am-1483
6
F710 Wireless Logitech Game
Controller
am-4049
1
M4 x 35mm Button Head Cap Screw
am-1441
4
10-32 x 2.0 Inch Socket Head Cap
Screw
am-1049
1
10-32 x 0.5 Button Head Cap Screw
am-1512
4
10-32 x 0.625 Inch Socket Head Cap
Screw
am-1007
4

8
Gearbox Assembly Instructions (QTY 2)
Each Rover 8” Pneumatic Chassis includes two (2) AndyMark Dual 775 Sport Gearboxes in a 52:1 ratio (am-
4010_52). Four (4) AndyMark 775a RedLine Motors with 16t Pinions (am-3775a_16T) are also included along
with the hardware necessary to mount the motors to the gearboxes. Additionally, a 57 Sport 3 inch Shaft (am-
3791) is included for each gearbox to allow for the cantilevered wheel setup utilized in the Rover Chassis.
The 52:1 ratio has been chosen specifically for use with the 8” pneumatic wheels to provide a fast and agile
platform to build upon. Other ratios or wheel sizes (sold separately) can be used on the Rover chassis to suit your
specific needs.
*Stall Torque and Free Speed are calculated using the unmodified specs of a pair of AndyMark 775a RedLine Motors

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Step 1: The 57 Sport gearbox is pre-assembled with a
cap on the back. Remove the four (4) #10-32 Socket
Head Cap Screws from the front of the gearbox and
carefully remove all components, being careful to
keep them together. The plastic cap can be discarded.
Step 2: The short output shaft needs to be replaced
with the longer 3 inch output shaft. Using a pair of
snap ring pliers, remove the snap ring from the
backside of the face plate. Be careful not to
permanently deform the snap ring by opening it too
wide.
Gearbox Assembly Instructions (QTY 2)
Step 3: Remove the output shaft by pulling it through
the front of the face plate and bearings.
Step 4: Insert the new 57 Sport 3 inch Shaft (am-
3791) into the faceplate. Be sure to push the shaft all
the way in until it rests against the outer bearing and
make sure the inner bearing remains seated in the
faceplate.
Step 5: Replace the snap ring on the new shaft. Be
careful to not permanently deform the snap ring by
opening it too wide. It should snap into the groove on
the output shaft around the full circumference.
Step 6: Reassemble the 57 Sport Gearbox using two
(2) #10-32 x 0.5 inch long Button Head Cap Screws
(am-1512) in place of the 0.375 inch long Socket Head
Cap Screws. Add the 57 Sport Flange Mount (am-
4132) to the front face of the gearbox –the screws
will be used in the pair of counter-bored holes on the
flange plate. Add a pea-sized amount of Red Tacky
Grease (am-2768) to each planet gear and the carrier
plate surfaces. Enough grease should be used so that
all internal surfaces get a coating of grease; however,
too much grease can cause the gearbox to drag.

10
Step 7: The 57 Sport Gearbox Assembly is now
complete. The Sport 2 Motor Gearbox and Motors will
be assembled next. The long Socket Head Cap Screws
will remain loose for now.
Step 8: The two plates for the Sport 2 Motor Gearbox
should already have the bearings inserted but give
them a light press to make sure they are fully seated.
Gearbox Assembly Instructions (QTY 2)
Step 9: Insert the 2 Motor Sport Pinion Shaft (am-
3988) through the front plate and bearing from the
side opposite where the bearing was pressed. Make
sure to push the shaft all the way in until it rests
against the bearing.
Step 10:Install the snap ring on the shaft. Be careful
to not permanently deform the snap ring by opening
it too wide. It should snap into the groove on the
output shaft around the full circumference.
Step 11:Install the 52T Hex Bore gear onto the hex
portion of the output shaft. Make sure the boss of the
gear is away from the snap ring (towards the inside of
the gearbox).
Step 12:Prepare the gearbox for the motors by
inserting the four (4) M4x25 Socket Head Cap Screws
through both the front plate and back plate and
closing up the gearbox. The Back Plate bearing should
slide onto the protruding portion of the output shaft.

11
Step 13:Add grease to the 16T pinion gears on the
775a RedLine Motors before inserting the motors into
the back of the gearbox.
Step 14:Line up the motors with the bolts and insert
the boss of the motor into the void on the back plate
of the gearbox. Tighten the four (4) M4x25 Socket
Head Cap Screws to complete the Two Motor Sport
Gearbox Assembly.
Gearbox Assembly Instructions (QTY 2)
Step 15:Join the 57 Sport Gearbox and the Two
Motor Sport Gearbox together using the #10-32 x 3.0
inch Socket Head Cap Screws. Make sure the thrust
washer is seated in the ring gear flush against the
planet gears before mating the two housings.
Step 16:Congratulations, you now have a completed
gearbox assembly. Repeat Steps 1 –15 to complete a
second identical gearbox.

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Wheel Assembly Instructions (QTY 4)
The Rover 8” Pneumatic Chassis includes four (4) high-traction wheels with a grippy rubber tire, a pneumatic
inner tube, and a strong plastic hub. The nominal diameter for this wheel is actually 7.65 inch when inflated
normally. When assembling the tube within the two hub halves, be careful not to pinch the tube rubber between
the plastic hub halves. If assembled with the tube pinched between the hub halves, the tube may puncture and
leak. These wheels will be assembled together with a ½” hex hub to be driven by the output shafts of the
previously assembled gearboxes and to ride on a chain driven shaft.

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Wheel Assembly Instructions (QTY 4)
Step 1: Insert the Inner Tube for 8 inch Pneumatic
Wheel (am-0973) into the Tire for 8 inch Pneumatic
Wheel (am-0972). Partially inflating the Inner Tub
may help hold it in position.
Step 2: Install two (2) of the Hub Half for 8 inch
Pneumatic Wheel (am-0971_half) into the wheel with
the valve stem going through the opening in the hubs.
Use six (6) #4-40 x 1 Inch Phillips Self-Tapping Screws
(am-1250) to join the two hubs together, three (3)
from each side in alternating holes.
Step 3: Using six (6) #10-32 x 2 inch Socket Head Cap
Screws (am-1049) and six (6) #10-32 Nylock Jam Nuts
(am-1063), attach a ½ Inch Hex Hub (am-0096a) to
the wheel. The hub will protrude partially through the
center of the wheel and should be installed from the
side opposite the valve stem.
Step 4: Congratulations, you now have a completed
wheel assembly. Repeat Steps 1 –3 three (3) more
times to complete a total of four (4) wheels.
Step 5: Inflate the wheels to a maximum pressure of 35 psi.

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Chassis Assembly Instructions
Step 2: Create two loops of #25 Chain (am-0370) with
64 pins in each. This can be done with a DarkSoul #25
Chain Break (am-4024) (sold separately) or with a
traditional chain break and a #25 Connecting Link for
Roller Chain (am-0371) (sold separately). Loop the
pair of chains around three (3) 17T Double Sprockets
(am-3999).
Step 3: Slide the sprocket/chain assembly into the
tube. It helps to hold the tube vertically and lower the
sprocket/chain assembly in from above using the
weight of the sprockets to keep the chain taut.
Step 4: Add a ½ Inch E-Clip (am-0206) to a Rover
Wheel Shaft (am-4133) and slide the shaft through
the front bearing and sprocket until the E-Clip is
against the bearing.
Step 5: Insert a Rover Idler Shaft (am-4126) into the
center bearing and sprocket. Use a ¼” Washer (am-
1027) and a ¼-20 x 0.5 inch Button Head Cap Screw
(am-1039) to retain the shaft on this side of the tube.
Step 6: Place a 0.25 inch long Hex Spacer (am-3948-
250) onto the output shaft of an assembled gearbox
and slide the output shaft through the rear sprocket
and tube from the same side as the previous shafts.
Step 1: Into one of the Rover Drive Rails (am-4094),
press two ½ Inch Flanged Hex Bearings (am-2986) into
the face with the small holes adjacent to the bearing
holes. One bearing should go into the middle hole and
the other into the front hole (to the right when
looking at this face of the tube). Note: The twenty-
four (24) End Rail holes are not centered vertically on
the tube and should be biased toward the top of the
tube.

15
Chassis Assembly Instructions
Step 7: Use two (2) #10-32 x 0.625 inch Socket Head
Cap Screws (am-1007) on the inner wall and #10-32
Nylock Jam Nuts (am-1063) to attach the gearbox to
the tube.
Step 8: On the opposite face of tube, add three (3)
more ½” Hex Bearings (am-2986). Align the hex to
slide onto the shafts and press the bearings into the
holes of the tube. You may need to gently tap the
bearings into plate to fully seat –be sure to use
something, such as a short piece of PVC pipe, to
ensure any force is being applied to the outer race of
the bearing only.
Step 9: Add a ¼” Washer (am-1027) and a ¼-20 x 0.5
inch Button Head Cap Screw (am-1039) to the middle
Rover Idler Shaft (am-4126) to capture it completely.
Step 10: Using twelve (12) ¼-20 x 1.75 inch Self-
Tapping Screws (am-1372), join the Rover Drive Rail
Assembly to two Rover End Rails (am-4131). The
Rover End Rails will have the rounded face towards
the top to ensure the top and bottom faces of all
three rails are flush. Use eight (8) 0.375 inch OD x
0.875 inch long Aluminum Spacers (am-1513) inside
the Rover Side Rail with the screws that are not
adjacent to the top wall to prevent crushing the tube.

16
Chassis Assembly Instructions
Step 11:Place a 0.25 inch long Hex Spacer (am-3948-
250) onto each of the two drive shafts.
Step 12:Place a completed wheel assembly onto each
of the two drive shafts. The hub should be adjacent to
the spacer and the valve stem should be away from
the Side Rail.
Step 13:Place a 0.5 inch long Hex Spacer (am-3948-500) onto each of the two drive shafts. Place an additional
0.188 inch long Hex Spacer (am-3948-188) onto the output shaft of the gearbox. Capture the wheel on the Rover
Wheel Shaft with a ¼-20 x 0.500 inch Button Head Cap screw (am-1039) and a 1/4 inch Washer (am-1027).
Capture the wheel on the gearbox output shaft with a #10-32 x 0.375 inch long Socket Head Cap Screw (am-
1359) and a #10 Washer (am-1523).
Step 14: Repeat Steps 1-13 to build the other half of the chassis. Be sure to mirror the assembly left-to-right and
orient the Rover Side Rail such that the 24 End Rail holes are in the same vertical orientation as the previous
assembly.

17
Step 15: With the rounded edges of the Rover End Rails still on top, place the Rover Chassis Bottom Plate (am-
4100_bottom) on top of the four rails oriented as shown below (the small groove should be on the bottom face
on the right, as seen below). Rivet the Bottom Plate in place using eight (8) 3/16 inch Rivets (am-1340) in the four
corner holes and every alternate hole in-between.
Step 16: The six (6) remaining holes along the End Rails should align with the through-holes in the End Rails but
may need to be drilled out to ensure a bolt may pass through.
Step 17: Flip your chassis over and you have completed the assembly of the Rover 8” Pneumatic Chassis.
Electronics will be added in the following section. You may skip to Step 19 of the Electronics Assembly when
assembling only the mechanical portion of the chassis or using a custom electronics package.
Chassis Assembly Instructions

18
Step 1: The Rover 8” Pneumatic Chassis is designed to use four (4) Victor SPX (am-3748) speed controllers and a
Hero Development Board (am-3206). The Rover Chassis Bottom Plate (am-4100_bottom) has mounting holes for
all pre-selected components. The following steps cover how and where to install the components but wires have
been removed from the images for clarity. A full wiring diagram can be found at the end of this section.
Electronics Assembly Instructions
Step 2: Mount the PowerPole Distribution Board (am-
3699) to a pair of S3 Corner Gussets (am-3606) using
M3 x 14mm Socket Head Cap Screws (am-1367) and
M3 Nylock Nuts (am-1023) through the middle hole of
a leg of the gussets.
Step 3: Mount the PowerPole Distribution Board
assembly to the top of the Bottom Plate using four (4)
M3x14 Socket Head Cap Screws (am-1367) and M3
Nylock Nuts (am-1023) on the underside of the
Bottom Plate.

19
Electronics Assembly Instructions
Step 4: Attach the CAN Connector (am-4130) to the
Bottom Plate using two (2) #10-32 x 0.5 long inch
Button Head Cap Screws (am-1512) and #10-32
Nylock Jam Nuts (am-1063) on the underside of the
Bottom Plate. Be sure to orient the CAN Connector
such that the wire terminals face away from the
PowerPole Distribution Board.
Step 5: Add PowerPoles (am-2198) to the four power
leads on each Victor SPX. Red PowerPoles should be
added to the Red and White leads and black
PowerPoles should be added to the Black and Green
leads. A PowerPole Crimp Tool (am-2554) (sold
separately) should be used to ensure a proper crimp.
Step 6: Add four (4) Victor SPX Speed Controllers (am-
3748) in two stacks of two with the CAN wires
oriented facing towards the CAN Connector. Use four
(4) M4x50 Socket Head Cap Screws (am-1401) and M4
Nylock Nuts (am-1435) to secure the controllers to
the top of the Bottom Plate.
Step 7: Cut one pair of CAN (yellow and green) wires
on one of the bottom Victors to approximately 3
inches long. Save the cut off wire for use in Step 9.
Strip the ends of the remaining wires and crimp 20
AWG White Ferrules (am-3738_20) onto each wire.
Insert the yellow wire into the CAN Connector in one
of the “HI” terminals and the green wire into one of
the “LO” terminals. Insert the legs of the CAN Resistor
(am-4111) into the remaining “HI” and “LO”
terminals.
Step 8: Connect the remaining CAN wires together
leaving one pair (from any Victor) open. Secure the
connections with the provided retainer clips
Step 9: Connect the cut off wire from Step 7 to the
remaining open pair of wires from Step 8. Strip the
cut ends of the pair of wires and crimp 20 AWG White
Ferrules (am-3738_20) onto each wire.

20
Step 10:Attach the 120A Circuit Breaker (am-0282)
on the other side of the robot using two (2) ¼-20 x 1.0
inch long Socket Head Cap Screws (am-1341) and ¼-
20 Nylock Nuts (am-1015) on the underside of the
Bottom Plate.
Step 11:Press the smaller end of four (4) 6mm
Standoffs (am-3749_standoff) into the top side of the
Bottom Plate and secure from underneath with four
(4) M3 x 10mm Socket Head Cap Screws (am-1021).
Electronics Assembly Instructions
Step 12:Place the Hero Development Board (am-
3206) on top of the standoffs with the USB port
towards the motors. Secure the Hero using four (4)
M3 x 10mm Socket Head Cap Screws (am-1021).
Step 13:Plug the CAN wires prepped in Step 9 into
the Hero Development Board. The connector is
labeled for the green and yellow wires.
Step 14:Insert the ends of the Hero Power Cable (am-
4114) with ferrules into the connector on the Hero
Board. Route this cable along the motors and past the
Victors and plug the PowerPoles into the PowerPole
Distribution Board closest to the Victors.
Step 15:Plug the red and black wires from the Victors
into the adjacent four sets of PowerPoles on the
PowerPole Distribution Board.
Step 16:Plug the Rover Chassis Power Cable (am-
4113) into the PowerPole Distribution Board at the
terminals furthest away from the motors. The ring
terminals will connect to the 120A Circuit Breaker.