NOVAK BRUSHLESS CONVERSION - KIT User manual
STEP 5 - INSTALL ESC & RECEIvER BRUSHLESS CONvERSION KIT INSTRUCTIONS
CONvERSION KITS AvAILABLE
The following Novak Brushless Conversion Kits are available (Refer to
www.teamnovak.com for additional and/or updated kit compatibility information)
#5010 Associated®RC8TM for Team Associated RC-8 Buggy
#5011 CEN®MatrixTM for CEN Matrix C-1 Buggy
#5012 Hot Bodies®LightningTM for Hot Bodies Lightning2 Evo Pro Buggy
#5013 Kyosho®InfernoTM for Kyosho Inferno 777, 777 SP-1, SP-2,
SP-2WC, and Sport ST-R Buggies
#5014 Mugen®MBX5TM for Mugen MBX5 and MBX5R Buggies
#5015 OFNA®9.5TM/UltraTM
for
OFNA 9.5 Series Buggies (ViolatorTM,
RavengerTM and Jammin X1TM) and the OFNA Ultra Series Buggies (MBXTM,
CompTM and LX1TM)
#5016 OFNA®Hyper 8TM for OFNA Hyper 8 and Hyper 8.5 Buggies
#5017 OFNA
®
Hyper 7
TM
for
OFNA Hyper 7 Buggies
#5018 XRAY®XB8TM for X-Ray XB8 TQ and XB8 EC Buggies
#5019 Losi
®
8ight
TM
for Team Losi 8ight Buggy
Car models listed are the registered trademarks of their respective company.
The Ultimate Conversion Kit to Convert Nitro Buggies to Electric Power!
include all of the necessary conversion components.
A Novak High-Voltage Brushless ESC and HV Brushless Motor are not included but required for completion.
#55-5010-1 • 4/2008
GEARING SETUP
1.
INSTALL NOVAK HV BRUSHLESS ESC
a. Select mounting position for ESC — refer to Figure 14
(on
For OFNA & Kyosho Dual Battery Setups: refer to Figure 15
For Losi 8ight: refer to Figures 20 & 21
Note: Be sure there is adequate
ventilation over ESC’s heat sink!
b.
Using the included double-sided tape, mount ESC to chassis.
Phillips FH self-tapping screws (see Figure 13) — chassis
and/or stone guard will need to be drilled and holes
countersunk to do this.
c.
Refer to the ESC instructions for further installation instructions.
2.
INSTALL RECEIVER AND ANTENNA MOUNT
a. Select mounting position for receiver and antenna — refer to
Figure 14
For OFNA & Kyosho Dual Battery Setups: refer to Figure 15
For Losi 8ight: refer to Figure 14
b. Install Receiver:
refer to receiver instructions.
c. (in
Add’l Hardware Bag — refer to Figure 13), using the M3x8 FH
tube that came with nitro vehicle.
Quality Racing Electronics since 1978
NOvAK ELECTRONICS, INC.
3.
INSTALL MOTOR PINION GEAR
Install a Mod 1 pinion gear to the output shaft. A hardened steel,
high-strength pinion gear is recommended with a 5mm bore. Novak
. Refer to
Figure 14
4.
INSTALL BRUSHLESS MOTOR ASSEMBLY
Each kit has a unique motor adapter plate.
Slotted Plates
Nylon insert lock nuts — see Figure 12.
Non-Slotted Plates: require the four screws (and cupped washers
depending on model) that were originally used to mount the nitro engine
to the chassis. Use thread-locking agent on these screws.
Mount motor assembly to chassis with the proper screws and
adjust gear mesh before tightening, being sure that the two
clamping screw holes in the heat sink face the outside of the
buggy. The motor’s solder tabs should face in the direction that
will provide the shortest wire length from the ESC to the motor.
•
For Losi 8ight Vehicle: refer to Figures 17-19 .
FIGURE 12:
Motor Adapter Plate Installation
Note: Motor and Heat Sink removed to show screw detail
5. INSTALL MOTOR FAN ON HEAT SINK
(refer to label on fan for direction).
•
screws (in Add’l Hardware Bag) through fan into heat sink — see
Figure 11 & Figure 14
.
•
Use included Y-harness (see Figure 1) to plug the motor fan and
ESC fan into the Novak HV High-Voltage Brushless ESC.
4-40x1/2” Socket Cap Screw (4)
#6x1” Phillips FH Self-Tapping
Screw (2)
M3x8 FH Screw (1)
Antenna Mount (1)
Servo Stand-Offs (4)
FIGURE 13:
Additional Hardware Bag Contents (#65-5010-3)
Note: For non-slotted plates, use the hardware that was included with
your Nitro engine. Do not use M4x10 FH screws of M4 lock nuts.
P1
P4
FIGURE 11:
Motor Heat Sink
Installed on
Motor Adapter
Plate
same side as engraved
Refer to Vehicle Specics Sheet for Novak’s
recommended Gearing Starting Points.
Motor operating temperature is the
ONLY
way to set vehicle gearing
BE SURE TO CREATE
SUFFICIENT VENTILATION
The Motor and Speed Control should not exceed
160-170°F MAX at end of the run!
Change the gearing to avoid overheating!
DO NOT FREE-REV MOTOR!
Free-running your brushless motor in a no-load condition can cause rotor
failure & ESC transistor damage and will void the product’s warranty.
WITH CUT-OFF WHEEL AND
SANDING DRUM
mm
mm
mm HEX WRENCH
mm HEX WRENCH
mm HEX WRENCH
OCOUNTER SINK TOOL
PLEASE READ ALL INSTRUCTIONS BEFORE STARTING
VEHICLE CONVERSION. The instructions for this
conversion kit are guidelines for installation. Some
customization and variance may be needed.
MUST BE 18 YEARS OR OLDER
Installation of this kit requires the use of power tools. Adult supervision is
required for users under the age of 18.
NOVAK 550-SIZE MOTORS ONLY
motors may cause damage to the motor.
MAY VOID VEHICLE’S WARRANTY
Refer to the warranty statement of your vehicle’s owner’s manual.
FOLLOW ESC & MOTOR PRECAUTIONS
HIGH QUALITY BATTERIES ONLY!
Stick type or pre-assembled NiMH sport packs are
NOT RECOMMENDED
.
for better balance, lower vehicle weight and longer run times.
*HV4.5 is for high-speed runs only
PRECAUTIONS
This product is guaranteed to be free from defects in materials or workmanship for a period of
-
ranty does not cover incorrect installation, components worn by use, or any damage caused
Because Novak has no control over the installation of
this conversion kit, no liability may be assumed nor will be accepted for any damage resulting
from the use of this product. By the act of installing the components of this conversion kit, user
accepts all resulting liability. In no case shall our liability exceed the product’s original cost. We
reserve the right to modify warranty provisions without notice.
reproduced without the written permission of Novak Electronics, Inc.
TOOLS NEEdEd
ACCESSORIES
MOD 1 PINION GEARS FOR 5MM SHAFT
HV BRUSHLESS MOTOR 5MM UPGRADE KIT
SUPER-FLEX SILICONE 14G WIRE
LEAD-FREE 3% SILVER SOLDER
INCLUdEd ITEMS
ac
d
e
f
*not shown
FIGURE 1: Included Items
There are four Hardware Bags included and are detailed in the
relevant instruction sections.
This kit requires a Novak HV Brushless ESC and
a 550-size HV Brushless Motor for completion.
Compatible Novak HV Brushless Motors:
STEP 4 INSTALL BRUSHLESS MOTOR (Continued)
2.
ATTACH HEAT SINK TO ADAPTER PLATE
motor’s heat sink on to the motor adapter plate — the motor’s
back endbell must be on the side of the
engraved name. Screw thread locking agent should be used
on these screws to prevent loosening
— see Figure 11
.
3. LOCATE & DRILL BATTERY BOX MOUNTING HOLES
aDrill completely through the two mounting screw holes in the
b. Position the battery box in the buggy. The front of battery box and
the battery wires must clear the steering servo and its linkages.
The back of the battery box must go inward as far as possible
away from the spur gear.
Refer to Figure 14
sheet) for correct location.
STEP 3 INSTALL BATTERY BOX (Continued)
5. INSTALL BATTERY BOX HOLD DOWN STRAP
a. With a 2.5mm Hex Wrench, screw one end of the battery strap
refer to Figure 7.
b At the other end, screw in an M4 post and use a body clip to
fasten the battery strap.
c.
the strap on the box. For thin batteries, attach one of the included
plastic spacers with an M3x8 BH screw on each 3mm spacer
hole — refer to Figure 8
Note: The M4 post should be placed on whichever end of the battery
box that has body clearance for it, which is usually the back.
For optimal side-to-side balance and vehicle performance,
Novak recommends installing one battery box. Novak’s battery
box can accommodate two, 2S Li-Po packs, which provides excellent
power and runtime.
For Dual Battery Box Setups: Refer to Figure 15 on the backside
box, and we don’t recommend it.
STEP 1 - REMOvE NITRO COMPONENTS
XRAY XB8 Buggy Shown
1.
REMOVE NITRO COMPONENTS
Remove the following items from your buggy (see Figure 2
Nitro Engine
(keep for all conversions)
parts
engine (keep mounting screws)
2. CLEAN BUGGY
If you are starting with an old buggy that is full of greasy dirt, we
highly recommend that you thoroughly clean your buggy.
FIGURE 2:
Buggy with Components Removed
(continued)
For STEPS 2-5: Refer to the vehicle-specific sheet that
is located in the bag with the motor adapter plate.
c. With the battery box in the correct location (refer to Figure 14
down through the hole in the battery box — Refer to Figure 6.
d.
From one of the Battery Box Hardware Bags, gather the needed
screws and washers — see table & Figure 5. A button head (BH)
screw mounts the battery box to the plastic stone guard, and the
e. After you have marked the hole, remove box and drill a 4mm hole
in this location. Using a 2.5mm Hex Wrench, mount box with the
proper screw (see table) and correct number of washers. Snug up
screw. This allows you to more accurately locate second hole.
f. Repeat steps c through e for the second battery box hole — see
Figure 7 for completed battery box.
Note: If hole is in the metal chassis, the hole must be countersunk
on the bottom of the chassis.
4. MOUNT BATTERY BOX
Remount the battery box with the proper screws, washers and
rubber foot (if needed).
•
Screw from the bottom of the chassis.
•
If a rubber foot is used, it will go under the inside rear corner of
the battery box for more rigidity, except Losi 8ight — see Figure
14 (
Note: In some installations, some of the stone guard screw posts
may interfere with the ribs on the bottom of the battery box. Simply
remove that portion of the rib until you have proper clearance.
When you are done, you should have a stable battery box with
little rocking motion.
M4x16 BH Screw (2)
M4x20 FH Screw (2)
M4x20 BH Screw (2)
M3x8 BH Screw (2)
M4x9 Washer (6)
M4 Post (1)
Body Clip (1)
Rubber Foot (1)
Plastic Spacer (2)
FIGURE 5:
Battery Box Hardware Bag Contents (#65-5010-1)
Note: There are two bags included — one for each battery box.
The following instructions are for a single battery box installation.
1.
LOCATE POSITION FOR BATTERY BOX
For the best side-to-side balance, we recommend installing the
battery box on the right side of vehicle (left side for Losi 8ight).
2. SELECT PROPER BATTERY BOX & HARDWARE
On the bottom of the battery box, there is a LEFT and RIGHT
notation. Follow the list below to know which box and what hardware
is used to correctly mount the battery box in your vehicle.
Model Number
Battery
Box(es)
Screw
Front*
Screw
Rear*
Front/Rear
#Washers
Rubber
Foot
#5010
Associated RC8
(Horiz)
Left BH FH 1
#5010
Associated RC8
(Vert)
Left FH FH 1
#5011
CEN Matrix
Right FH FH
#5012
Hot Bodies Lightning
Left BH FH 1
#5013
Kyosho Inferno
Left BH FH 1
#5013
Kyosho Inferno
(Dual)
Both BH (2) BH (2)
#5014
Mugen MBX5
Right BH FH 2 / 4 1
#5015
OFNA 9.5 / Ultra
Right FH FH 1
#5015
OFNA 9.5/Ultra
(Dual)
Both BH (2) BH (2)
#5016
OFNA Hyper 8
Left BH FH 1
#5017
OFNA Hyper 7
Left BH FH 1
#5018
XRAY XB8
Left BH FH 1
#5019
Losi 8ight
Left FH BH 5 / 4 1
(continued)
M3x16 BH Screw (2)
M3x8 FH Screw (4)
M4x10 FH Screw (4)
M4 Nylon Insert Lock Nut (4)
FIGURE 9:
Motor Hardware Bag Contents
(continued on back)
FIGURE 8:
Battery Box with Thin Batteries
FIGURE 6:
Sample Location
of Drilled Mounting
Holes for Battery
Box.
XRAY XB8 buggy
shown. Refer also to
Figure 14 on insert.
spacers
P2 P3
FIG. 7:
Completed
Battery Box
a
e
c
d
FIGURE 10:
Motor
Heat Sink
Installation
Clamping holes in
FIGURE 4:
ModiedServoTray*
Be sure to smooth
sharp corners and keep
mounting holes intact.
*OFNA Hyper 7 Servo Tray shown
For Losi 8ight Vehicle:
refer to Figure 16
1.
REMOVE & MODIFY SERVO TRAY
Cut off the part of the servo tray that holds the throttle servo. This is
best done with a Dremel Tool with a carbide cutting wheel. Round
off the sharp corners where necessary — see Figures 3 & 4.
Make sure that the three or four (depending on kit) servo tray
mounting post holes remain intact.
2.
RE-INSTALL STEERING SERVO ASSEMBLY
Install steering servo assembly to chassis and hook up steering
linkage. Refer to Figure 14
(or Figure 15 for
dual battery set-ups if applicable).
•For Associated RC-8:
You can either mount the steering
FIGURE 3:
Servo Tray*
Cut servo
tray along
line with a
Dremel Tool
Hardware Bag contents in Figures
5, 9 & 13
used for comparison.
A Novak 550-size brushless motor is required for this
conversion kit. If the motor does not have a 5mm output shaft,
the motor needs to be upgraded (Novak Kit #5924). This step uses
parts from the Motor Hardware Bag
— see Figure 9
.
STEP 2 - INSTALL STEERING SERvO
1.
INSTALL MOTOR HEAT SINK
a. Remove front endbell and sleeve of Novak
— being careful not to lose any shim washers.
b. Using the included cotton swab, apply a thin coat of thermal
paste to outside of the motor’s stator and to the inside of the
heat sink sleeve.
c. Slide heat sink onto motor, being sure that the two clamping
screw holes in the heat sink face the outside of buggy
— see
Figure 10
.
Refer to Figure 14 (or Fig. 15 for applicable dual
d. Replace front endbell and tighten the three motor screws.
e.
Slightly re-loosen the three motor screws and,
clamping screws.
f.
on the motor’s front endbell.
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