Basic Assembly Eng

Micom Car Rally Kit
Main Unit Assembly

Manufacturing Manual
Version3
1.00E Edition
19/06/2006
Japan Micom Car Rally Executive Committee
Main unit assembly manufacturing manual
Important Notice
Copyright
*Copyright concerning this manual belongs to the Japan Micom Car Rally Executive Committee.
*This manual is protected by the copyright law and the international copyright agreement.
Prohibited Use
User must not do the following things.
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*Use wherein harm might be caused to life and human body by using the content of this manual
Reprinting, reproduction
Prior approval of Japan Micom Car Rally Executive Committee is necessary for reprinting and reproduction of
this manual.
Liability Restrictions
The information described in this manual is carefully prepared to ensure accuracy. However, Japan Micom Car
Rally Executive Committee does not assume any responsibility, if any damage occurs due to the description
error of this manual.
Other
In this manual the model car controlled by microcomputer is defined as the micom car. The information
contained in this manual represents information at the time of publication of the manual, and Japan Micom Car
Rally Executive Committee is liable to occasionally change this information or specification described in this
manual without prior notice. Refer to the information published on the official homepage
(http://www.mcr.gr.jp/) of Micom Car Rally when manufacturing micon car.
Contact Address
Head Office, Renesas Technology Micom Car Rally Executive Committee
162-0824 Tokyo Shinjukuku, Ageba cho,2-1 Karuko saka, MN Building
TEL (03)-3266-8510
E-mail : official@mcr.gr.jp
-1-
Index (Table of contents)

1. Outline ..........................................................................................................................3
2. Photograph on Completion ..............................................................................................3
3. Components list..............................................................................................................4
4. Essential Tools ...............................................................................................................5
5. Assembly.......................................................................................................................6
5.1. Gear Box Assembly ....................................................................................................................... 6
5.2. Manufacturing Connector for Motor ........................................................................................... 9
5.3. Tire Assembly.............................................................................................................................. 13
5.4. Battery box Assembly ................................................................................................................. 15
5.6. Manufacturing of front parts ..................................................................................................... 27
5.7. Installation of Stud ..................................................................................................................... 32
5.8. Assembly of chassis parts........................................................................................................... 34
5.9. GearBox Installation .................................................................................................................. 38
5.10. Servo Assembly/installation..................................................................................................... 40
5.11. Tire Assembly/installation........................................................................................................ 42
5.12.Circuit Board Assembly............................................................................................................. 46
5.13. Manufacturing and installation of cable ........................................................................................... 52
5.14. Installation of Kagu-Suberu (skidding material) ............................................................................... 58
5.15. Manufacturing of CPU board communication cable .......................................................................... 60
6. Conclusion...................................................................................................................65
-2-
1. Outline
This manual is meant for manufactures of micom car.

• Main unit of micom car (Ver.2) newly designed in 2002
• Sensor board (Ver.2) newly designed in 2002
• Motor drive board (Ver.3) newly designed in 2005
Though only the motor drive board (Ver.3) of the current micom car kit (Ver.2) was changed, since the detailed
version might cause confusion, it was made as [Micom car kit Ver. 3]
Though in this manual [motor drive board (Ver.3)] is explained with photographs, when using [motor drive
board (Ver.2)] + [motor drive extension board (Ver.2)], assembly should be done by replacing the board. The
mounting location of the board is mounted is unchanged.
While making kit main unit, it is assumed that the motor drive board and sensor board have already been
manufactured. Therefore, if they are not manufactured before, then assemble each board by referring to the
motor drive board manufacturing manual and sensor board manufacturing manual.
2. Photograph on Completion
After completion, the kit looks as shown in the photograph below. It has become more practical compared to the
previous kit.
-3-
3. Components list
Name Model Maker Quantity
Sports tire set (2 pieces)
Tire set (Comfort Industry series Tamiya Company 2
No.111)
Gear Box High-speed gear box HE Tamiya Company 2
RC-260RA18130
Motor Mabuchi Motor Co., Ltd. 2
6V Carbon brush
Universal plate set (Comfort
Plate set Tamiya Company 2
Industry series No.98)
HS-425BB
Servo 0.20second/60 degrees by 4.8V Hitec 1
and 3.3kg/cm
Pan head machine screw
(diameter 3mm×length 60mm)
Screw 2
31mm of front end of twisted
part
Screw 2
(diameter 3mm×length 20mm
Screw 4
(diameter 3×length 15mm)
Screw 2
(diameter 3mm×length10mm)
Plate screw (diameter 3mm
Plate screw 4
×length 15mm)
SJE-303 white, internal diameter
Teishin Electric
Delrin collar 3.2mm, external diameter 6mm, 2
Company
height 3mm
Nut Nylon nut 3mm 5
For 3mm screw, height 8mm

Stud 8
metallic, female-male
For 3mm screw, height 15mm
Stud 2
metallic, female-male
Flat washer
Washer Outside diameter φ8mm 30
Inside diameter φ3.2mm
Flat washer
Washer External diameterφ6mm 2
Internal diameter φ3.2mm
Spring washer
Washer 34
Internal diameter φ3.2mm
“Kagu-Suberu” round shape
”Kagu-Suberu” Nichias Corporation 1
diameter 37mm
MD-4B for 4 pieces of size AA
Battery box battery Takachi Electric Industry 2
W35×H19×D72.5mm
Toggle Switch MS240 Mamiya Company 2
10 color flat cable Approx.

Flat Cable
1.27mm pitch 50cm
Approx.
Cable Twisted wire Red 0.3KV 12 core
1m
Twisted wire black 0.3KV 12 Approx.
Cable
core 1m
-4-
Japan Aviation
10 pin female connector PS10SEND4P1-1C 6
Electronics Industry, Ltd.
RS-232C connector 9 pin female 1
RS-232C connector Connector cover for 9 pins 1
Rubber Bush BU-687 Special small Sato parts Company 1
Japan Aviation
2 pin female connector IL-2S-S3L 3
Japan Aviation
Contact pin IL-C2-10000 10
Proper
Solder Diameter 0.6mm
quantity
Heat shrinkable tube Transparencyφ1.5mm Fujikura Ltd. 10cm
4. Essential Tools
Manufacturing is possible with the help of following tools.
Tool Name Explanation
Minus and plus drivers are used. It is better to keep large and small size
Driver
of each type prepared
Pliers (large, small) Used for various operations.
Lead nipper Used to cut the wire and components of Industrial series of Tamiya.
Used to pare off the wire cover. Though it can be pared off by nipper, it
Wire stripper is comparatively difficult. Better to use P-906. of Hozan Tool Industrial
Co., Ltd.
Crimping tool/Pressure Used to fix the contact pin in the connector and wire. Better to use
pliers P-706 etc. of Hozan Tool Industrial Co., Ltd.
Saw for plastic cutting Used to cut universal plate set
Used to drill a hole. Though hand drill is OK, electric drill is

Drill
convenient. Drill bit is, Diameter 3.5mm, 5mm, and 6mm.
Used to fix flat cable and connector. Moreover, depending on the usage,
Jack/Vice
can be used for fixing of components.
The following are also necessary.
CPU board
It is a board of the microcomputer, main part, which operates the kit.
RY3048F-ONE
Rechargeable size AA
batteries 1.2V
Power supply to operate the micom car. 8 batteries can be operated.
Nickel metal-hydride
Moreover, the battery charger is also necessary.
battery
Or, Ni-Cd battery
-5-
5. Assembly
5.1. Gear Box Assembly
“MCR" stamp
1. This is [High-speed gear box HE] 2. This is [RC-260RA18130] manufactured by

manufactured by Tamiya. The photograph Mabuchi Motor Co., Ltd.
shows only one side set, however there are 2 Size is interchangeable to RE-260 which is
sets since right and left motors are used in kit. readily available in the market. The operating
voltage range is 4.5-6.0V. The carbon brush has
a longer durability than metal brush of RE
series. If higher voltage is applied, the speed
increases but the motor durability span shortens.
3. At first the pinion gear should be inserted in 4. The motor is installed in the gear box as shown
the motor. in the photograph. The motor has a cut as shown
in the encircled [c] part, should face upwards.
-6-
5. A plastic case is attached to the rear side of the 6. Screws are fixed in 3 locations.
motor.
1mm
7. A mark is put at the location in the photograph 8. It is an enlarged photograph. A mark is put at
after removing the perforated shafts from their about 1mm below the hole and is only one side.
respective boxes.
Note: There is 1 perforated shaft in 1 box.
2 are taken out from 2 boxes.
9. The part where the mark was put is cut with 10. Enlarged photograph.
iron saw. The cut edge is filed and made
smooth.
-7-
Joint Joint
21mm 3mm
11. Right side gearbox. Fixed at joint. The 12. Left side gearbox. Fixed at joint. The distance
distance between the gear box and the edge of between the gear box and the edge of the shaft
the shaft is adjusted to about 21mm. is adjusted to about 3mm.
13. Hereafter follow the handling manual which is in the paper box of the gear box set. The gear can be
selected from 2 types [A] 18:1 and [B] 11.6:1 but, currently [B] 11.6:1 has been selected. Yellow and
orange colored gear is used. This is the photograph after completion. The right gearbox is for right
side and the left side gear box is for left side.
14. Finally, the ceramic condenser attached to motor drive board (V0l.3) set is installed between the
terminals of the motor. Please refer to the motor drive board-manufacturing manual for details.
Note: In case of motor drive extension board Ver.2), though there is no ceramic condenser installed between the
motors, obtain the component separately and install it. Reset of problem CPU by electrostatic defect and etc. can
be eased.
-8-
5.2. Manufacturing Connector for Motor
×2
20cm
1. Make provision for two of 2 pin 2. Connector x 1 piece, contact pin x 2 pieces, red and a black
connectors, 10 contact pins (4 will wire are coupled. 2 cords of 20cm are made. Keep the
be used), red and black twisted wire remaining wire for later use.
(0.3KV, 12 center core).
Coating Copper wire
2mm
3. Crimp the contact pin to the wire. First, about 4. Set the copper wire in the center of the contact
2mm of coating/cover from the wire tip is pin so that the cover comes in the protruded
peeled off with wire stripper. triangular part.
1.7L
5. The center of contact pin is crimped. The 6. It is ok if it is same as shown in the photograph.
installation of copper wire uses the [1.7L] of
crimping tool. The crimping tool is pressed to
the maximum.
-9-
2.0L
7. Next is the crimping of the coating part. [2.0L] 8. It is ok if the metal is inserted into the insulation
of crimping tool is used. Since the coating part cable, same as shown in the photograph.
is crushed when pressed to the maximum, stop
the crimping tool to about 2/3 of the maximum
open state and maximum pressed state.
Black line
CoatingCopper
line 1 | JAE
Red line 1 2
9. If it crimped properly, it becomes as shown in 10. Contact pins are inserted in the connector. The
the photograph. There is probability of failure, connector photograph is seen from top. 1|JAE
because crimping is a comparatively difficult is written which can be seen if looked
work. carefully. [ 1] side is 1 pin.
However since there are 4 spare contact pins,
in case of failure these can be used. 2 pairs of
pins for each right and left side of motors are
used.
- 10 -
Black Red
Projection
1 2
1 2
Hole
11. The contact pin is inserted in the connector. 12. Red wire is put in 2 pin side after that.
The marked 1 pin side of the connector is
inserted with black wire, and the marked
2-pin side is inserted with red wire. As shown
in the photograph, the hole of the connector
and the direction of the projection of the
contact pin are matched and inserted. When
inserted till the end, a [click] sound is heard
and the contact pins get locked. Confirm that
the pins do not come out with a slight tug.
13. Next the wires are twisted. Red and black 14. It becomes as shown in the photograph.
wires are twisted and bundled together.
15. Since the length of the red and black wires 16. Cut and arrange them as shown in the
goes on changing as the wires are twisted, the photograph.
leftover part is cut in order to match them.
The twisting should be balanced well so that
the difference in the lengths is least.
- 11 -
Incision
Red
Black
17. The 3mm coating of the wire is pared off, and 18. After soldering, the upper side facing in the
soldered. photograph is red and also the side where
motor has incision is red. A black wire is
soldered to the motor terminal on the opposite
side.
Right gear box
Left gear box
19. The processing of the gear box is complete. The upper side becomes the right gear box and the lower
side becomes the left gear box.
- 12 -
20. The connector for the battery box is also 21. Connector is installed in the same way by,
made here. Connector, contact pin, and paring the coating of the wire and crimping the
remaining wire are used. contact pin.
1 pin is black wire, and 2nd pin is red wire.
(Refer to "12." on page 11.)
22. It is complete now. This wire is used in

assembling the battery box.
5.3. Tire Assembly
Front side Rear side
1. The contents are of the sports tire set. This is 2. One with more depth becomes rear side. The
used for making two sets. wheel hub (triangular components) is installed
from the rear side.
- 13 -
1 1
2 2
3. Two wheels fit the wheel hub (1 part of 4. Screws are fixed from front side.
photograph) for the hexagonal shaft fitting and
the other two wheels fit the wheel hub (2 part
of photograph) for a round shaft.
5. Rear side is fixed with nut. Nut wrench is 6. 4 pieces are ready now. Upper side is fitted with
inserted in sports tire. Wrench may break if it wheel hub for round shaft and lower side is
is tightened with too much power, because it is fitted with wheel hub for hexagonal shaft.
made of plastic.
7. It is completed by fitting tires.
- 14 -
5.4. Battery box Assembly
Front side Rear side
1. This is the battery box. Two styles of box are 2. The lid has been taken off.
processed. One is for Motor and the other is
for CPU.
8 For Motor 17 8
7
5.0 -2
3 .5 -2
30
15
8 17 For CPU 8
7
3 .5 -2 5.0 -2
30
15
3. This is perforation process diagram of the battery box. There are two types. Though hole of φ5mm is in
the same position on both boxes; hole of φ3.5mm are symmetrical on left-right, therefore utmost care
should be taken while drilling the holes as their positions are different.
- 15 -
4. Measurements are marked with pencil. Using a magic marker is also OK. Plus marks shown by arrow
indicate the place where holes are to be drilled. The hole is drilled using a drill but should be carried
out with utmost caution so as to prevent any accidental error.
5. Holes are drilled as shown by arrows in the photograph.
ド drill
リル
6.0mm
1. 2.
電Battery
池ボッbox クス
断面Section
3.5mm 3.
皿ネジがぴった
The plate screw is
り、収まり
installed ます
accurately
6. This part is fitted with the plate screw. 7. It becomes like this. While handling the plate
Therefore it is processed in such a way that the screw, it is difficult to stop the drill during the
plate screw can be fitted with diameter 6mm drilling, thus it is recommended that it should be
drill. done by hand
- 16 -
8. The side surface is drilled with diameter 9. Next, soldering is carried out. Gearbox, cable
5.0mm. Rear side is also drilled. With this the with connector, two-pin connector attached to
drilling of the holes is completed. CPU board, 2 switches, which are made at the
time of assembling 2 battery boxes are used.
25cm
10. Connector already manufactured at the time 11. This is the switch. There are two of them, for
of assembling gearbox is twisted in same way CPU power supply and for motor power
as before. It is twisted approximately at 25cm supply.
and it is not yet cut.
Cable is
Hole
inserted
on
the
right
side.
12. If all the screws that are attached to the 13. Battery box that has the hole drilled on right
switch are taken off, it becomes as shown in side is used. The cable is inserted from the
the photograph. Among these, components outside in the hole on a right side in the battery
enclosed with (black frame) are used. box.
Switch is soldered in advance.
- 17 -
14. As shown by arrow mark in the photograph 15. This is an enlarged photograph.
stopper knot is tied at approximately 25cm.
This part becomes more than 5 mm in
diameter and therefore it cannot come off
through the hole, through which it has been
passed.
5mm
16. The wire is pulled out from outside and it 17. Black wire is cut at the point shown in the
stops here, the soldered part does not have to photograph. The distance is approximately 5
bear more load. mm from left edge.
18. It becomes like this. 19. Red wire is also cut at the same length, and the
coating is pared off by approx. 2mm and
presoldered. Moreover, the terminal of the
battery box shown by the arrow is also
presoldered.
- 18 -
+
-
20. Black wire is soldered to the terminal on a 21. Red wire is connected to the terminal with a
minus side of the battery box. short side of switch.
22. The Surplus red wire left after cutting, is 23. Cut the wire at approximately 5cm. This wire
soldered to the long terminal of switch center. is soldered on the side with + on the battery
box.
24. Approx. 2mm of terminal coating is pared off 25. It becomes like this.
and then soldered.
- 19 -
Front
Outer terminal
Back
26. Switch is inserted from inside. 27. The switch is made in such a way that outer
terminal of the switch faces front side of the
battery box as shown in the photograph.
Tooth lock washer
Nut
28. Fit the tooth lock washer and nut. 29. Switch is fixed in straight position by the pliers
and it can be stopped by turning the nut for
4mm.
30. After it is fitted. 31. The inside wire is pressed below. The purpose
is to prevent the stopper from colliding, when
the lid of the battery box is closed.
- 20 -
Lid
32. It is a photograph where the lid was capped. If the wire is not pushed down, it gets stuck and the lid
cannot be closed till the end.
33. The battery box and the connector for the

motor power supply are complete and ready.
7～8cm
Hole
in
the
left
side.
34. Battery box for the CPU board is ready. First of all 35. 7-8cm of the wire at the end is left
the red wire and black wire of 2-pin connector without twisting. Further, terminals of
attached to the CPU board are twisted and battery box and switch are presoldered in
bundled together. advance. The battery box with a hole
Note: CPU board is not attached in kit. drilled on left side is used.
- 21 -
6～7cm
1. After the
2. Stopped knot
line is passed
36. After the wire is passed from outside, stopped 37. The black wire is turned back.
knot is tied at about 6-7 cm from the edge of
wire.
－＋
38. The Black wire is turned and cut as shown in 39. It becomes like this.
the photograph. Approximately 2 mm of the
coating from the edge of the wire is pared off
and presoldered. It is soldered to the part of
the battery box marked [-] sign as shown in
the photograph.
40. Pare off the red wire coating of the point for 41. Solder it to the short terminal of switch end
approx. 2mm and presolder it. side.
- 22 -
3cm
42. Cut the remaining red wire for approx. 3cm 43. Solder the wire to long terminal of switch
and pare off 2mm coating from both edges center.
and presolder it.
44. Solder the reverse side of wire attached to 45. Switch is inserted in the hole from inside.
switch center to the + side of battery box. Switch is fixed by nut and tooth lock washer
from outside by screwing in.
Front
External
Rear
46. As shown in photograph, the switch is put in 47. Inside wire is pushed out.
such a way that the external terminal of the
switch faces the front side of the battery box.
- 23 -
Lid
48. If the wire is not pushed up and the lid of the 49. After it is completed.
battery box is closed, stopper collides with
the wire and the lid does not close properly.
50. 2 battery boxes are arranged in the way shown in the photograph. If a white connector attached to the
left side battery box, then it is a battery box on CPU side and if a brown connector attached to the left
side battery box; then it is for the motor drive board side.
- 24 -
5.5. Processing of plate
1. The universal plate set is processed. The photograph shows 1 set of the universal plate set. In the kit, 2
such sets are used. Part encircled with c is cut beforehand. Cut-off piece is not used.
1 5 6 7 10
2. The line is drawn lengthwise at the 6th and 10th hole from the left and is cut on 2 lines using a plastic
cutting saw.
1 5 6 7 9 10 11
3. Cutting is complete. After cutting, filing is done and burr is collected. All 4 corners are rounded off
- 25 -
1 1 4
1
1 4 4 1
4. Another plate is also processed. The lines are drawn as shown in the photograph. A vertical line is
drawn at the 4th hole from the right and as shown in the photograph, 2 diagonal lines are drawn on the
left. Since screws will be fixed later to the hole enclosed in circle, the 5th hole from the left side should
be left.
Note: If you need the frame to protect servo, the vertical line must be changed 4th hole to 8th hole from
the right.
1 4 5 4 3 1
5. After cutting it becomes like this. The 2 diagonally cut ends are not used.
3 2 1
6. Processing of the angle material attached in the universal plate set. As shown in the photograph, it is
cut in the middle of 2nd and 3rd hole.
7. It becomes like this. The marked part is cut and filed.
- 26 -
5.6. Manufacturing of front parts
1. These are contents of servo box. The servo 2. Screws of the fixed servo horn are removed and
main unit contains the bag of joints. Contents the servo horn is taken out and kept.
of bag are not used.
3. This is aerial view of servo horn. 4. Holes of 3.5mm are drilled at 2 places of ○
mark shown in the photograph.
5. Servo horn is drilled after the holes. It is fitted 6. At the reverse side of servo horn, there is
in the plate having 3-drilled holes that are cut projection in the center part. This part is made
before. smooth with the file or cutter etc.
- 27 -
7. This is after filing is done. 8. It becomes flat/smooth.
5 4 3 2 1
1 2 3 4 5
9. Next, the servo horn and plates is screwed 10. The screws are inserted in the fifth position of
together. 2 screws and 2 nuts are used from the the upper row from the right side and the fifth
universal plate set. position of the lower row from the left side.
11. The part of servo horn where hole is drilled is 12. The plates fitted in the servo horn and angle
passed through the part where screw is materials, which are not cut, are prepared.
inserted and both are screwed together. If the
filing of the protruding part is not done in the
process7, screw can not be fitted properly.
- 28 -
13. The screws are fitted after matching c with 14. It becomes like this.
c and with .
15. Next is shaft installation for the front tire.

Here, 2 screws of 60mm, 2 Delrin collars of
3mm height, 4 flat washers, 2 nuts are used.
The nuts used are from the sports tire set.
16. First, the angle material of the smaller size that is cut previously is prepared.
- 29 -
17. A flat washer and the angle material are passed through the screw.
18. Next, the screw is passed through the angle 19. After the screw is passed through the angle, the
material of the plate side. short angle is screwed to the plate. 2 nuts and 2
screws from universal plate set are used.
20. Flat washers, Delrin collars, and nuts are 21. It becomes like the photograph. As the groove
passed through the screw in the order given. is only on half of the screw length, turning of
the screw is continued till the nut stops.
22. The opposite-side is also similarly fitted. 23. The shaft for the front tire is completed.
Confirm whether or not it is smoothly rotating
by turning the screw. When it is not rotating
smoothly, the positions of long angle and short
angle are adjusted in such a way that it rotates
smoothly.
- 30 -
24. Next, the servo is installed. 25. The servo is inserted in the servo horn, as
shown in picture.
100～
110 degree
100～
110 degree
26. Turn to full right. Turn up to approximately 27. If turned to full left, even left side becomes
100-110 degrees. When it does not turn up to approximately 100-110 degrees. If the degree
these degrees or when it turns more than these of angle of the left and right side differs then
degrees it means that left-right balance is not keep adjusting the insertion of servo horn till
proper. Therefore after turning to full right they become same.
remove the servo horn once and reinsert it so
that it can be turned in 100-110 degrees.
- 31 -
28. Finally connecting parts of the servo and 29. In the end the projected/protruding part shown
plates are screwed and the assembly is by c mark is cut by nippers etc. and then the
complete. The screws, while removing the process is complete.
servo horn in the beginning are used as it is.
5.7. Installation of Stud
1. It is manufacturing of the fuselage part of the micom car. 2 big plates and 8 stud of 8mm height, 8 flat
washers, 8 spring washers and 8 nuts are kept ready. The nuts used are from the sports tire set.
- 32 -
1 5 10 15 17
2. First, Stud is installed in the plate that is chamfered. The position is topmost and bottommost hole in
5th, 17th line from left side. The flat washer and the spring washer are inserted from reverse side and it
is tightened by fitting the nuts.
3. It is tightened from the top and bottom by using 2 wrenches from sports tire set. It is fastened tightly so
that it doesn’t become lose.
- 33 -
11
1 4 4 1
4. Studs are fixed in 1 more plate. 4 places where studs is fixed are 4th position from left and right side of
the bottom most line (line 1) and 4th position from left and right side of the 7th line from below as
shown in photograph. The flat washer and the spring washer are inserted and it is fitted with the nut.
5.8. Assembly of chassis parts.
1
2
1. (1) ~ (3) plates, 2 battery boxes, 4 plate screws of 15mm, 4 flat washers, 4 spring washers and 4 nuts
are used. The nuts used are from the sports tire set.
- 34 -
Battery box for

motor power
supply 3
1
1 6 6 1
2. Plate 1 is kept on top of plate 2. The position is adjusted in such a way that, bottom left hole of plate 1
is aligned with the hole of plate 2 in 6th position from left and 3rd position from bottom. Battery box is
kept ready as power source for motor.
1
1 2
3. Plate screw is passed through in the sequence of “ battery box → plate 2 → plate 1“ in the position 2nd
from left and 9th from bottom of plate 1 that is encircled with c mark. Flat washer and spring washer
are passed from the topside of this screw end and fixed with a nut in position.
- 35 -
4. Plate 3 is passed through the space between battery box and plate 1.
5 Plate 3
4
1
1 2
1 2
5. Plate screw is passed through from the lower side in the sequence of “ battery box→ Plate 3→Plate 1”
at the position indicated by c that is 2nd right and 5th in upward direction from the stud position shown
in the photograph. Then flat washer and spring washer are put and fixed by nut. Mount the plate 3 as
shown in the photograph by .
6. It looks like this from side view.
- 36 -
Battery Box for Battery Box for

motor CPU
7. Battery box for CPU board is also screwed by plate screws in 2 places having symmetrical positions
in similar method used for fitting battery box for motor.
8. The assembly of chassis part is completed.
- 37 -
5.9. GearBox Installation
1. Mount the gearbox on the chassis. 2 gearboxes, 4 screws, 4 flat washers, 4 spring washers and 4 nuts
are used. Screws used are from universal plate set and nuts used are from the sports tire set.
Left Gear Right Gear
2. Put and Mount in the directions shown in the photograph. Mounting/installation position for left
gearbox is shown by cand for right gearbox by.
- 38 -
Collide
Left Gear Right Gear
3. The position of the gearbox is reversed in the photograph as it is seen from the opposite side. (Refer to
“2.” on page 39. )
Gearbox must be partly chipped off because left gearbox collides at the part marked with c.
4. Cut the part of left gearbox shown as cin the photograph into V shape using either a file or large
nipper. Keep approx. 2mm depth. Now it will not collide even though mounted in the position
mentioned before. Cut/chip off the colliding part again if it still collides with the nut.
- 39 -
5. Pass the screw from the lower side. “Screw → gear box → plate” is the sequence. Flat washer and the
spring washer and nut are inserted from upper side of the screw and fixed. It becomes as shown with
symbol c.Gear box assembly is completed.
5.10. Servo Assembly/installation
1. Install the servo on the chassis. Align and fix the servo mounting holes with part of chassis marked as
c.
- 40 -
2. Use 2 screws of 15mm length, 2 spring washers and 2 nuts and bearings material of universal plate set
for assembly. Nuts used are from the sports tire set.
3. Pass the 15mm screw through plate, servo, bearing material, spring washer from the lower side and fit
it with the nut at the end. Use bearing material for strengthening servo assembly.
4. It is a top view. Here the Servo assembly is completed.
- 41 -
5.11. Tire Assembly/installation
2
1
1. Mount the tires. c is a component called as split pin. 2 split pins of c and 2 nuts of d are used. It is a
component of high-speed gear box set HE (High Efficiency).
2. Insert the split pin. Insert it in such a way that it is in the center as shown in the photograph. Push it
with pliers, as it is very hard. If the split pin is crushed and inserted, it can fall off/come off easily so do
not crush it.
- 42 -
Gap
3. Mount the tire that is made and kept ready. The tire that is fitted with the wheel hub for round shaft is
used as rear tire. Assemble in such way that the split pin and wheel hub groove match together.
Tighten the nut
4. Mounted. Inserted till inner side. 5. Fit the tire from side with the nut. Mount the tire
on a reverse-side similarly.
- 43 -
6. Next, mount the front wheel. The tire, which is attached with a wheel hub for hexagonal shaft is used
for front wheel.
7. The front wheel shaft is fixed by pliers and tires are screwed in. It is similar to inserting nut in the
screw. Here, there is a tire in place of nut. Keep turning until it penetrates.
- 44 -
8. Come close to be penetrated. 9. Penetrated.
5mm 5mm
10. Screw till the gap becomes 5 mm. Mount the opposite side tire similarly.
11. Assembly is completed.
- 45 -
5.12.Circuit Board Assembly
1. Install the motor drive circuit board, sensor circuit board, (Main , Sub) and RY3048F-ONE (CPU)
board on the main body. In case RY3048 or MS304CP01 boards are used for CPU board , refer to the
"Remodeling for using the RY3048F and MS304CP01 board” described later. Use 8 screws of 10mm
length,2 screws of 15mm, 2 screws of 20mm ,10 flat washers,2 small flat washers, 12 spring washers, 2
studs 15mm high, 2 nylon nuts, 2 angles that are already cut and 2 "I" shape horns. 6 screws of 10 mm
are from universal plate set and remaining 2 are components from kit. Other nuts and screws are also
components of kit.
The nylon nut (right side photograph) is difficult to fall off even in case of vibrations as
the ring shape nylon is built in the nut that causes friction with the screw.
This time the sensor circuit board, is used in the movable part to maintain the constant
distance with the course for Micom car. They are frequently used in the radio control
model car etc.
2. Mount the motor drive circuit board first. 3. The screw is fitted in the sequence of “ Stud →
Match 4 holes of the circuit board with the 4 circuit board →Flat washer →Spring washer ”.
studs. It is fitted in 4 places.
- 46 -
4. Same as shown in the photograph. 5. Next, mount the CPU board. It is screwed and
fixed using flat washer and spring washer in the
2 places near the motor drive circuit board.
6. Mount 15 mm high studs in the 2 holes to the 7. Mount in the sequence of “ Flat washer →
left of the CPU board. Spring Washer → Stud ”. Tighten the studs
using plastic wrench from the sports tire set.
8. 2 screws and 2 studs are mounted. 9. Connect the connector from the battery box to
the CPU board.
- 47 -
out
put
side
Input
Side
The side with the
resistor network is
input side.
10. Connector is attached. 11. Mount the sensor sub circuit board on the studs
of the CPU board.
Mount in 2 places in the sequence of “ Flat
washer → Spring washer → 10mm screw ”.
The input connector side is the servo side (left
in the photograph).
Input Side Output Side
12. Side view. 13. Next, mount the sensor circuit board with the
movable part which is used to maintain the
constant distance with the course for Micom
car. Use angle material, 15mm screws and
nylon nuts.
14. Fit the screw from inside and stops with the 15. It is an enlarged photograph. It is difficult to
nylon nut. Should be able to move up and move when tightened too much and rattles
down as shown by arrows. when too loose. Adjust the firmness so that
angle material moves perfectly.
- 48 -
16. Complete the other side assembly in the same way.
17. Next, mount the sensor circuit board. Take 2 each of “I” horn, 20mm screws, small flat washers,
spring washers and nuts.
- 49 -
18. Cut the “I” horn at the base. It is easily cut 19. Magnified photograph after cutting. Do not use
using nipper, as it is a plastic component. the right side part.
20. Cut the projected/protruded part diagonally, 21. It becomes like this after cutting.
as shown in the photograph, as it may hit
against this part while fitting the screw.
22. Pass the screw from lower side through the position of the sensor circuit board as shown in the
photograph.
23. Place the “I” horn that is cut before in the screw.
- 50 -
24. Insert the screw from lower side of the head 25. Use pliers etc. as wrench cannot be used for
of the angle material then passing flat washer fixing the nut. When it is fitted it looks as
and spring washer and fit it using the nut. shown in the photograph.
26. With this, the sensor circuit board assembly is completed.
- 51 -
5.13. Manufacturing and installation of cable
1. Connect ten-pin connector with flat cable. 6

pieces of 10 pins female connectors and flat
cable of 51cm length are kept ready. The 51
cm concerns with a multiple of 3.
The minimum length of the flat cable that we
can cut is just 3cm.
B
A
2. Connection diagram for flat cable installation. Cable A is connected to sensor circuit board ~ sensor sub
circuit board, cable B is connected to sensor sub circuit board ~ CPU board (port 7) and cable C is
connected to CPU board (port B) ~ motor drive circuit board.
27cm of cable A and 12cm of cable B, C each are made. A little shorter length is also permissible but
there may be cases where distance is increased after reconstruction.
Cutting part Cutting part
3cm 3cm 3cm
3. Since the flat cable of the kit is 51cm, cut it in 3 pieces, each of 27cm, 12cm, 12cm. As shown in the
photograph, the flat cable is repetition of 3cm of connected 10 wires part and 3 cm of separated 10
wires part. Position to be cut is central of the connected 10 wires part.
- 52 -
4. Cutting can be done by ordinary/usual standard 5. If it is right-angled like this, it is OK.

scissors also. The cutting direction has to be at
right angles.
C
6. After it is cut.
Stopper
7. The flat cable is inserted from the place where the T sign on the 10-pin connector is printed. The
stopper is made on the reverse-side such that the inserted cable stops there. Each pin in the 10-pin
connector has V-cut tooth.
Brown Black
8. Pin #1 of the connector is shown by T sign. 9. Inserted till the flat cable reaches the stopper on
A brown colored wire of the flat cable is fitted reverse-side.
Pin #1 together and inserted in crevice of
connector.
- 53 -
10. In the case of applying pressure to the flat 11. Hold while pressing the connector edge from
cable, special pressure application device is both sides. While doing this, precaution is
used. However, ordinary/usual vise is also taken so that the flat cable is not inclined and
acceptable. shifted.
12. Half of the connector is placed between the 13. Tightening is done by turning the handle of the
vise. Precaution is taken so that the flat cable vise. The force of tightening is such that it cuts
does not shift. a little bit into the flat cable.
14. Insert the10-pin connector into the vise with 15. The connector was pinched completely
your thumb so that the whole of connector is between the vise.
pinched between the vise
- 54 -
16. The vise is tightened. Ten all wires of the flat 17. If it is tightened little by little, "snap" sound is
cable are wedged into the V-cut pins of the heard and if tightened still further, the sound
connector at once. "snap" is heard again. It means you hear the
sound “snap” twice. You can understand right
and left stoppers of the connector and entered
completely with the sounds. Tightening is now
complete.
18. Is, as shown.
19. The opposite connector is installed. When a brown colored wire of the flat cable is fitted Pin #1 (T)
of connector together and the final shape of the cable will be the crank like the above.
- 55 -
A
B
20. Three are made. The pressure application of flat cable is completed.
C
B
A
21. Three cables are fixed to 10-pin connector.
Right motor
Left motor
Motor power supply Servo
22. The connectors of servo, motor power supply, right motor and left motor are also wired together.
- 56 -
Flat cable
Motor supply
Black
Yellow
Servo
Left motor Right motor
23. Enlarged photograph of motor drive circuit board (Vol.3) part.
Flat cable
（From below plate）
Motor power
Left motor
Right motor
Servo
Black Yellow
24. Incidentally if motor drive extension circuit board (Vol.2) is installed it becomes like shown here.
- 57 -
5.14. Installation of Kagu-Suberu (skidding material)
12～13mm
37mm
12～13mm
1. The skidding material called Kagu-Suberu is 2. Cut at approximately 12~13mm distance as

pasted to the reverse side of the sensor circuit shown in photograph. The lower side is also the
board. Round in shape with a diameter of same. It can be cut by scissors.
37mm approx.
3. It is installed at the location shown by mark O.
Adhesive face
4. The white surface of the Kagu-Suberu is a seal and when it is taken off, it can be pasted. This is then
pasted on the part marked by ○. The edge of Kagu-Suberu at ● part and the edge of circuit board
should be matched together.
- 58 -
5. Is, as shown here. Precaution should be exercised so that it does not cover/touch the Modulation-type
Photo sensor.
8mm
6. The side view looks like this photograph. Since the course and sensor always at constant intervals, the
sensitivity of sensor is not changed even before or after the downward and upward slope.
- 59 -
5.15. Manufacturing of CPU board communication cable
1. RS-232C of DOS/V personal computer is equipped with 9 pin male connector. Therefore, connector
to be created uses the RS-232C 9 pin female. Here, RS-232C 9-pin female, cover component, thermal
contraction tube and 3-pin connector cable enclosed in CPU board are used.
Note: 3-pin connector cable is not enclosed in the micom car kit.
1 2 3
2mm
2. A 3-pin connector used for communication. 3. It is a cable on a 9-P connector's reverse-side.

There is a projection between Pin #1 and Pin Insulation of the cable is pared off by approx.
#2 as shown by the arrow mark. The side that 2mm and it is presoldered.
has 1 pin is Pin #1.
- 60 -
1 5
2 3 5
6 9
4. The reverse side of 9 pin male connector is the 5. Hereafter the location where the pin is to be
surface to be wired. Blue part of the connector wired is presoldered and kept ready. Pin #2, #3,
holds the pin number and is seen, if looked #5, #7 and #8 are presoldered. In the
carefully. photograph, Pin #2, #3 and #5 have already
been presoldered.
8 7
3mm
6. In the photograph Pin #7 and #8 have been 7. Jumper of 3mm width is made by the
presoldered. remaining lead wire for jumping the Pin #7
and #8.
And both side of the jumper is presoldered.
8 7
10mm
8. Jumper wire is soldered to Pin #7 and #8. 9. Next, thermal contraction tube is put in the wire
before soldering the wire. Approximately 10mm
of tube is cut and inserted in 3 wires.
- 61 -
2 3 5
2 3 5
1 3 2
1 2 3
10. Next, 3 wires are wired to the connector. Wire 11. After wires are connected, it becomes like this.
connection is as follows,
Connector → RS-232C
1 2
2 5
3 3
12. Thermal contraction tube is pushed towards 13. It becomes like this.
the connector side. And, tube is contracted by
heating the tube with a drier or a soldering
iron, etc. At this time, precaution must be
taken while heating the tube because, if the
connector or the wire is heated too much, it
may melt.
14. Next, installation arrangements in 15. Wire is inserted in the 2 clasps/clamps and
connector case is done. Components shown in clamps are screwed together.
the photograph are prepared.
- 62 -
Little long
40mm
16. Clamp is positioned at a short distance from 17. Wire is tied making a stopper knot with clamps
the connector cover. Standard position of the at the position of the clamp adjusted.
clamp is approximately 40mm from the
connector.
18. Wire is set in the connector case. First of all, 19. Next, the connector is set in the case like the
clamps are put in ○ part. part highlighted with ○frame. At this time,
the cable is made in the shape of S and play is
brought about.
20. Screw and clamp as shown in the photograph 21. Screw passes through the clamp and screw is
are prepared. inserted in the connector in the direction of the
arrow.
- 63 -
22. Covered. Screw and nut are kept ready as 23. Connector is screwed in, at the 2 places
shown in the photograph. indicated by the arrow.
24. It is completed.
25. Incidentally, 3-pin connector is used by connecting it to the part indicated by c mark on CPU board.
- 64 -
6. Conclusion
With this, the manufacturing of main body of micom car is complete.

Next, development environment is installed in the personal computer by referring to "Development environment
installation manual". Additionally, operation test of the micom car being currently manufactured is done by
referring to "Operation confirmation manual".
- 65 -

Basic Assembly Eng

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Basic Assembly Eng

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Micom Car Rally Kit

Main Unit Assembly

Index (Table of contents)

This manual is meant for manufactures of micom car.

Nut Nylon nut 3mm 5

For 3mm screw, height 8mm

Toggle Switch MS240 Mamiya Company 2

10 color flat cable Approx.

Manufacturing is possible with the help of following tools.

Tool Name Explanation

Pliers (large, small) Used for various operations.

Saw for plastic cutting Used to cut universal plate set

Used to drill a hole. Though hand drill is OK, electric drill is

The following are also necessary.

5.1. Gear Box Assembly

1. This is [High-speed gear box HE] 2. This is [RC-260RA18130] manufactured by

5.2. Manufacturing Connector for Motor

Coating Copper wire

Right gear box

Left gear box

22. It is complete now. This wire is used in

5.3. Tire Assembly

Front side Rear side

7. It is completed by fitting tires.

5.4. Battery box Assembly

Front side Rear side

5. Holes are drilled as shown by arrows in the photograph.

Tooth lock washer

33. The battery box and the connector for the

5.5. Processing of plate

7. It becomes like this. The marked part is cut and filed.

5.6. Manufacturing of front parts

7. This is after filing is done. 8. It becomes flat/smooth.

15. Next is shaft installation for the front tire.

5.7. Installation of Stud

5.8. Assembly of chassis parts.

Battery box for

6. It looks like this from side view.

Battery Box for Battery Box for

8. The assembly of chassis part is completed.

5.9. GearBox Installation

Left Gear Right Gear

Left Gear Right Gear

5.10. Servo Assembly/installation

4. It is a top view. Here the Servo assembly is completed.

5.11. Tire Assembly/installation

Tighten the nut

8. Come close to be penetrated. 9. Penetrated.

11. Assembly is completed.

5.12.Circuit Board Assembly

Input Side Output Side

16. Complete the other side assembly in the same way.

26. With this, the sensor circuit board assembly is completed.

5.13. Manufacturing and installation of cable

1. Connect ten-pin connector with flat cable. 6

Cutting part Cutting part

3cm 3cm 3cm

4. Cutting can be done by ordinary/usual standard 5. If it is right-angled like this, it is OK.

18. Is, as shown.

21. Three cables are fixed to 10-pin connector.

Motor power supply Servo

Left motor Right motor

23. Enlarged photograph of motor drive circuit board (Vol.3) part.