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ID

Value

Type

Identification

Polarised Yes - line up black band No No No No No Yes - positive lead is l No Yes - positive lead is l No No Yes Yes Yes Yes No

D1 1N4148 on diode with R1 15K R2,R3 1K R4 4K7 R5/R6 680R R7 180R R8 10M C1-C5 onger C6 C7 onger C8,C9 C10/C11 U1 U2 U3 Q1 Y1 1uF 1nF 10uF

Diode 4148, small, orange white band on PCB Resistor br/grn/blk/red/br Resistor br/br/blk/blk/br Resistor yel/pur/blk/br/br Resistor Resistor br/yel/blk/pur/br Resistor br/grn/blk/blk/br Capacitor Capacitor Capacitor 1uF or 1u 35 102 10uF or 10u 25 104 27 or 33 MAX232 78L05 4060 (74HC4060) BC549 large silver thing

0.1uF Capacitor 27/33nF Capacitor 16pin 3 pin 16pin 3 pin RS232 Driver Voltage Reg binary counter NPN Transistor

2.45mhz Crystal

J1,J2 5 pin 90deg Header ing outwards though) DS1 onger DS2 onger DS3 onger Red Green LED LED

gold pins with plastic No (need to get pins fac red... green... yellow... Yes - positive lead is l Yes - positive lead is l Yes - positive lead is l

Yellow LED

Suggestion construction 1. Place the diode, D1. Bend leads down at right angles, close to body 2. Place the resistors, R1,R2,R3,R4,R8. Bend leads down at right angles, close t o body 3. Place capacitors in middle of board, C9, C6, C11, C10. 4. Place the two ICs, U1 and U3. The small semicircle on one end of the ic shoul d match the orientation on PCB. The dot one on corner of the chip should also ma tch the square pad on the PCB (only one of the 16 pins hs a square pad. Bend the pins inwards slightly using a flat object, such as the side of a table to make it fit easier. 5. Place capacitor C8, voltage reg U2, transistor Q1 at top left the transistors legs so theyre straight and close together (like ) if they are not already. Solder carefully as the legs are very e the voltage reg and transistor match the silkscreen overlay on their flat side to the right. of board. Bend the voltage reg close. Make sur the board, with

6. Place the 2 x 5 pin Headers, so they face outwards on either side of board. G ently push into holes, theyll fit, just need to be done carefully (dont mash it in basically, just push firmly)

7. Place the crystal, Y1. This is tricky, as the crystal needs to be suspended i n the air. To do this, press down on the ends (rather than close to crystal body ) of the two leads until the leads are facing down at 90 degrees - ensure the le ads DO NOT touch the crystal body. Place into the PCB, and allow the crystal to site parallel to the pcb, about 4-5mm above it (so its above the top of the plas tic on the headers, and away from contacting anything. Crystal will hang over th e edge a bit if u have done this correctly (if it doesnt, then the leads may be touching the crystal body. 8. Place the capacitors, C7,C1,C2,C3,C4,C5. Note the longer leg is the + and sho rter leg -. Also, one of the legs may be marked - (for eletrolytic) or + (for ta ntalum). 9. Put the two serial connectors on to the end of the board - the Female connect or on the left (near capacitors), the Male connector on the right (near crystal) . The outside pins will bend out slightly to get all 5 pins in the 5 cups. Once the pins from both sides are in the cups, put the board into the plastic connect or housing, and adjust how far the pins are in the connector cups so that the co nnectors sit nicely in the grooves in the housing. Solder whilst the connectors and PCB remain in the housing is the safest way to ensure the connectors fit nic ely. Dont let too much solder flow into the cups (as it may be drawn into the co nnector, stopping the male serial port of a laptop from inserting all the way in . 10. Place the 3 LEDs. The LEDs are the two holes on the left or rightmost edges of the board (for Red and Green/Yellow LEDS respectively). The holes next in are for the resistors that go in after. This part is too hard to explain, so youll have to use your own common sense to get the led in. The LED is intended to poke through the holes in the serial connectors, so that it can be seen with the pla stic connector sealed. The longer led is the positive one (the side with the sli de of plastic cut out of the LED is the negative). The Red LED goes top left of board, on the outermost two holes on the left. The positive hole is the BOTTOM h ole. The Green LED goes to the top right of the board, with positive hole being the TOP hole. The Yellow LED goes to the bottom right of the board, with the po sitive hole being the TOP hole. 11. Place the resistors for the LED's, R5,R6,R7. These resistors go in standing up, meaning one lead of the resistor is bend down alongside the resistor body. R 7 is 180R and goes in the holes second from the left of the board (the left most two are for LED). R5 is 680R and goes in the bottom right, second from the righ t, and R6 is 680R and goes in the top right, second from the right. PCB Complete! Dont seal it in the housing yet though, wait till it's tested firs t! 12. Strip 20mm of the outer sheath from the 2M cable. Any more and the serial pl ug we're putting on one end will not have the outer sheath to clamp (and thus ev entually the inner wires could be exposed). The the green wire away at the base of the sheath (as we dont need this one). Strip the remaining 5 wires about 5 mm . 13. Locate the second female solder cup connector, and the plastic connector hou sing (grey). When looking at the back of the connector, the top row pins are lab elled 1 to 5, left to right. The following wires should go in each cup: 1 - White (CLK) 2 - Black (GND) 3 - Red (IGN/12V) 4 - Blue (RX) 5 - Yellow (TX)

Solder wires into cups. Locate 2 clamps, 2 shortest screws from connector shell packet. Optionally put a few layers of Place clamp on, with screws on lightly. P ut connector into shell to determine position to tighten clamp. Remove and tight en clamp, then place back in, put shell together, and secure with 2 hex nuts and 2 screws (with half thread). 14. Locate the consult plug, 5 consult pins, and the other end of the cable you just put a serial connector on. Strip about 40mm of outer sheath from the cable. Cut the green wire off again. Strip the remaining 5 wires about 5mm. At the end of each pin (the crimp/top side of pin, not blade) there will be two sections t hat would normally be crimped in somehow. As most of us will not have a crimping tool for this, then the following can be performed: * Cut the bottom (longer, but shorter) tabs on both side (want to roughly half t he height of them so pins go in connector. * Bend each side of the top tab in with some pliers. Just bend at 90 degrees wil l suffice. Once both are bent in, may need to pinch it sideways/top to bottom in order to make that section a bit smaller/squarer so it fits into the consult pl ug. * Insert the stripped wire into the pin for soldering. Only insert it so far as where the second tab finishes - we dont want any solder past this point (as part of the plastic consult connector inserts past here). * Solder wires into pins. Solder the Blue, Yellow and Red wires, then flip cable over and solder the White and Black (this is because those two sets of pins fac e opposite ways since they are on opposite rows in connector). 15. Now pins are ready to be inserted into consult connector. Get the consult co nnector, and look of the back of it, turning it around so the flat side is to th e right, and the rounded side to the left. From here, we insert 2 wires in the t op leftmost two positions, 2 in the bottom leftmost two positions, and one in th e top rightmost position. Back of connector (B = Blue, Y = Yellow, R = Red, K = Black, W = White) ___________________ / | | B Y - - - - R | | | | K W - - - - - | \__________________| Insert the wires into their positions as show. The top of the pins (the side wit h the line thru middle, side that was soldered) goes towards the outside of the connector (both top and bottom, so top row faces up, bottom faces down). Push al l the connectors half way in, then push them as far as u can in with your finger nail on the pin (dont try push in via the wire, it will just bend as not strong enough). Once in about 3/4, you can pull it all the way through with a pair of n eedle nose pliers. Grip the pin firmly and draw in. 16. With pins now in the consult connector, we (attempt) to seal them in with th e plastic tabs that are hanging off the connector. Push them in, then the tiny t abs should lock in. You may have trouble locking them in if too much solder was applied to the wire/pin. Do you best, then take some electrical tape and start w rapping from the connector (around the sealing tabs) and up until you pass where the sheath was cut off at.