## Manual Scope

This manual uses the same part numbers from the numbered photo breakdown. Follow the build stages in order: frame, drive, sealed electronics, touchscreen, claws, remote, branding, wiring, water-resistance checks, and operation.

Wet-use rule: GAR-BOT is water-resistant only when electronics are covered by gasketed lids, cable glands, driver covers, buck covers, wire channels, and drip loops. Exposed electronics are bench/service-only.
45Numbered cards in the photo breakdown.
38Printable STL files in the verified set.
2Front claws mounted to the forward shoulder bridge.
4Direct-drive 24V wheel motors with IBT-2 drivers.

Open the complete GAR-BOT BOM for hardware, electronics, printed parts, and water-resistant materials.

GAR-BOT final layout reference with two front claws, 7 inch touchscreen, sealed body, and covered electronics.

## Real Photo References

### 1. Two claw assembly

Reference for the two forward claw shapes and pivots.

### 2. Claw servo controller board

One board per claw for servo channels.

### 3. IBT-2 motor drivers

Four motor drivers, one for each drive motor.

### 5. RP5 relay HAT stack

Main robot controller stack inside the sealed electronics bay.

## Tools and Materials

### Print Materials

- PETG or ASA for water-resistant parts.
- TPU, silicone sheet, or foam gasket tape for lids and bezels.
- M3 heat-set inserts and stainless M3 screws.
- Cable glands, bulkhead fittings, and drip-loop clips.

### Assembly Tools

- Soldering iron with heat-insert tip.
- Metric hex drivers, flush cutters, crimper, and multimeter.
- Thread locker for metal-to-metal fasteners only.
- Calipers for checking printed holes and gasket compression.

### Electrical Safety

- Fuse the 24V battery bus close to the battery.
- Test buck converter voltage before connecting the Pi.
- Keep servo power separate from Raspberry Pi power.
- Use one common ground point for logic reference.

## Bill Of Materials Summary

The complete BOM is available as a web page, Markdown file, and CSV file.

Group | Qty | Main BOM Items
--- | --- | ---
Controller and interface | 1 set | Raspberry Pi 5 with Wi-Fi, RP5 relay HAT, Pico Voice on the 40-pin header, 7 inch USB touchscreen.
Drive and power | 4 motors / 4 drivers | Direct-drive 24V gear motors, IBT-2 motor drivers, batteries, fuse, e-stop, buck converters, common ground block. No chain or sprocket drive.
Two claws | 2 sets | Two Keyestudio-style servo controller boards, 12 servos, left/right claw printed assemblies.
Remote transmitter | 1 set | RP Zero 2 W with Wi-Fi, Pico Voice board, LoRa transmitter path, 5V power, printed remote enclosure.
Water resistance | As needed | Cable glands, USB bulkheads, SMA bulkhead, gasket material, conformal coating, dielectric grease, stainless screws.
3D printed parts | 38 STL files | Frame, sealed electronics bay, covers, touchscreen mount, claw parts, remote case, branding badges.

Files: BOM web page, Markdown BOM, CSV BOM.

## Assembly Instructions

### Print, inspect, and prep the frame

Print the structural parts first. Remove support material, deburr cable slots, dry-fit all mating faces, and install M3 heat-set inserts before final assembly.

- Side rails run front-to-back.
- Crossmembers square the front and rear.
- Bottom skid plate, battery tray, and deck plate stack into the frame.

8 9 10 11 12 13 14 15

### Install motors, motor drivers, and power covers

Mount each motor at a wheel corner so it direct-drives its own wheel. Route motor leads away from signal wires. Install IBT-2 covers, buck converter cover, splash shields, and drip-loop clips before wet testing.

- Use one IBT-2 driver per motor.
- Do not install chain, sprockets, or exposed belt reductions in the active wet-use build.
- Keep 24V motor current on the fused switched bus.
- Leave service slack inside covered cable channels.

3 4 6 19 20 21 22

### Build the sealed electronics bay

Mount the Raspberry Pi 5 and relay HAT in the electronics bay. Use RP5 Wi-Fi for SSH, setup, touchscreen/API service, and local maintenance. Confirm Pico Voice remains on the 40-pin header. Route all external wires through the gland panel, then seal the lid.

- USB ports: left claw, right claw, touchscreen, LoRa/radio or powered hub.
- Do not use FT232RL USB-TTL in the active RP5 USB plan.
- Measure 5.1V supply before connecting the Pi.

5 16 17 18 42

### Install the 7 inch touchscreen frame

Bolt the uprights to the deck, attach the top tie bar, seat the screen in the bezel, and fit the rain hood. Check cable strain relief before closing the electronics bay.

23 24 25 26 27

### Mount the two front claws

Bolt left and right base mounts to the forward shoulder bridge. Add shoulder pivots, servo pockets, wrist cradles, palms, fingers, link bars, gear guards, wire covers, and controller covers.

- Confirm left and right claws mirror each other.
- Run servo wires inside forearm covers.
- Use one servo controller board per claw.

1 2 28 29 30 31 32 33 34 35 36 37 38

### Assemble the remote transmitter

Place the Raspberry Pi Zero 2 W and Pico Voice board inside the remote case. Use Zero 2 W Wi-Fi for SSH, Picovoice setup, and short-range LAN command tests. Mount the LoRa antenna bulkhead through the wall and verify the remote boots before closing the case.

7 39 40 41

### Install K2Aley branding and warning badges

Install the lid badge, side badges, and water warning badge after wiring and sealing checks are complete. Keep badges clear of gasket surfaces and service screws.

43 44 45

## Wiring Summary

System | Connection Rule | Check Before Power
--- | --- | ---
24V motor bus | Battery pack to main fuse, emergency stop, switched 24V bus, then IBT-2 motor drivers. | Fuse installed, e-stop opens bus, no loose strands.
RP5 power | 24V-to-5V buck output feeds Pi 5 at 5.1V with common ground. | Measure voltage with multimeter before plugging in RP5.
Servo power | Servo buck feeds Keyestudio servo V/G rows. Pi does not power servos. | Servo voltage is correct and ground is common.
USB | RP5 has four USB ports: left claw, right claw, touchscreen, LoRa/radio bridge or hub. | Pico Voice is on the 40-pin header, not USB.
Wi-Fi | Both Raspberry Pi 5 and Raspberry Pi Zero 2 W have Wi-Fi for SSH, setup, API testing, and short-range LAN command tests. | Both Pis join the expected LAN and respond at their assigned IPs.
Remote | RP Zero 2 W connects to Pico Voice and LoRa path. | Remote boots and radio serial path responds.

## First Power-On and Operation

1. Lift GAR-BOT so wheels and claws cannot hit anything.
2. Power the 5V buck alone and confirm Raspberry Pi 5 boots cleanly.
3. Confirm the touchscreen turns on and touch input works.
4. Connect left and right claw controllers and confirm serial devices appear.
5. Enable motor power with the e-stop reachable.
6. Jog each motor one at a time at low speed.
7. Open and close each claw slowly while watching for binding.
8. Test LoRa/remote commands before ground driving.

Shutdown: stop motion, disable motors, shut down the RP5 software, then switch off the 24V bus.

## Water-Resistance Test

1. Power off GAR-BOT and remove battery power.
2. Place dry paper towel strips inside electronics bay, driver covers, buck cover, and claw controller covers.
3. Close all lids, glands, and covers.
4. Mist the outside lightly for 30 seconds.
5. Wait 10 minutes, then open covers and inspect the paper.
6. Fix leaks before powered testing.
7. Repeat with wheels and claws moving off the ground.

GAR-BOT is not designed for submersion, pressure washing, or deep standing water.

## Maintenance and Troubleshooting

### Before Each Run

- Check tire/wheel fasteners.
- Check claw pivots and link bars.
- Inspect cable glands and drip loops.
- Confirm e-stop and fuse are installed.

### If Motors Do Not Move

- Confirm 24V bus is enabled.
- Check IBT-2 logic VCC and ground.
- Verify RPWM/LPWM GPIO wiring.
- Test one motor/driver at a time.

### If Claws Bind

- Back off pivot screws slightly.
- Check mirrored left/right bases.
- Re-center servos before installing horns.
- Inspect forearm wire cover clearance.

### If Water Gets Inside

- Stop and power off immediately.
- Dry the area fully before testing.
- Replace or compress gasket material.
- Move cable entry to a gland or bulkhead.

## Final PASS Checklist

- All 38 STL parts are printed, deburred, and checked against the part accuracy report.
- Frame is square and all heat-set inserts hold.
- Four motors spin in the correct direction at low speed.
- Both claws move without binding.
- Electronics, drivers, buck converters, and claw boards are covered.
- RP5 local control, touchscreen, remote transmitter, and LoRa path pass bench checks.
- Water-resistance paper towel test passes with no dampness inside protected bays.