Assembly Instructions

Step-by-step guide to assembling your Data Walker device.

Required Tools

• Small Phillips screwdriver
• Soldering iron and solder (for sensor wiring)
• Wire strippers
• Multimeter (for testing connections)
• Hot glue gun (optional, for securing cables)

Step 1: Prepare the Enclosure

1. If 3D printing, ensure all support material is removed
2. Test-fit the ESP32 board in its mounting position
3. Verify the display window is clear
4. Check that the USB port aligns with the enclosure opening

Step 2: Install the ESP32

1. Place the ESP32 board on the mounting posts
2. Secure with M2 screws (do not overtighten)
3. Connect the OLED display via I2C header
4. Route cables away from the USB port

Step 3: Wire the RJ22 Jack

1. Strip approximately 5mm from each wire end
2. Tin the wire ends with solder
3. Connect to ESP32 pins:
   • Pin 1 (Red): 3.3V
   • Pin 2 (Green): GPIO 34
   • Pin 4 (Yellow): GND
4. Secure connections with heat shrink tubing

Step 4: Install the Display

1. Position the OLED display in the window
2. Secure with a small amount of hot glue on corners
3. Ensure the display is level and centered
4. Connect the I2C cable to the ESP32

Step 5: Close the Enclosure

1. Route all cables neatly
2. Check no wires are pinched
3. Attach the enclosure lid with screws
4. Test the USB port is accessible

Step 6: Prepare the Wheel Sensor

1. Mount 3 magnets evenly spaced (120° apart) on the wheel
2. Use adhesive or drill shallow recesses
3. Ensure all magnets have the same pole facing outward
4. Attach the Hall sensor bracket near the wheel
5. Position sensor within 5mm of the magnet path

Next Steps

After assembly, proceed to flash the firmware and run the self-test to verify your assembly.