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Roller – Dingo: Assembly Guide
From time-to-time, it might be necessary to disassemble your Roller / Dingo in order to perform maintenance tasks, or to install custom / replacement parts. The disassembly / reassembly procedure is quick and straightforward – however, it should be carried out carefully, mainly due to the small size of certain components, which can be easily misplaced or damaged.
Failure to follow the disassembly / assembly guidelines described here might lead to issues such as:
- Misfires, due to bad contact of an internal or external component.
- The button might be hard to push, get stuck or not lock properly.
- Big voltage drops.
- Permanent component deformation or damage.
- …
Contents
1. Disassembly
Following these steps will allow you to completely disassemble the unit. Depending on the component that you intend to inspect or service, some of these steps might not be required.
A. Disassembly of External Components
All external components of the Roller / Dingo should be periodically disassembled and inspected / maintained, since they make up the negative-side of the mod’s circuit. The only exception is the button, which is electrically isolated for safety reasons.
The external, current-carrying components are:
- The 510 connector.
- The External Switch Housing.
- The Main Tube.
- The Bottom Cap.
The Main Tube of the Roller is a two-piece component. It consists of an Internal Tube, which is mounted on the External Switch Housing and an External Tube, which slides over the Internal Tube. The tube of the Dingo is a fixed-size, 18350 piece.
The Bottom Cap also consists of two pieces, since the bottom disc (where the serial # is located) is removable. For RO40 / DI40 units and onwards, an allen key can be inserted in the vent to easily remove the disc or adjust its height.
To disassemble the above components, follow these simple steps:
- Un-screw the 510 connector from the External Switch Housing.
This can be easily done by using a thin coin — insert the coin into the slot found on the 510 connector and use it to easily loosen it from the External Switch Housing.
- Un-screw the Main Tube from the External Switch Housing.
If you own a Roller, you will need to loosen the Outer Tube first, and then unscrew the Inner Tube from the External Switch Housing. If you own a Dingo, then simply loosen the fixed-length 18350 Tube and detach it from the External Switch Housing.
- Detach the Bottom Cap from the Main Tube by simply un-screwing it.
The Bottom Cap includes a black washer and a brass spring, which you can also remove for maintenance. If you have an RO40/DI40 series unit or newer, the bottom disc can also be detached by using an allen key.
B. Disassembly of the Switch
The Switch Assembly, which is located in the External Switch Housing, contains all switch components and is removable and 100% serviceable. To remove the Switch Assembly from the External Switch Housing, follow these steps:
- Remove the Button from its Axle.
The easiest way to do this is by gently lifting the button from the axle by using a tea-spoon or coin. First, slightly lift the top-side of the button closer to the 510 connector, and then, do the same for the opposite side of the button. Repeat carefully until the button pops out.
Important: Before removing the button, you need to twist it to a position that allows the next step to be completed. The right position is the one where the button can be pressed deeper. In the case of RO25/RO40/RO50 revision switches, this will be the “on” position, while in the case of most RO60 switches this will be any of the “locked” positions.
Removing the button will expose: a) the top of the Switch Axle, where the button is mounted, and b) a black delrin Washer.
- Remove the exposed delrin Washer from the External Switch Housing.
The easiest way to do this is to gently pull the washer out the hole with a pair of tweezers, a small screwdriver, or other similar object. Insert the tweezers’ tip deep into the exposed hole and progressively lift the washer from below by applying the same side-to-side technique you used to remove the button in Step 1.
If you maintain the switch on a regular basis, you may find it easier not to install the delrin Button Washer at all. This part is entirely optional and only helps keep some dust out of the switch.
- Un-screw the 510 Connector and remove the Switch Assembly from the External Switch Housing.
If you haven’t done so yet, remove 510 Connector with the help of a coin. To remove the Switch Assembly, you will need to press the axle with your thumb and at the same time push the switch assembly out of the metal housing. This might be easier if you insert the back side of a pencil or pen into the hole of the removed 510 connector and use that to gently push down the switch assembly.
Important: The above procedure should always be carried out inside a deep bowl or bag, with the axle facing down. If the switch assembly is removed without keeping the axle in place, the latter one might literally fly away, along with every switch component mounted on it.
- Take out the Axle and remove both Contact Pins from the delrin Housing.
To avoid any damage to the delrin housing or Contact Pins, they should be pushed outwards from inside. Simply insert any non-sharp object in the Axle hole and use it to gently push out the Contact Pins. The atomizer Contact Pin should always be the easiest to remove, so always remove that first. If the battery-side one is giving you trouble, it is easier to remove it by pushing it through the atomizer pin hex hole.
- Identify all Switch Assembly components.
With the Switch Assembly removed from the External Switch Housing, the disassembly is almost complete. All components included the switch of your Roller / Dingo can be easily located and identified.
C. Internal Switch Assembly: Component Identification
The Switch Assembly consists of the following parts:
- An Internal Switch Housing. Its primary role is to hold together the moving and fixed contacts of the double-break switch.
- A Reinforcement Ring. This is attached on the back of the Internal Switch Housing.
- A moving Axle with a 4mm Spring. The Axle is inserted in the center of the Internal Switch Housing, with the 4mm Spring mounted on its bottom.
- A Contact Rod. This is the moving contact of the switch and is inserted in the middle of the switch Axle.
- A 2mm Ball-Bearing and 2mm diameter Spring. Both are inserted in the 2mm hole on the head of the switch Axle.
- A hexagonal, flat-top Battery Contact Pin. This pin is inserted in the battery-side slot of the Internal Switch Housing.
- A hexagonal, adjustable-height Atomizer Contact Pin. This pin is inserted in the atomizer-side slot of the Internal Switch Housing. The pin’s height is tuned by adjusting the position of the screw mounted on its top.
- A liquid-sealing o-Ring. The o-ring is mounted on the atomizer-side of the Internal Switch Housing, over the atomizer-side pin.
The Contact Rod, Ball-Bearing, and 2mm / 4mm Springs require no disassembly and can be easily removed from the Axle once it has been lifted out of the Internal Switch Housing.
The hexagonal Contact Pins can be easily pushed out of the delrin housing after the Axle has been removed. To remove the hex Contacts, insert a framing nail, toothpick or small, non-sharp screwdriver into the center of the Axle hole and gently push the contacts outwards.
2. Assembly
For this detailed assembly procedure, it is assumed that all components are disassembled. For a trouble-free assembly, all steps should be followed carefully in the right sequence.
- Examine the Internal Switch Housing.
Identify its 2 sides: the battery-side and the atomizer-side. The battery-side of the housing can be easily identified by the channel where the reinforcement Ring is attached, while the atomizer-side is the slightly recessed one.
Take a good look at the empty Axle hole from the top and visually locate the 3 Ball-Bearing channels carved inside it. Two of them are symmetrical and face each other (at 0 and 180 degrees), while the third one is carved at 90 degrees.
- Insert the hex Contact Pins in the Internal Switch Housing slots.
The non-adjustable, Battery Contact Pin is inserted in the slot found on the battery-side of the housing, while the Atomizer Contact Pin (the one with the screw) is inserted in the atomizer-side slot.
Important: Both pins have a rather tight fit. Take a look at the slots and make sure you insert the pins with one of the flat hex sides facing upwards. Then, push them all the way in and make sure that they have been inserted evenly!
After inserting the Pins, examine the exposed contacts and make sure that their surface is not covered or obstructed by any delrin particles or dirt, no matter how small.
Note: The Adjustment Screw comes pre-assembled in the Atomizer Contact Pin threading, with a tiny o-ring inserted under its head! Take care not to lose the screw and o-ring, and remove the o-ring if you are going to use the recessed version of the 510 connector. This can always be done later.
- Attach the liquid-dealing o-Ring on top of the atomizer-side of the Internal Switch Housing.
With the pins fully inserted, push the liquid-sealing o-Ring on top of the Atomizer Contact Pin. It should be held in place rather firmly.
- Assemble and insert the Axle into the Internal Switch Housing.
First, carefully examine the Axle for signs of delrin flakes or machining leftovers, especially around the hole/channel drilled in its middle, right beneath its head. The hole and channels should be perfectly clean.
Insert the 4mm Spring in its Axle mount. The side of the Spring that should be sleeved into the Axle is the tighter one.
Then, insert the 2mm Contact Rod in the 2mm slot drilled in the middle of the Axle shaft and ensure that it has a loose fit. No foreign particles or delrin flakes should be visible in the slot before or after inserting the Contact Rod. Take care not to lose the Contact Rod, since it can easily fall out of the slot.
Now, the tricky part: Insert the 2mm Spring in the hole found on the Axle head, and then carefully place the Ball-Bearing on top of the spring. This is only possible by holding the Axle sideways, with the hole pointing upwards.
With the Ball-Bearing standing on the Spring, put your index finger over the Ball-Bearing and push it into the hole. Then, hold the Axle with your index finger covering the hole, to prevent the Ball + Spring from flying out.
Finally, with your index finger always covering the Ball-Bearing hole, carefully insert the Axle into the Internal Switch Housing. The Axle should be inserted with the same orientation as the one it had when you disassembled it. RO40/50 and DI40/50 switches will be easier to slide into the Metal Housing if the Contact Rod is aligned to the Contact Pins.
At this point, the assembled Axle should be in the Internal Switch Housing and your index finger should be placed over the Axle head to prevent it from coming out. Make sure that the Ball-Bearing is in a channel that allows the Axle to sit deeper, otherwise, the next step might be impossible to complete.
- Insert the Switch Assembly into the External Switch Housing and align it with the button hole.
You can do this by either inserting the Switch Assembly directly into the External Switch Housing, or with the help of the 18mm PVC Tube supplied with new switch assemblies.
If you choose the direct method, continue from the previous step by holding the Switch Assembly with your index finger over the Axle. Then, slowly insert it into the External Switch Housing. Keep in mind that: 1) The Axle head should be aligned with the button hole of the External Switch Housing. 2) The Axle should be always held in the delrin assembly, to prevent the Ball-Bearing from falling out. 3) The switch assembly should be inserted with the right orientation (the adjustable pole-height screw must end up below the atomizer).
If you have purchased a spare switch, you might find it a lot easier to complete this step by using the 18mm PVC Tube that the switch came assembled with – just insert the assembly in the supplied 18mm PVC tube and then push the Switch Assembly into the metal housing through the tube. The PVC ring will simply pop out.
Finally, make sure that the Axle head is aligned with the button hole of the External Switch Housing. If necessary, twist the Switch Assembly until the head of the Axle is properly aligned with the center of the hole.
- Firmly attach the delrin Button Washer around the External Switch Housing hole.
This washer is used to prevent metal-to-metal contact between the button and metal housing when pressing or twisting the switch. When fully inserted, it also prevents delrin-to-metal friction between the delrin Axle shaft and the inside of the metal housing.
Once the washer is inserted, make sure you push it all the way down to the bottom.
- Firmly attach the metal Button on the Axle head.
If you have installed the Switch Assembly in the correct position, ensure that the “on” indicator of the button is pointing exactly at 12 o’clock and then evenly secure the button on its Axle mount without applying a lot of pressure. To prevent damage to the contacts, the button should be fully mounted with the Axle in the “locked” position. At this point, you should be able to lock the switch by twisting it 90 degrees. With the switch locked, apply even pressure to all sides of the button until it is firmly mounted on the Axle head.
- Attach the Main Tube on the External Switch Housing.
First, firmly insert the Reinforcement Ring in the channel located on the battery-side of the delrin (internal) switch housing.
Then, slowly tighten the Inner Tube of your Roller (or fixed-size tube/extension of your Dingo) on the External Switch Housing.
Note: As you reach the end of the threading, make sure that the Tube doesn’t twist the Switch Assembly inside the metal housing, as this might cause the button to be misaligned and grind or jam against the washer.
Note: If you have already attached the button, you can keep it pressed while slowly tightening the tube to keep it properly centered.
- Test the Button by pressing and twist-locking it.
Its movement should be smooth, both when pressing and twisting it. The button should not grind or jam anywhere.
- Attach the 510 Connector on the External Switch Housing.
With the switch fully assembled, it’s time to attach the exchangeable 510 Connector. Simply screw the connector in its threading all the way in, and tighten it by inserting a coin in the slot carved on it.
Important: When using a ‘Recessed’ 510 Connector, always remove the o-ring found under the pole adjustment screw.
- Test the Button again and, if necessary, push the button left or right to align it properly.
- Assemble the remaining External Components.
Attach any Tube extensions — including the Outer retractable Tube of the Roller.
Finally, assemble and screw the Bottom Cap. The Bottom Cap includes a black delrin Washer and safety Spring, which should be assembled first. Make sure that the top and bottom sides of the spring are clean and that the spring contact area on the back of the Bottom Cap is free from dirt and oxides. Oxide films cannot be seen with a naked eye — it is a good idea to periodically clean the top / bottom of the spring and the inner side of the bottom cap (the removable disc) with a non-corrosive cleaning solution.
