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iRobot Roomba 500 Series Servicing And Repair Manual
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iRobot Roomba 500 Series Servicing And Repair Manual

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Ch. 8: How To Replace Roomba's Main Brush Motor
Roomba 500 Series Servicing and Repair Guide
Chapter 8: How To Replace Roomba's Main Brush Motor
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Summary of Contents for iRobot Roomba 500 Series

  • Page 1 Ch. 8: How To Replace Roomba’s Main Brush Motor Roomba 500 Series Servicing and Repair Guide Chapter 8: How To Replace Roomba’s Main Brush Motor...
  • Page 2 Please note that if your Roomba is under warranty, servicing the robot will void the warranty. For robots under warranty, please consult the warranty policy of the distributor where purchased, and/or contact iRobot’s customer service. How to Replace Roomba’s Main Brush Motor How to Remove the Old Main Brush Motor 8.1.1 Start by flipping the robot on...
  • Page 3 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.2 Loosen the four screws holding the brush deck in place, shown by the orange arrows. 8.1.3 Firmly grip the brush deck module. You can grab it by the brush guard even grabbing its blue ‘frame’...
  • Page 4 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.4 Pull up to remove the brush deck module from the Roomba. 8.1.5 View of casing removed from the Roomba.
  • Page 5 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.6 Flip the brush deck module over, and remove the round motor tension cable cover. 8.1.7 Remove the three screws shown by the orange arrows.
  • Page 6 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.8 Wedge apart the blue frame with a screwdriver or similar tool, as shown by the red arrows. Grab the motor tension cable with a pair of pliers and lift it out of its spot, as shown by the orange arrow.
  • Page 7 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.10 The motor tension cable should hang loosely, as shown in the picture. 8.1.11 Using a pair of pliers, grip the motor wires located on the right side of the blue frame.
  • Page 8 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.12 Unhook the wires from their holder, as shown in the picture. 8.1.13 Push the motor connector board down into the blue frame. This will make it easier to remove the casing from the blue frame.
  • Page 9 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.14 Stand brush deck module on end to make it easier to get access to the casing. 8.1.15 To release the casing from its blue frame, pull the left side of the blue frame outward with your thumb, while lifting the green casing up with your index...
  • Page 10 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.16 Do the same thing with the right side of the casing. 8.1.17 The brush casing should come right out of the blue frame now that its hinges have been released from the blue frame.
  • Page 11 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.18 Remove the four screws shown by the orange arrows. 8.1.19 Lift the motor from the right side to remove it from the casing.
  • Page 12 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.20 With the motor removed, lift and remove the dirt detector cover from the casing. 8.1.21 Remove the two screws holding the dirt detector board to the casing, shown by the orange arrows.
  • Page 13 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.22 If you flip over the dirt detector cover, it is a good place to put all the loose screws. 8.1.23 Remove the dirt detector board from the casing.
  • Page 14 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.1.24 View of casing with the brush motor removed. How to Install the New Brush Motor 8.2.1 Start by first removing the rubber seals from motor’s dirt detector contact microphone (the bronze colored metal disc).
  • Page 15 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.2 Take your new brush motor and install the white foam spacer on the end of its shaft. Please note this foam bushing may vary in color and material, or it may not be present on some older Roombas.
  • Page 16 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.4 Push the motor over to the left until the foam spacer is compressed. 8.2.5 Lift the brush motor on the right side to hook it into the casing. You’ll notice a small hook on the end of the motor;...
  • Page 17 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.6 Hooking the motor in place can be made easier by pushing down on the tab on the end of the motor, shown by the orange arrow. This will push the hook into its slot.
  • Page 18 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.8 Place dirt detector rubber seal with hole through it. into the slot on the brush casing. 8.2.9 Install the remaining dirt detector seal onto the dirt detector’s contact microphone (the metal disc attached by two wires).
  • Page 19 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.10 View of dirt detector with rubber seal properly installed. 8.2.11 Place dirt detector contact microphone onto the casing, matching up the shape of the seal to the outline on the casing.
  • Page 20 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.12 Place the dirt detector board into the rectangular outline in the casing, and insert the two screws. 8.2.13 Once the board is secured in place, put the two wires from the board into the slot on the casing, putting the brown wire in first and lining up its terminal...
  • Page 21 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.14 Place the dirt detector cover over the board, making sure to have it the right side up. The slot for the wires should be at the bottom, as shown by the orange arrow.
  • Page 22 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.16 Insert tighten cover’s screws. 8.2.17 We’re ready reassemble the casing to its blue frame.
  • Page 23 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.18 Insert the motor connector into the slot provided by the blue frame. Make sure the connector board’s orientation is as shown in the picture – the red and black wires coming directly from the motor should be toward the outside edge of the blue frame.
  • Page 24 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.20 While keeping connector pushed in all the way, insert its two screws and tighten them. 8.2.21 The motor connector should look like this once the screws are inserted. The connector must be straight as shown in the picture, otherwise it wasn’t pushed in all the way when the...
  • Page 25 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.22 Place the grey wire and the red and black wires for the motor into the hook on the blue frame. The red and black wires should go underneath the grey wire.
  • Page 26 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.24 Pry the blue frame open at the seam with a screwdriver (or similar tool). Pull the cable through the opening, slipping it into the slit in the center of the blue frame, as shown by the orange arrow.
  • Page 27 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.26 Push motor tension cable down until it is flush with the blue frame, then place a piece of tape over it. Insert the blue frame screw just to the right of the cable.
  • Page 28 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.28 Reinsert the green casing’s hinges into the blue frame by pushing down and inward with your thumbs on the green hinge ‘arms’, while pulling outwards with your fingertips on the blue frame.
  • Page 29 www.RobotShop.com Ch. 8: How To Replace Roomba’s Main Brush Motor 8.2.30 Drop the brush deck module into Roomba. Take care to make sure it is aligned properly. It may need to be moved from left to right, or jiggled slightly in place, to get it to settle into position.
  • Page 30 For details on how to reassemble your Roomba, please see Roomba 500 Series Servicing and Repair Guide Chapter 3: How to Open Up Roomba Looking for a different guide? Please see the full list of repair guides available at the...