Robotronics Pluggie Robot Operating Manual page 46

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More detailed troubleshooting by system is included with each subsystem. For additional help or parts call
our service dept. at 801-489-4466.
Problem
Robot Battery System
No functions will operate.
Battery will not take a full charge.
Needle on charger will not move.
Drive Motors
Neither drive operates only.
To correctly evaluate drive problems,
look at wheels off the ground.
One drive only does not operate.
Determine first if it is the drive motor or
drive circuit. To do this swap the wires
that go to the motors
connector. Same motor still not
working then motor is bad.
switches to other motor, then problem
is in main box possibly the drive circuit
itself.
Drive motors moving on their own even
when the stick is in the center.
Robot not driving straight.
Character Head Turning System
Head is out of position but operates.
Head motor is keeping head in not
centered position
Head motor is not operating
Eyelids and Eyes Left and Right
An eyelid or eyes L/R does not operate
One of the eyelids is at a different level
No operation of any eye functions.
Appendix A: Quick Reference Troubleshooting Chart
Check wires and connector from battery to the
robot.
Battery is very low or bad.
Battery has not been kept fully charged
Both drive fuses blown.
Radio control drive section problem.
Contact Robtronics for help.
Drive motor pulley loose.
Broken connection at motor connector.
Drive circuit not getting power.
at white
Problem
Drive motor damaged.
Drive Circuit on main board problem.
Drive trim sliders not in center.
Joystick potentiometer broken.
One motor pulley set screw loose.
Straight drive
adjusted.
Loose head set screw or head was hit.
Head turning pot or pot shaft slipped
Character board is not getting power
Broken wire.
Rod linkage came off.
Servo wire broken or wire came out of eye
servo board
Eyelid rod bent or eyelid out of adjustment
Connection at eye servo board has come off.
Wire(s) bringing 5 Volts and signal to servo
board are not making a connection. Broken
out of 37 pin connector.
No 5 Volts going to eye servo board.
Cause
adjustment needs to be
Solution
Push battery connector pins in until it clicks in
place. Pin could have slipped out of position.
Charge battery or replace if it will not charge.
Also test charger.
Charge and discharge repeatedly.
battery if it does not start charging.
Replace drive fuses on fuse block.
Tighten motor pulley set screws.
Check blue/yellow wires and in line motor
connector at motor
Check drive motor fuses on fuse block (blue
wires). Check wires coming from fuse block to
motor circuit on the main board. Broken solder
joint?
Repair or replace motor.
Send main electronics box back to Service Dept.
Move drive stick sliders to center or position to
neutral the robot.
Send to Robotronics for repair.
Tighten set screws.
Find adjustment on the main circuit board. See
diagram of main board in Appendix.
Re-position head and tighten set screw. Better to
do this with the robot on.
Re-center head by adjusting
feedback pot- blue pot below motor. Then tighten
the set screws on the metal tube. See procedure
in head section.
Check fuse on main fuse block.
Check power (red/black)
(blue/yellow).
Get to eyelid rods and ball links and re-attach.
Trace wires from servo motor of the eyelid or eyes
and follow this wire to the eye servo board to find
problem.
Straighten bent rod or change eyelid position by
removing the servo arm.
lengthen the rod by twisting the servo arm. You
can also change the position of the servo arm on
the servo shaft.
Vehicle- located on underside of upper robot.
Robots with Character- located in character.
Vehicles- locate
(red/black/gray/yellow/black) going from the 37 pin
up to the eye servo board. Repair broken wiring.
Robots with Character- Check gray/yellow/black
and red black to eye servo board.
Find broken wire on red/black or check fuse for
eye servos on fuse block.
Replace
head turning
and motor wire
Then shorten or
the wires