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NOTES: 1. There are no adjustments to any part, so if a faulty or worn part causes the robot to malfunction, replace that part.
2. If you are not well-skilled at soldering, please send in your Control Box for service when soldering is indicated.
Control Box parts are small and easily damaged. Improper soldering may void your warranty and service policy.
3. If you open the 1040+/2040+ Control Box, unscrew ONLY the 4 corner screws. DO NOT remove the 4 screws in
the middle. (See Figure 1B, page 6 for more details.)
4. If the suggestions below do not help, please consult the troubleshooting section of our website at
www.newgy.com. It is updated periodically and will be more current than the information given below.
5. The following solutions will apply to all models of Newgy Robots, except if marked with the following footnotes:
Robo-Pong 1040+ only,
1
NO POWER PROBLEMS
1.
PROBLEM
No robot functions work and Power Switch on Control Box
does not light up when turned on.
SOLUTIONS
A. Make sure transformer is plugged securely into a
power outlet. Verify there is power in the outlet. Check
that transformer input (on top of transformer) matches
local electrical specifications. See Chart on pg. 17.
B. Check that the pin of the transformer cord is plugged
securely into the Power Jack of the Control Box.
C. Transformer is defective. Test for proper output with a
voltmeter. If defective, replace.
D. If Control Box has been knocked off the table, a break
may have been created on the circuit board. Inspect
and resolder any broken connections. Break is usually
where the Power Jack is soldered to the circuit board.
E. Verify that wires are properly attached to the Power
Switch. Red wire should be closest to "off". Brown or
white wire should be attached to the middle terminal.
Black wire should be closest to "on".
F.
Power Switch is bad. Replace.
2.
PROBLEM
No robot functions work or only work intermittently, and
the Power Switch
lights up when turned on.
1,2
SOLUTIONS
A. Make sure Connector Cable is securely plugged in at
both ends.
B. Check fuse in Control Box. If blown, replace.
C. Fuse holder is not making good contact with the fuse.
If loose, tighten; if defective, replace.
D. Bridge Rectifier is bad. Especially indicated if fuse
keeps blowing after power is turned on. Replace.
E. Defective Connector Cable. See Solution 14A.
BALL FEED/FREQUENCY PROBLEMS
3.
PROBLEM
Robot will not pick up balls.
SOLUTIONS
A. Pong-Master Scoreboard (an optional accessory) is
controlling Ball Feed. Turn Scoreboard off.
B. Ball jam. See Problem 18.
C. Ball Feed Motor is not running. See Problem 14.
D. Ball Feed Motor runs backward. See Problem 13.
E. Ball Feed transfer gears and/or Main Gear are
damaged or assembled incorrectly. Replace gears with
stripped teeth or other damage.
F.
Pickup fingers are broken or loose. If loose, tighten; if
broken, replace.
TROUBLESHOOTING GUIDE
Robo-Pong 2040+ only,
2
5
1,2
1,2
1,2
1,2
1,2
20
Robo-Pong 545 only.
G. If Control Box emits a high-pitched squeal when
power is turned on, even if Connector Cable (and
Linking Cable from Pong-Master Scoreboard, if
applicable) is unplugged from the box, the U4 chip or
12V Relay on the circuit board is defective. Replace.
H. If problem occurs only at low ball frequency, spray
inside Ball Feed Motor with tuner lubricant/cleaner.
I.
Ball Feed Main Gear is frozen to shaft of BF Mounting
Plate. Replace gear and plate.
BALL SPEED/DISCHARGE PROBLEMS
4.
PROBLEM
Ball speed seems to be slower than when new.
SOLUTIONS
A. Incorrect Transformer.
B. Hair or fibers are entwined around drive pin of Ball
Speed Motor. Remove Ball Discharge Wheel and
inspect at base of brass shaft on the motor. Clean, if
necessary.
C. The brass shaft on the Ball Speed Motor is loose. The
Ball Discharge Wheel is screwed onto this shaft and
then the shaft is permanently pressed onto the motor's
drive pin. It cannot be reattached. Replace the motor.
Test by holding the rubber wheel with a finger and
then turn power on and adjust Ball Speed to 10. If you
hear the motor spinning while you are holding the
wheel stationary, then the brass shaft is loose. If the
motor does not spin, then shaft is securely fastened.
D. Ball Discharge Wheel and/or Friction Block are worn.
Replace both parts.
E. Ball Speed Motor needs lubricating. Spray inside
motor with an electrical contact cleaner/lubricant.
F.
Friction Block (FB) is not moving freely. Test by
pressing FB down with your thumb and visually check
to see if FB tabs are returning to the top of their slots.
If FB is hanging up in its travel, remove FB and smooth
its tabs and/or sides by filing. Also, clean out FB tab
slots in the head housings. Replace FB if necessary.
May also be caused by overtorquing of robot head
screws. If loosening these screws frees up FB travel,
replace left head housing.
G. Potentiometer, Voltage Regulator, and/or Bridge
Rectifier inside the Control Box are bad. Replace.
H. Balls are too small. Check with Ball Dam. See page 11.
5.
PROBLEM
Robot picks up balls, but balls just fall out of discharge
opening instead of shooting out.
SOLUTIONS
A. Check balls to be sure a 38mm ball is not mixed in with
1,2
1,2
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