Robotronics Toby Tire Robot Operating Manual Download | Manualshive

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Maintenance: Recommended Tool Kit

Recommended Tool Kit

Fuses- 1, 3, 5, 15, 20, 30 Amp (AGC Type)
4" cable ties
#53 Miniature bayonet bulbs (automotive panel type)
Precision regular Phillips screw drivers
Screwdrivers (flat head and Phillips)
Socket and ratchet set
Needle nose pliers
Crimper/Wire strippers
Wire cutters (diagonal cutters)
7/16" & 3/8" wrenches
Set of Allen wrenches (Especially 3/32" and 1/8" sizes)
Extra 9 Volt alkaline batteries
Small soldering iron and solder
Small can all purpose lubricant
Digital Multimeter (Volts/Ohms)

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Summary of Contents for Toby Tire Robot

Page 1: ...i Toby Tire Robot Operating Manual Version 6 5 ...

Page 2: ...usefulness grow as your needs grow Please read this manual carefully It will help you make the most of your robot Attention to maintenance and proper training will greatly prolong the life of your robot Most problems you encounter will be minor and the manual will provide an answer Please feel free to contact us if you have unanswered questions relating to operation maintenance and repair Also if ...

Page 3: ...m 12 Adapter for Charging and 110 V Power Supply 13 Chapter 3 Voice System Overview 14 Location of Voice Units 14 Belt Transmitter 15 Robot Receiver 16 151 System Robot TX and Belt 151 Receiver 17 Voice System Troubleshooting 18 Mouth Operation 20 Operator s Voice Headset Transmitter and Receiver 21 Chapter 4 Cassette Tape Player System 22 Cassette Tape Player Diagram 23 Chapter 5 Siren 25 Chapter...

Page 4: ...ppendixes Appendix A 41 QUICK REFERENCE TROUBLESHOOTING 42 Robot Circuit Block Diagram 45 Appendix B Robot Parts Identification 46 Inside View 47 Main Box Inside 48 Battery Compartment 49 Main Board 50 Fuse Block Detail 51 Side Arm View 52 Eyes Servo Board 53 Eyes 54 Arm Control Board 55 Notes Section 56 Technical Tips Section 57 These sections can be used to place additional notes that you would ...

Page 5: ...r arising from the use of the robot this manual or any procedures herein The buyer is further responsible to ensure that proper and complete training be given to those operating the robot system as all aspects of such operation cannot be covered in a brief manual such as this In no event shall ROBOTRONICS Inc be liable for any incidental or consequential damages in connection with or arising from ...

Page 6: ...es The shipment must be labeled on the paperwork and on the outside of the container that it is For Educational Purposes If it is a warranty replacement or a repair return this also must be indicated both ways on the customs documentation Contact your customs agency on how to document the shipment correctly to avoid unnecessary customs charges After The Warranty Repair and Help Our technical staff...

Page 7: ...re hazards to be avoided Safe clearance should be maintained between these obstacles and the robot Never leave the robot ON when unattended or in direct sunlight for extended periods of time The robot is designed to be operated on hard smooth surfaces and carpet Avoid extra deep shag carpet dirt gravel or grass surfaces Avoid steep inclines or large uneven surfaces such as curbs gutters or uncover...

Page 8: ...C ON first and then turn the robot ON Check that the RC battery level meter reads to the right The ON OFF switch for the robot is located inside the rear door or trunk on the main electronics panel Push the switch up to turn the robot on Step 5 Set the Volumes Check that the volume of the voice and tape player are at the level that your want The tape player volume can be changed on the tape player...

Page 9: ... left with a partial charge The transmitter battery should be charged if it is low All of the major functions of the robot each have a section in the manual with more details and diagrams Refer to these for more in depth information The Appendix has pictures and diagrams of where various parts are in the robot These will help you become familiar with where the parts are located and their function ...

Page 10: ...e trailers typically do not have the same level of shock absorption as a car or van A good rule of thumb to follow is that if the vehicle is adequate for transporting a computer it should also be fine for the robot Double check that the upper robot is latched and secure There are two latches Secure the robot in transport so that it does not roll around inside your vehicle CAUTION If the upper robo...

Page 11: ...ystem C Cassette Tape Player D Siren E Robot Battery Systems F Drive Motors G Eyelids and Eyes Left and Right The systems block diagram found in the Appendix shows how the various subsystems and their components are interrelated Following are explanations of each subsystem some operating instructions and trouble shooting hints where appropriate ...

Page 12: ... wheels Pushing the stick forward will cause the robot to move forward Pulling the stick back will cause the robot to move backward Moving the stick to the right or left will cause the robot to turn to the right or left respectively Movement is fully proportional so any variation or combination of movement is possible The horizontal and vertical trim tabs to the left and below the joystick are for...

Page 13: ...9 Radio Control Diagram RADIO CONTROL TRANSMITTER Hi Tec 2 9 12 14 11 10 7 8 6 4 5 3 16 15 1 13 ...

Page 14: ... moving slightly slide this a few clicks until robot stops moving 5 Left and right Trim lever for right control stick Normal Center Neutrals the drive motors If the robot is moving slightly slide this a few clicks until robot stops moving 6 Crystal 7 On Off Switch 8 Recharge jack Plug the RC battery charger in here to recharge the internal battery The charge light will come on on the charger 9 For...

Page 15: ...11 Top Switch Functions 12 Tape player 13 Blink eyes 14 Dance and Handshake 15 Unused 16 Siren ...

Page 16: ...g time is the type of over charging that is meant here and the battery getting hot When the battery level needle goes in the red the robot should be turned off because the robot could act erratic without the transmitter signal To avoid a RC battery going dead during a presentation start the program with a fully charged battery or be aware of how much charge there is left in the battery If you have...

Page 17: ...nd that will go directly to your battery The charging time is still 16 hours 110 Volt RC Transmitter Power Supply Option The 110V RC Power Supply is a power unit that plugs into a standard electrical outlet and in to the RC transmitter This allows you to have continuous power without using batteries This connects into the same connection as the battery To make the connection you need to take the b...

Page 18: ...r which is worn by the operator This is amplified and sent to the speaker in the operator s headset Important The operator s transmitter and receiver should be kept as far separate as possible such as on opposite sides of the operator s waist Do not attach the units together this may cause interference effects The antennas should not be wrapped around each other or around the headset wire but shou...

Page 19: ... power switch with a fresh alkaline 9 Volt the battery light will blink on momentarily and go out This indicates that it is powering up and that the battery is good Because the light is a low battery indicator when the light is on constant this indicates the battery is too low below 7 Volts Replace with a new alkaline battery Tip The operator s voice units both have metal clips that contact the po...

Page 20: ...he robot is turned on You could turn the sensitivity down slightly but turn the adjustment as little as possible because adjusting it will affect the range Function of the LEDs TX LED This indicates that you are receiving a signal from the transmitter On some units it is a single TX light On other units it may have an A or B that it will alternate between AF LED This light indicates that audio is ...

Page 21: ... until the feedback is gone Function of LEDs When turning the volume knob on with a fresh alkaline battery the red light will blink on momentarily and go out This indicates that it is powering up and that the battery has enough charge on it As labeled the light is a low battery indicator When the light is on constant this indicates that the battery is below 7 Volts It then would need to be replace...

Page 22: ... the batteries are good in the operator s transmitter and in the 151 receiver Normally when you turn the 151 receiver on the low battery light should blink on and go off When turning on the power switch of the transmitter the light should blink on and go off If either of these lights stays on constant the 9 volt battery is too low and must be replaced 2 Check that the battery is in the correct pol...

Page 23: ...et in 1 Low Battery LED on steady or no LED flash 1 Replace the 9 Volt battery 2 Battery posts not touching the metal clips in the operator s receiver 2 Bend out the metal clips Put foam under clips 3 Headset plug to 151 RX has a broken wire 3 Unscrew cover of plug and look for broken wire 4 Robot 151 transmitter not turned on 4 Turn on audio and power 5 Power plug to robot 151 transmitter unplugg...

Page 24: ... is set based on a typical voice volume and the headset microphone being about 1 inch from the operator s mouth Adjustment The adjustment is preset at the factory and should not need any adjustment If an adjustment is necessary see the Main Circuit Board diagram in the Appendix for the location of it It is labeled Moving Mouth sensitivity When this pot is adjusted clockwise this makes the mouth mo...

Page 25: ...21 Operator Voice Units Operator s Voice Transmitter and Receiver Mic Plug 3 5mm or 3 Pin mini XLR 3 5mm Headphones Plug ...

Page 26: ...pstan roller Troubleshooting Cassette Player Problem Cause Action Cassette Player No tape operation 1 Tape player not on tape mode or volume not turned up 1 Put mode select to tape and turn volume up 2 Play button not pushed 2 Must push play button before hitting the switch on the radio control 3 Bad Tape 3 Check tape in other tape player 4 Tape is too tight 4 Loosen with a pencil by spinning tape...

Page 27: ...23 Cassette Tape Player Cassette Tape Player ...

Page 28: ...24 Cassette Tape Player ...

Page 29: ...per located on the siren mode select To control the oscillating speed adjust the siren frequency trim pot in the siren circuit The siren mode select is set to the common siren for your robot If the siren mode select is changed the siren frequency will very likely need to be adjusted NOTE The volume and oscillation are preset at the factory and do not need to be adjusted unless you want a different...

Page 30: ...s that you are in the middle stage of charging The robot is supplied with an automatic type battery charger It will go to a float charge when it reaches a full charge on the battery Taking Care of the Robot Battery The number one rule for battery care is to keep the batteries fully charged at all times Like all batteries there is some discharge that occurs every day Because of this you should char...

Page 31: ...tions Warnings HAZARD OF EXPLOSIVE GAS MIXTURE When charging a lead acid battery gives off hydrogen gas The Gel type battery is a lead acid battery with pressure relief type vents Although it only gives off a small percentage of the gas that a wet lead acid battery does the following precautions should be observed 1 Charge the battery in a dry well ventilated area This is why it is important that ...

Page 32: ...ger is working by connecting it to a battery that is known to be good Leave the charger on for a few days and see if the battery starts taking a charge Turn the robot on and try to operate it Connect to the charger again If it still will not take a charge it s time to replace the battery ...

Page 33: ...oystick could be pushed in the on position while the connector is being checked for an intermittent connection If there is a bad connection the connector and or pins should be replaced While doing the test just explained have the robot wheels off the ground Perform the following depending on the symptoms indicated Note The best way to look at what the drive motors and wheels are doing is to put so...

Page 34: ...he main electronics box would need to be removed to access the adjustment Take the cover of the box completely off and set outside the robot so that it cannot touch the post s of the robot battery CAUTION The robot battery posts should never contact the metal of the main electronics box or the metal of the drive base This will result in damage to electronic components especially inside the main el...

Page 35: ...tor Set screw on the motor hub Troubleshooting Arms The arm is out of position but operates This is not likely because the arm is kept in position on a keyway Check the set screws for tightness The arm motor is keeping the head position to the extreme left or right 1 The in line connector to the feedback pot has come disconnected 2 The feedback pot shaft could have slipped out of position The feed...

Page 36: ...r shaft is coupled to the eyelid with a servo arm and then an eyelid rod Troubleshooting Eyes An eyelid does not operate 1 Check the linkage from the servo motor Look for the servo arm off the servo shaft or the eyelid off the ball link 2 Follow the wires from the specific servo motor with the problem The wire will run to the eye servo board If it is disconnected reconnect according to the eye ser...

Page 37: ...sound Typically set this on EFX for the full effect 10 H R Key switch Not used 11 Pitch Switch Adjusts the amount of pitch shift 12 Mode Switch Selects the mode Typically use the pitch shifter mode The pedal on the pitch shifter is used to turn it on and off When the pitch shifter is on the power light labeled check will be lit The shifter will take a few seconds to power up To turn it off push th...

Page 38: ...ed do not allow the shifter power wire plug to contact the metal box The metal box surface has a ground connection The fuse related to the shifter is the audio fuse located on the fuse block Below is a typical setting for the robot voice This will give you a shifted cartoon character or robot type voice Balance clockwise Pitch About 2 00 Mode pitch shifter ...

Page 39: ...51 voice transmitter and the receiver antenna wire 2 Remove the box by lifting up and out Removing the drive base from the body This would be necessary only if you needed to get to the drive pulleys belts or remove a drive motor 1 On some models the main electronics box and bracket have to be removed first 2 Remove the 6 nuts holding the drive base to the plastic frame 3 Disconnect the drive motor...

Page 40: ... come off with soap If this causes the finish of the plastic to become dull apply ARMOR ALL brand protectant Do NOT use alcohol on windows or pupils 7 Check the Radio Control System and Voice Transceiver for broken wires controls cases etc The metal clips that are in the voice units and contact the 9 Volt battery should be bent out routinely to maintain good contact 8 Fully charge the battery and ...

Page 41: ...ion regular Phillips screw drivers Screwdrivers flat head and Phillips Socket and ratchet set Needle nose pliers Crimper Wire strippers Wire cutters diagonal cutters 7 16 3 8 wrenches Set of Allen wrenches Especially 3 32 and 1 8 sizes Extra 9 Volt alkaline batteries Small soldering iron and solder Small can all purpose lubricant Digital Multimeter Volts Ohms ...

Page 42: ... with masking tape and paper to protect against over spray Use a very narrow masking tape to tape the line and then much larger tape beyond that Method 2 If your robot has been pre painted an automotive type paint was used You should contact a professional painter that has had experience painting on various types of surfaces These paints typically include a primer and base coat For a glossy look y...

Page 43: ...ill keep the glue from running Apply some of the PVC or ABS glue along the seam only on the inside of the body Check to make sure that the glue is not running through the crack on to the outside of the body Note Avoid getting the glue on your hands 5 Immediately put the fiberglass mesh on the glue and pat it down to saturate into the glue 6 Apply some more PVC or ABS glue over the fiberglass mesh ...

Page 44: ... to be done 6 Clean the body and top as per instructions in maintenance section If robot is stored with a dirty body it may be harder to clean at a later date as stains may become permanent 7 Storing your robot with a dust cover on it will keep the robot clean and protect the body from scratches It will also keep ultra violet light from affecting the ABS plastic body 8 The robot and batteries shou...

Page 45: ...41 APPENDIX A ...

Page 46: ...fter then from output A into the main box and plug on to the main board 6 Headset plug to transmitter broken 6 Take apart and look for broken wire or solder joint TEST Connect robot mic to transmitter If it now works problem is in headset Repair or replace Operator cannot talk 7 Still not working Call Robotronics Send transmitter receiver and headset in 1 Low Battery LED on steady or no LED flash ...

Page 47: ...otor pulley loose 1 Tighten motor pulley set screws 2 Broken connection at motor connector 2 Check blue yellow wires and in line motor connector at motor 3 Drive circuit not getting power 3 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 4 Drive motor damaged 4 Repair or replace motor One drive only does not...

Page 48: ... block 1 In line fuse blown 1 Replace the 5 Amp fuse which is in line on the wire Follow wire from water squirter switch Water Squirter Cannot fill reservoir 2 Broken wire at water squirter switch or coming from main box 2 Repair break 1 Water squirter switch is not in on position 1 On position is not the center position Cannot squirt no pump sound 2 Broken wire at pump or W S switch 2 Repair re s...

Page 49: ...45 Appendix A Robot Functional Block Diagram ...

Page 50: ...46 APPENDIX B ROBOT PARTS IDENTIFICATION ...

Page 51: ...47 Appendix B Inside View Inside View Microphone Voice Transmitter Fuse Block Voice Modifier Voice Receiver Tape Player Battery strap On Off Switch Battery Connector ...

Page 52: ...48 Appendix B Main Box Inside Main Box Inside Main Fuse Block Main Circuit Board Arm Board Signal Wires Left Arm 5Volt Right Arm Active Audio Filter ...

Page 53: ...49 Battery Compartment Battery Compartment Inside View Battery Connector Drive Motors On Off Switch Robot Battery ...

Page 54: ...oard Gray Yell Blk 5 V to Eye Servo Board Vehicle Reset button Cass 3 Volt Regulator 9V To Voice Modifier Cassette 3V Power Siren Frequency Siren Volume Siren Mode Select Cassette Audio In 101 RX Audio In Out to Audio Amplifier Drive Straightness Adjustments Forward Reverse Output 5 Output 6 Output 4 Output 7 Output 8 Processor Left Drive Circuit Right Drive Circuit ...

Page 55: ... AMP standard RIGHT DRIVE 20 AMP super 15 AMP standard 5 VOLT REG 3 AMP Processor RC Receiver SWITCHED OUTPUTS 15 Amp 5 VOLT REG 3 AMP Eyes Servo Board Red wire Red wire Red wires 12 Volt Power wires from Main On Off Switch Audio Fuse 0 Robot voice transmitter 151 Robot voice receiver 101 audio booster active filter cassette player siren Switched Outputs Fuse 4 Switched outputs are 2 pin outputs ...

Page 56: ...52 Appendix B Side Arm View Side Arm View Arm Motor Connector Arm Feedback Pot Arm Motor Speaker ...

Page 57: ...w Black Brown 1 Eyelids 2 Eyelids Appendix B Eyes Servo Board Character White Black Red 4 Pin Connectors Gray Black Yellow NC Red 5V NC NC Black 1 Eyelids 2 Eyelids 5 Pin Connector White Black Red 1 2 3 4 5 6 7 8 COPYRIGHT 1993 ROBOTRONICS 4015 1 2 COPYRIGHT 1993 ROBOTRONICS 3 4 4015 5 6 7 8 1 2 COPYRIGHT 1993 ROBOTRONICS 3 4 4015 5 6 7 8 ...

Page 58: ...54 Appendix B Eyes Eyes Eyelid Servo Servo Arm Eyelid Rod Servo Board ...

Page 59: ...55 Appendix B Arm Control Board Arm Control Board Left Arm Signal 5 Volt Power Right Arm Signal Right Arm Circuit Left Arm Circuit ...

Page 60: ...56 Notes ...

Page 61: ...57 Technical Tips ...

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