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If you're having problems with your i-Que turning or moving at all, this document may help you solve the problem.

WARNING: This document contains detailed instructions which must be followed precisely. It will also void your warranty becuase it requires you to open up the unit. Mechanical and technical skills are required.

DISCLAIMER: I'm not to be held responsible if you somehow destroy your bot while following these directions. Follow these instructions at your (and your bot's) own risk!

Checklist:

Please do the following before making a repair attempt. This will help rule out any other possible causes, and save you time.

1. Check that the batteries in the communicator are good.

2. Be sure that the robot's battery pack is fully charged.

3. Clean the robot's sensors.

4. If steps 1 - 3 do not work, Reset the robot.

If the above steps do not resolve the issue, it's time to take apart the robot to check the drive motor gearbox and assembly, and make any replacements.

PARTS NOTICE: At this time, I am unable to locate replacement parts for the i-Que. However, when I do I will update this document.

WIRING NOTICE: Wiring may be shown as a different color in the photos due to color changing due to flash in the camera. Best to go by the text for the wiring sequences.

CONNECTOR REMOVAL NOTICE: Be careful when unhooking cables as sometimes the base of the cable may come off the circuit board. Go slowly and if you see the plug not coming out of the base of the plug and the whole thing coming off the board, use two hands and/or a pair of needle nose pliers to hold the base to the board and pull only the plug out. Be sure that the base of the connector is flush against the board after removal so that the connector plug can make proper full connection.

What You Need:

• Windex is good for cleaning sensors and the outter plastic parts, except gears. For that just use a dry, lint-free cloth.

• Having some vinyl or latex disposable gloves is useful (gears in gearbox have lots of grease).

• Grease safe for use on plastic gears (in case you need to regrease them).

• Q-Tips (good for cleaning)

• Rags (one coarse like an old dishcloth and one cotton lint-free soft cloth)

• Tissues

• Small-width Phillips screwdriver. If it's too wide, it won't fit into the holes on the underside of the robot. Also the groves on the screwdriver head must not be too shallow.

• Long needle-nose pliers (useful in case a screw gets loose - literally!)

• Small plastic bags, pen and masking tape. *** YOU NEED THIS! *** This is so you can keep track of what screws went where as there are different sizes.

• Electrical tape

Disassembly of Robot:

1. Remove Battery cover and battery. Remove the screws that are circled. Note the locations of the screws and mark a small plastic bag and put those screws in. This way you can keep track for later reassembly.

   
   
   
   Figure 1
   
   

2. Set the robot on it's side as so with the two pieces open. Notice I used some styrofoam packing from the original box to prop the bottom part up. You will need something for the parts to lean against.

   
   
   
   Figure 2
   
   

3. There a couple cables that are connecting the top assembly to the bottom one. Locate the one on the top part of the unit as shown. This cable is located just below the center black plastic box-looking item. Follow that cable to the main board and unhook it as shown in step #4.

   
   
   
   Figure 3
   
   

4. You'll notice between the wheels is the main CPU board and cartridge board. There is a row of connectors here which are covered by masking tape. Take off and throw away the masking tape. You can cover this during reassembly with electrical tape which is a better idea anyway. (They used a lot of masking tape in this unit!)

   
   
   
   Figure 4a
   
   

   Once uncovered, remove only the cables noted below from the mainboard. Do not remove any other cables then those described.

   
   
   
   Figure 4b
   
   
   
   
   

   NOTE for Reassembly:
   
   Note each cable and the way it goes in. With the unit's back wheels facing you. Wiring is Left to Right unless noted otherwise.
   
   Large white connector (This is coming in from the top piece): orange, yellow, green, blue, purple, grey, white
   
   Large red connector on top: white, yellow, red, orange, brown, grey, purple, blue, green
   
   Small white connector: red, black
   
   White connector (Under two black connectors) (Wiring Left to Right): white, grey, purple, blue, green, yellow, orange, red, brown
   
   Small black connector (Wiring goes Top to Bottom: red, orange, black

   
   

5. Unplug the larger set of orange and black cable from by motor #240 (the left-side with back of robot towards you).

   
   
   
   Figure 5
   
   
   
   
   

   NOTE for Reassembly:
   
   This plug is white, and the notched end goes towards the wheels.

   
   

6. Unplug the smaller black/orange wire with black plug (speaker connector) from the front near where the blue ball is. This is the front of the circuit board located just behind the left back where which motor #240 hovers over.

   
   
   
   Figure 6
   
   
   
   
   

   NOTE for Reassembly:
   
   The notched end of this connector goes towards the front of the unit. So that with the back facing you, the wiring is Left to Right: orange, black.

   
   

7. Disconnect the top piece from the battery board located behind the right side wheel with the robot's wheels towards you. This is a red connector at the front of the board as shown.

   
   
   
   Figure 7
   
   
   
   
   

   NOTE for Reassembly:
   
   The red connector wiring is as follows Left to Right: white, aqua, blue, green, yellow, orange, red, brown, black.

   
   

8. Now you can separate the two parts. Set aside the top part as we'll be working with the bottom part of the unit.

   
   
   
   Figure 8
   
   

9. Remove drive housing screws.

   
   
   
   Figure 9
   
   

10. We still need to remove some more cables from the battery board (located on the right with the wheels towards you) to free up some things.

    
    
    
    Figure 10a
    
    
    
    
    

    NOTE for Reassembly of above connectors:
    
    Small red connector (Left to Right): grey, blue, yellow, green
    
    Small white connector (Left to Right): yellow, green, grey, blue
    
    Large White Connector (Front of Unit to Back): white, grey, purple, blue, green, yellow, orange, red, brown.

    
    

    These are near the front of the unit:

    
    
    
    Figure 10b
    
    
    
    
    

    NOTE for Reassembly of above connectors:
    
    Red connector (Front of Unit to Back): purple, blue, green, yellow, orange, red, brown
    Black connector (Front of Unit to Back): blue, orange, red, purple, brown, green, yellow

    
    

11. Remove the gearbox screws.

    
    
    
    Figure 11a
    
    
    
    
    
    
    Figure 11b
    
    

12. Remove the main board/cartridge board assembly by lifing it upwards. Then disconnect the red connector now that it's clear.

    
    
    
    Figure 12
    
    
    
    
    

    NOTE for Reassembly:
    
    Red connector (From Left to Right with back of unit facing you): green, yellow, orange, brown, red, black

    
    

13. Removing the gear boxes and wheels can be a bit tricky. Do one side at a time. First, note the outer side of each wheel has a white clip on it. Carefully pull the wheel upward and then move the clip to the side and remove.

    
    
    
    Figure 13a
    
    

    Now, hold the wheel so it takes tension off the belt (loosens it). Grab a pair of needle nose pliers and gently pry up the white plastic piece on the inner side.

    
    
    
    Figure 13b
    
    

    Once you do that, the wheel and gear box can be removed. Do this for the other side. Do not try to remove the belts just yet.

14. Remove the gearbox screws as shown.

    
    
    
    Figure 14
    
    

15. Put on a pair of gloves and open the gear box. There's grease in here (lots of it) so that's why you'll want the gloves on. It's messy.
    
    Carefully lift up and remove the belt gear. You may want to clean it off and apply some more grease to it.

    
    
    
    Figure 15
    
    

16. Remove the belt from the other side and inspect. Clean it off if needed. If the belt appears to be worn or mangled, then it will need to be replaced.

17. Once repaired, reassemble the robot in the opposite order that you took it apart, paying extra attention to the NOTE for Reassembly sections for putting the connectors on correctly.

18. Be sure the battery is fully charged before powering up the robot to see if he's responding better.