Disassembly Precautions

News and information about the Neato XV-11 Robotic Vacuum. All discussion and troubleshooting questions go here.

Disassembly Precautions

Postby glnc222 » April 21st, 2012, 8:43 pm

Avoiding problems assembling, disassembling Neato cases

(for photos and general procedure see
http://www.robot-doc.com/20.html

Excellent Vorwerk VR100 (similar to XV models) disassembly video, use of tools https://www.youtube.com/watch?v=bEwAftujajY&feature=youtu.be German but commentary not needed.

slide show and brush motor cleaning: http://www.robotreviews.com/chat/viewtopic.php?f=20&t=18031

and http://www.robotshop.com/blog/neato-xv-11-disassembly-see-the-guts-of-your-robotic-vacuum-978
video https://www.youtube.com/watch?v=G8G72NAppKY

and http://hbrobotics.org/wiki/index.php?title=Disassembling_the_XV-11 [seems discontinued 7/1/2915]

and http://www.robotreviews.com/news/2010/8/23/neato-xv-11-unboxing-and-breakdown

taking note of later revisions in http://www.robotreviews.com/chat/viewtopic.php?f=20&t=15940)

[edit] long instructional video of Neato disassembly and repair https://www.youtube.com/watch?v=XSLGBzEumAM&list=UUllFkMo5A0V5UKYNltNEt4Q&index=9

brush motor disassembly and repair
http://froodystuff.blogspot.no/2014/03/neato-robotics-oh-dont-give-me-none.html

drive wheel assembly
http://random-workshop.blogspot.com/2010/12/neato-xv-11-drive-wheel-assembly.html
[seems discontinued 7/1/2015: it is just a motor and gears; try the long repair video above]

case screw sizes
Thin screws (bumper etc.) M2.9 x 16mm (bumper edge under wall sensor shortened)
Thick screws (bottom cover etc.) M3.9 x 16mm
Sheet metal screws or special self-threading for plastic. Available from screw distributors such as instockfasteners.
(Botvac different, Torx screws T10 -- thin long shank driver needed)

1. Stripping screw threads in plastic

The problem of screw threads in soft plastic stripping from excess torque is reduced putting a distance limit collar on the driver shaft, similar to used on drill bits. Simplifies using powered drivers. Measure position before removing screws the first time. Collars can be crafted from a dowel slice with a side set screw when not on hand for drills. Screws in plastic should be only seated, not really tightened, to avoid stripping threads. May be sufficient to hold power drivers lightly with fingers only, allowing to twist as soon as seated. Not so much a problem on Neato than other machines, but the inter-cover screws in deep wells are vulnerable.

Loose screws near the front can allow the two case halves to separate slightly putting pressure on the front bumper sides, causing them to stick. Check for a crack in between the two halves. Screw holes should be repairable by applying epoxy around the inside and then self-threading the screw again. JB Quick Weld is steel infused epoxy especially strong. If too much is applied just drill a hole for the screw.


When threads are stripped in plastic they still sink screws properly, but continue to rotate at the bottom, confusing when sinking into deep wells. [added 4/22/12] I think there is more a slipping of threads, bending them, limiting tightness, since they still hold and screw in, just not extra tight. Sometimes plastic screws preserve material better as well, but are more common in machine screws instead of self-threading or sheet metal threads. We will now move on to driving nails...

Also short screws on dust bin top http://www.robotreviews.com/chat/viewtopic.php?f=20&t=17183#p117333

2. LCD ribbon cable

No strain relief on the LCD board, easily ripped off, requires special equipment to solder, not separately sold. Cover with epoxy glue for a strain relief (as Protech Robotics does on parts they sell). Also see http://www.robotreviews.com/chat/viewtopic.php?f=20&t=17299

3. Wheel springs moved to top cover

On some recent cases the springs are attached to the top cover instead of a prong on the bottom frame (which tended to break). Springs must be detached from the wheels before separating the top cover from the bottom frame. Ignoring this can lead to ripping off the LCD ribbon cable, above. The old plastic block is still there, and it may be advantageous to move the springs back to the old location with a screw as was previously fixed. Removing and reattaching the spring from the wheels while installed can scrape off the lever arm on the microswitches for "picked up" detection if not protected -- see following post.

4. Screws in narrow wells

Inter-cover screws in deep wells are hard to see much less pull out when unscrewed. A small hook bent from a paper clip can assist when lacking more professional tools, magnetized drivers etc.
These screws are also vulnerable to over-tightening thread stripping from lack of visibility when installing.

5. USB port cover

Rubber plug sandwiched between the top and bottom cover, will fall out if not removed before opening case.

6. Dust bin switch cover

Rubber cover not fastened, can fall out and get lost.

7. wall sensor plug on system board

The connector body can come off with the plug, leaving the pin orientation not visibly marked well or polarized -- risk of inserting backwards. Easy to grip the socket along with the plug and the glue is not much stronger than the tight plug.

8. bumper paddles ("actuators")

It is possible to close the case with a bumper paddle off it's socket on one side, revealed in a "bumper stuck error".
Since the case can be closed, they must be checked afterwards.

9. internal partitions

Any vertical partition in the bottom frame no matter how short, small flat pieces, mate with matching pieces in the top cover. No wires can be left over these bottom edges or the case will not close tightly, even though it closes. Then the front bumper pinching both the top and bottom will be sticky from pressure. Observe any cracks near the front between the halves.
replacement screws
Edit 3/14/13: Metric tapping screws are available mail order some places such as instockfasteners.com. Case fastening screws are metric M2.9 x 16mm sheet metal (except not pointed). Slightly larger than a #4 screws, metric threads. The bottom vacuum and battery cover screws are M3.9 x 16mm sheet metal.

10. Deformed battery compartment heat sinks or wheel arm pivot shaft -- scraping shaft screw
see thread http://www.robotreviews.com/chat/viewtopic.php?f=20&t=17303&p=118413#p118411
Last edited by glnc222 on November 27th, 2016, 2:30 pm, edited 19 times in total.
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Re: Disassembly Precautions

Postby glnc222 » April 26th, 2012, 8:12 pm

Wheel Switch Levers Falling Off

A tab on the wheel drive pivots against a microswitch plugged into sockets on the system board to detect "pick up" off the floor. The switch is pressed when the wheels rise out of the case when picked up, so loss of this tab just prevents getting the "put me down" msg, not too good if it starts to run when not on the floor but quickly stoppable.

The tiny 1/2" x 1/8" metal lever or flap with a slit lengthwise, which presses on the stud in the center, covered with a bit of cushioning plastic, appears not to be fastened in, and falls out of the Neato when the wheels are removed -- and may not be readily recognized. The slit allows sideways compression to fit tiny pivot ends into the slot on the microswitch. The plastic covering applied may be help it stay spread and attached.

Seems to become detached when re-attaching the springs, where a tab on the wheel casing can scrape against the tab and be pressed harder than usual, with twisting the wheels to insert the pivot shaft. It is covered by the wheels when this occurs, and can easily not be noticed.

USB interface includes a command to disable "pick up" detection from this switch.
Attachments
microlever.jpg
wheel microswitch lever falling out
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Re: Disassembly Precautions

Postby chris-s » May 8th, 2012, 11:22 am

glnc222 wrote:On some recent cases the springs are attached to the top cover instead of a prong on the bottom frame (which tended to break). Springs must be detached from the wheels before separating the top cover from the bottom frame.
How do you detach spring before separating top cover ? Have a picture ?
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Re: Disassembly Precautions

Postby vic7767 » May 8th, 2012, 1:48 pm

"Springs must be detached from the wheels" first, then the top cover can be lifted just enough to then disconnect the UI interface ribbon cable (right side) and s two conductor cable (left side).
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Re: Disassembly Precautions

Postby chris-s » May 8th, 2012, 3:08 pm

Yes, but there is no access to the spring attachement from the outside ! :shock:
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Re: Disassembly Precautions

Postby vic7767 » May 8th, 2012, 3:30 pm

That is correct. To access the two drive motor springs just flip the Neato upside down, remove the 4 screws that hold the large plate that has the two small rollers on it. Once the plate is lifted you will see the two drive wheels and springs will be visible on each drive wheel.
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Re: Disassembly Precautions

Postby chris-s » May 8th, 2012, 4:57 pm

I'm sorry, but I had removed the rear plate, and if I can see the spring attached to upper cover, I can't see the other side of the spring, this one I need to remove.
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Re: Disassembly Precautions

Postby vic7767 » May 8th, 2012, 5:02 pm

To remove the top cover the two drive wheel springs only need to be removed from the drive motors, not the other ends of the motor springs.
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Re: Disassembly Precautions

Postby chris-s » May 8th, 2012, 5:05 pm

Yes, but from the outside, I can't access to the drive motor spring.
I only see the other end of the spring, where there is the screw on the top cover.
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Re: Disassembly Precautions

Postby vic7767 » May 8th, 2012, 5:22 pm

You have to unmount the drive motor from the swivel axle.
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Re: Disassembly Precautions

Postby glnc222 » May 8th, 2012, 7:38 pm

wheel spring access photos

beware the microswitch lever under the back tab when reattaching pivot in clip -- pressed when wheel pulled up, so keep down, hold finger over lever.
Get the tab over the lever before pressing down on it, avoid scraping up the open end. Reattach if knocked off.
Problem may be installing with the pivot still in -- maybe best to remove it until last step -- like Vic's advice above.
Attachments
coveroff.jpg
back cover off exposing wheel pivots
pivotunclipped.jpg
pivot pin twisted out of clip (can be removed sideways)
twistmore.jpg
twist more to clear circuit board
springsaccess.jpg
springs visible under wheels -- pull wheel up to reach
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Re: Disassembly Precautions

Postby chris-s » May 9th, 2012, 8:09 am

vic7767 wrote:You have to unmount the drive motor from the swivel axle.
OK, that was the missing step.
Thanks.

And thanks for pictures 8)
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Re: Disassembly Precautions

Postby glnc222 » June 20th, 2012, 12:57 am

favorite Neato assembly tools
Attachments
tools.jpg
favorite Neato assembly tools
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