535 Gearbox pic

Duf · Joined: 10 Jul 2006 Posts: 231 Location: Naples, FL

Proof that Irobot doesn't want your robot to last!

Why else would they design the gear box to trap hair??! This is a pic of the inside of the 535 gearbox I attempted to do the ball bearing mod on, before the attempt. As you can see it is choking on hair.

Gordon · Posted: June 8, 2008, 1:48 pm Post subject: Re: 535 Gearbox pic

Duf wrote: Proof that Irobot doesn't want your robot to last! Naaaah! That's not true; the Company wants it to last 366 days! Quote: ...Why else would they design the gear box to trap hair??! ... ...and by omitting grease from that gear-box there is just enough volume to collect an average 366-days of collected hair in that chamber! :party:

fancyfreewv · Posted: June 9, 2008, 8:41 am Post subject:

No wonder you have roombarf on your carpets, Duf. My gearboxes are never close to this bad when I clean them. I think your excess hair is what is being deposited on the rugs.

Duf · Joined: 10 Jul 2006 Posts: 231 Location: Naples, FL

fancyfreewv wrote: No wonder you have roombarf on your carpets, Duf. My gearboxes are never close to this bad when I clean them. I think your excess hair is what is being deposited on the rugs.

My point is it shouldn't require what is technically, warranty voiding disassembly of the unit to keep it working!

:)

douggee · Joined: 09 Jun 2008 Posts: 1

Thanks for the great pic :D I've had intermittant problems with my brushes not turning since shortly after buying my 535. iRobot is finally sending a replacement module, if they don't require me to return the old one I'll disassemble it and thoroughly clean the gears since, with 3 dogs and a cat, I'm sure it is packed full of hair.

When removing all the modules to do a thorough monthly cleaning I've noticed another problem area with the brushes module which doesn't require cracking it open to clean. The first time I removed this module I noted that the motor was completely encased in lint, dust, and pet hair. Using both the dusting brush and crevice tool on my upright vac I managed to remove quite a bit of it. However, there is a very small part of the motor shaft that is exposed. There was so much pet hair and carpet fiber wound around the shaft that the motor had stopped turning. Using tweezers and working delicately with a small, sharp knife I managed to remove all these fibers and hairs.

I'm reasonably sure that the motor had probably over-heated more than once which led to the brushes not turning. Unfortunately the sensor never alerts me that the brushes have ceased to rotate and as soon as I notice strips of lint being left on the carpet I put the Roomba into demo mode and listen for the brushes to rotate. If no rotation is heard I know it is time to remove and clean the module again.

Thanks again for the pic of the gearbox and i hope my cleaning suggestion may help some of you experiencing the same problem.

fancyfreewv · Posted: June 9, 2008, 11:34 am Post subject:

I clean the gearbox on my unmodded 535 fairly frequently and I have also noticed the hair around the motor shaft.

In my case, this doesn't require much to remove using my curved tweezers and a brush and air compressor but I agree that it has the potential just like hair in the gears of causing problems.

And Duf, no, we should not have to do this in order to keep them running. I feel badly for anyone who has not found this site, doesn't use the internet and just relies on IRobot to give them information.

I guess when IRobot gets tired of warranty claims and keeping whole divisions open to take care of the consumer market, they might realize that anyone who is burned on one of these is not going to buy another. Possibly the government contracts and pricing is so lucrative that it can support all this but it's a heck of a way to run a business and do marketing. :?

robodude · Joined: 26 Sep 2007 Posts: 103 Location: AL

douggee wrote: iRobot is finally sending a replacement module.

douggee, did you get your replacement module from iRobot? I've been told they are on backorder. I've been waiting for 2 weeks now.

jtchambliss · Joined: 17 May 2008 Posts: 5

[quote="robodude"] douggee wrote: I've been waiting for 2 weeks now.

I've been waiting 4 weeks. I emailed iRobot last week to inquire how much longer it would be and they said 1-2 weeks (from 6/13...when I received the email from iRobot)

fancyfreewv · Posted: June 17, 2008, 7:44 pm Post subject:

Awww give them a break.

IRobot must not have realized (AHEM) that this gearbox arrangement and materials - (which I don't think has changed since the first robot they put out) - was going to cause this much trouble! I guess that's the excuse for not having enough on hand.

Someone there must be more than a bit nearsighted (or stubborn) to say the least about the design of this dirt and hair collector thingy.

:roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll:

jtchambliss · Joined: 17 May 2008 Posts: 5

I'm holding out hope that the long wait is due to a redesign of the gearbox. I'm not holding my breath though... :?

vic7767 · Joined: 14 Jan 2006 Posts: 3429 Location: Louisiana

Rats, I just had to order a new Cleaning Head Module from IRobot for my 535 Roomba, the email answer was it will be sent via UPS in 7 to 10 days.

Jeff Carver · Joined: 19 Jan 2008 Posts: 117 Location: Massachusetts

Out of curiosity, Vic, was the module that failed one that was still in warranty, or one that had the ball-bearing mod on it?

jtchambliss · Joined: 17 May 2008 Posts: 5

vic7767 wrote: Rats, I just had to order a new Cleaning Head Module from IRobot for my 535 Roomba, the email answer was it will be sent via UPS in 7 to 10 days.

That would be consistent with what iRobot emailed me on the 13th. With an improved design of course :shock:

vic7767 · Joined: 14 Jan 2006 Posts: 3429 Location: Louisiana

Hehe, you know that I have no ball bearing Cleaning Head Modules.

The CHM is from my original 535 unit that has not been modified. I ran it just long enough to reach the point of "Clean Roombas Brushes" even though we know the brushes were clean. Naturally now that IRobot is sending me a new one this one is going to be modified with the 3 ball bearing fix.

jtchambliss · Joined: 17 May 2008 Posts: 5

Vic,

I'm getting ready to do your bearing mod, including the 3mm ones on the side plate. When by box went, it distorted the case and made one of the gear shaft holes slotted. I'm thinking of making a new cover out of stainless steel sheet metal. Any thoughts?

- Jeff

dermbrian · Joined: 14 Jun 2008 Posts: 14

The pictures of the pet-hair covered white gears and red plastic have been reminding me of something, but I couldn't think of what it was until just now. A toy from the 1960's.....

YouTube Mr. Machine commercial

I'll leave you to judge which has better mechanical tolerances, materials, and dust seals.

Brian

vic7767 · Joined: 14 Jan 2006 Posts: 3429 Location: Louisiana

jtchambliss, I've got some 1/4 aluminum plate that I had considered using awhile back. Then the ball bearings seemed to be a better way to go for an immediate fix.

You might want to go to Chris' site RoombaExchange. He sells the empty gear case and also just the side plate. That may be the better way to go unless you just like working with metal.

jtchambliss · Joined: 17 May 2008 Posts: 5

Thanks Vic. I think I'll take your advice and order a new cover. That should be a timesaver.

I ordered the flanged 3mm bearings from VXB.
http://www.vxb.com/page/bearings/PROD/3mm/SCB3X6-1

I plan to install them with the flanges in the gearbox. Is this how you did your 3mm mod.

Thanks again for your help and advice.

- Jeff

vic7767 · Joined: 14 Jan 2006 Posts: 3429 Location: Louisiana

Yep, the flanged 3 mm bearings are easier to fit into the brass bushing square hole and stay.