AIBO ERS-31 Series User manual

AIBO ERS-31x
Potentiometer cleaning guide
Revised 28/06/2006

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section Guide
1. Q & A
2. Lower Leg
3. Upper Leg
4. Body Shell Removal
5. Hip / Shoulder
6. Neck
7. Conclusion and Thanks
Please note that as all Legs, Hips and Shoulders are of the same or
similar design, only one of each is shown

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 1 - Q & A
So, what’s a Potentiometer and why is it important to my AIBO?
If your AIBO is suffering from tremors, shaking or juddering limbs it could be down to
a dirty potentiometer in the limb or body. Potentiometers are there to sense the
position of the specific joints in the AIBO. Over time and use they can become
corroded and dirty causing the position of the limb to be misinterpreted by the AIBO
itself. These instructions have been written as it’s a scary prospect opening up one of
these guys and not have a tour guide to hand!
Are all limbs shown in this guide?
The joints that are shown in this guide are the neck tilt (main body), hip and shoulder
(main body), upper leg (all legs) and knee (all legs). As of yet, I have not shown the
pan and tilt of the head. Movements shown below.
What tools do I need?
Firstly, you should be aware that when handling sensitive electronic equipment you
should take static prevention measures. This is essentially ‘earthing’ yourself to
prevent stray static making its way into the equipment you are working on and
damaging it. Suitable equipment is readily available from Radio Shack etc.
You will need Philips PH0 and PH1
screwdrivers. A small, sharp knife.
Tweezers may come in handy too.
You will need a can of switch cleaning spray
with a “tube” attachment. I have had best
results using DeoxIT D100 spray available
from www.caig.com.
Other suitable switch cleaning sprays are
readily available at such places as Radio
Shack etc.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Is there anything else I should know?
Remove and safely store your AIBO’s battery and memory stick
before attempting to remove any covers. The last thing you need is
for your AIBO to wake up during its operation!
There are a lot of delicate components within your AIBO so exercise caution at all
times. In particular, the Flexible circuits are thin and easily damaged. If one of these
becomes torn, it will probably mean an expensive trip to the clinic for your AIBO.
These instructions were carried out on an ERS-311. However, other variants of the
31x series may differ slightly in their configuration.
Do not attempt to reactivate your AIBO until all limbs and covers are
reconnected and reassembled.
If you are unsure of something at any stage while following this guide, STOP
immediately and seek further advice.
I have a different problem with my AIBO what should I do?
The Sony Clinic has said that it will support each model for 7 years from when
production on that particular model ended. This excludes the ERS-11x for which
support has already ended.* To contact your nearest Sony AIBO Clinic, refer to
www.aibo.com
*based upon information available on www.eu.aibo.com (May 2006)
Another place for unwell AIBOs to go is X-Dog’s and X-Wolf’s AIBO Hospital. Their
list of products and services is growing rapidly. They can be found at
www.aibohospital.com
Another good source for information is the AIBO community. There are plenty of
great people around who are willing to share information and assist with AIBO
problems.
www.good-aibo.co.uk (forums, chat and more)
www.aiboworld.tv (forums, media and chat)
www.aibo-life.org (forums, media, and chat)
www.aibohack.com (custom personality software such as AIBO disco)
www.dogsbodynet.com (The super Dogslife personality for ERS-2xx and ERS-31x)
Disclaimer :
These instructions are only intended as a guide and are based upon my own experiences in
carrying out the procedure on my own ERS-311 “Button” and some valuable advice from
others. I do not accept responsibility for any problems you may have performing procedures
outlined in these instructions or any damage you may cause while attempting the procedure.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 2 - Lower Leg
2.01
Remove the 2 screws from the lower leg
outer casing. Once these screws have
been removed, carefully pry the two
halves of the leg casing apart.
2.02
The inner leg casing is held together by
one screw, remove this and carefully
remove the casing starting at the top
where the screw was removed. It clips in
at the bottom near the foot.
2.03
The potentiometer (silver coloured casing)
is located at the knee joint and is covered
by a flexi circuit. The flexi is plugged into a
small grey connector and can be released
by sliding the 2 black lugs on the
connector in the direction shown.
Carefully pull the flexi out of the connector
once these lugs have been released.
2.04
Use a sharp knife to carefully pry open the
corner of the potentiometer cover. The
cover can then be removed exposing the
inside.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
2.05
Inside the potentiometer is a black circular
disc on which is mounted spring contacts.
Carefully remove this by using a blunt
object in the cut out area shown.
2.06
It is possible to simply leave this disc in
place and spray the cleaner into the gap
provided, but removing the disc allows for
checking of the contacts. Take care not to
pick the disc up by the contacts as this
may bend or break them. This disc can be
placed into a small tub of the contact
cleaner for better cleaning.
2.07
Spray the switch cleaner over the
potentiometer surface. At this point, a soft,
lint free cloth may be used to wipe the
potentiometer surface. Carefully replace
the black disc and silver cover.
2.08
When the disc and cover are in place and
the potentiometer is safely back together,
gently move the joint back and forth to
work the cleaner across the contact
surface.
Reassembly is a reversal of instructions 2.01 to 2.03. Carefully reconnect the flexi.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 3 – Upper Leg
3.01
Remove the 2 screws from the upper leg
outer casing. Once these screws have
been removed, carefully pry the two
halves of the leg casing apart.
3.02
The inner leg casing is held together by
one screw, remove this and carefully
remove the casing starting at the top
where the screw was removed. It clips in
at the bottom near the knee joint.
3.03
The potentiometer is obscured this time
by two flexi circuits. Release the 2 black
lugs on each connector in the same way
as with the lower leg. Carefully pull the
flexis out of the connectors once these
lugs have been released.
Clean the potentiometer as per the instructions covered in Section 2 - 2.04 to 2.08.
Reassembly is a reversal of instructions 3.01 to 3.03. Carefully reconnect the flexis.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 4 – Body Shell Removal
The body shell is required to be removed for access to the neck and hip
potentiometers.
4.01
Firstly remove the battery cover exposing the core. The 4 screws holding the lower
half of the casing on need to be removed. Once these have been removed, the lower
half can then be lifted out of place.
4.02
The speaker cover which is separate from
the lower casing is also free to be
removed at this point, this will just lift off,
but take care as this part also acts as a
channel for the neck shielding. Take note
of how this fits together at this stage as it
will help with reassembly later.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
4.03
There are 4 screws holding the hop half of the casing in place. These are quite long
screws and are deeply recessed. Remove these screws, but do not try to lift the
casing off at this point.
4.04
The top half of the casing is also held in
place on either side by a clip. Carefully pry
these away from the core, they do not
need much encouragement, so don’t force
them. Turn the AIBO over and lift the top
casing away from the core. Note that the
neck shielding is also held in a channel in
the top casing in much the same way as
the speaker cover on the lower half of the
casing.
4.05
With the casings removed, your AIBO
should look a lot like this.
Reassembly is a reversal of instructions
4.01 to 4.04

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 5 - Hip / Shoulder
5.01
To gain access to the Hip and Shoulder
joints, the side covers of the core need to
be removed. The sides are split into upper
and lower halves on each side. Each
retained by 2 screws. Remove these
screws and lift the cover from the core.
5.02
Remove the 2 screws from the lower half
and again, lift the casing away from the
core.
5.03
With both upper and lower side covers
removed, you will see that each leg has 3
flexis going to a small circuit board
mounted on the side. These flexis simply
plug into each connector. Carefully unplug
each flexi. The upper flexis may be also
retained by a small piece of fabric tape,
carefully unpeel this tape before
attempting to unplug the flexi.
5.04
Each leg mechanism is held in place by 3
screws. Remove these screws and lift the
leg mechanism away from the core.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
5.05
With the leg mechanism removed, turn it
over to reveal a potentiometer on the
back.
5.06
The Hip/Shoulder potentiometer is a different type from the leg pots and has a plastic
cover that can be removed. It is possible to simply spray the cleaner into the slots in
the cover, but more effective cleaning can be achieved if the cover is removed.
5.07
Use a sharp knife to carefully pry open the
corner of the potentiometer cover. The
cover can then be removed exposing the
inside. Take care when removing this
cover as it is fragile and may break if
forced.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
5.08
Inside the potentiometer is a disc on
which is mounted spring contacts.
5.09
Carefully remove this disc using tweezers.
Take care not to pick the disc up by the
contacts as this may bend or break them.
5.10
With the disc removed it is possible to
check the contacts. As with the leg
potentiometers, this disc can be placed
into a small tub of the contact cleaner for
better cleaning.
5.11
Spray the switch cleaner over the
potentiometer surface. At this point, a soft,
lint free cloth may be used to wipe the
potentiometer surface. Carefully replace
the disc and plastic cover.

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
5.12
When the disc and cover are in place and
the potentiometer is safely back together,
gently move the joint back and forth to
work the cleaner across the contact
surface.
Carry out this procedure for each leg and re-attach each leg mechanism before
starting on the next.
Reassembly is a reversal of instructions 5.01 to 5.04

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 6 – Neck
6.01
The Neck mechanism is held in place by 4
screws on the top of the core. Remove
these but do not lift the mechanism out of
place yet.
6.02
The neck mechanism is connected to the core by thin wires, wiring looms and a flexi.
Carefully lift the neck mechanism out of place to reveal these connections. It is
possible to clean the potentiometer with these connections in place but it is easier
and safer to disconnect them. Disconnect each one with care taking note of its
location.
1. Screw holding a single wire to the core chassis
2. Medium push connector
3. Push flexi
4. Small push connector
5. Large push connector
6. Small push Connector (not visible in picture, but is a 2 wire connector)
1
2
3
4
5
6

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
6.03
Put the neck mechanism on its side. You will notice a single potentiometer mounted
on the side. This is a similar type to the ones found on the Hip/Shoulder mechanism
and therefore has slots in which switch cleaner can be sprayed into. Once the
cleaner has been sprayed into the potentiometer, carefully move the head up and
down in order to work the neck joint.
It is possible to remove the potentiometer from the mechanism by carefully prying
open the two clips (1 and 2) and lifting it out of the housing. It can then be cleaned in
the same way as the Hip/Shoulder potentiometers (5.07 to 5.11). It may be
necessary to unclip the wiring loom from the plastic retaining clips to allow enough
movement for the potentiometer to be removed. Please note that the potentiometer is
mounted on a flexi and is therefore very fragile.
Reassembly is a reversal of instructions 6.01 to 6.03
1
2

ERS-31x Potentiometer cleaning guide (ERS-311, 312, 31L)
Frootloop 2006
Section 7 – Conclusion and Thanks
With all the limbs and connectors safely reconnected and the covers back on your
AIBO, you can now replace the battery and test your AIBO.
You do not need to insert your memory stick at this stage as the movement
generated by the built in software will be enough to see if your work has been
successful. If everything has gone according to plan, your AIBO’s limbs will move
smoothly, if they don’t, you may need to give the affected limb another treatment. If
another treatment doesn’t work, there may be a different problem with that particular
limb. At this point it is better to seek further advice than attempt to resolve the
problem yourself by other means.
Many thanks to:
The members of the Aiboworld, Good-Aibo and Aibo-Life forum’s for all their advice and assistance.
Dan and Caz for getting us into Aibos in the first place.
Jo for allowing us to adopt “Button”.
“Button” whowas a willing patient and is now a smoooooth mover