iRobot Roomba Discovery 4 Series User manual

www.RobotShop.com Chapter 2: How to Open Roomba / Replace Frame
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Roomba Discovery 4XXX & 4XX Servicing and
Repair Guide
Chapter 2: How to Open Roomba / Replace Frame

www.RobotShop.com Chapter 2: How to Open Roomba / Replace Frame
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To service and maintain your Roomba Discovery 4XXX/4XX series, you will need to be
able to open and close the robot’s frame. The Discovery Series Roomba has two main parts
that need to be loosened and removed to gain access to its insides. These two parts are the
robot’s front bumper, and top frame cover. This also doubles as a guide on how to replace your
front bumper and/or top cover. The Discovery Series Roombas are those pictured below:
Please note that if your Roomba is under warranty, servicing the robot will void the
warranty. For robots under warranty, please consult the warranty policy of the distributor where
purchased, and/or contact iRobot’s customer service.
2.1 Front Unit
Removal and Assembly of the Front Bumper
Removal Phase
1- Unscrew the screws (A)
Screws (A)

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2- Push with both thumbs
at points (A) and (B) in order
to take the front bumper
out of its sockets.
3- Take a pair of pliers and
remove the connector
from the front bumper
(if needed)
Point (A) Point (B)

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Assembly Phase
1- Reconnect the connector
for the front bumper with
pliers or fingers.
2- Align the bumper at points (A),
(B) and (C) and push on the
bumper with both hands in
order to insert the bumper into
position.
Point (A)
Point (B)
Point (C)

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3- Rescrew Screws A
2.2 Cover Unit
Removal and Assembly of the Cover
Removal Phase
1- Unscrew the screws (A)
Screws (A)

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2- Push with both thumbs
at points (A) and (B) in order
to take the front bumper
out of its sockets.
3- To replace the top cover you
may want to remove the front
bumper, though this may not
be necessary. Using a pair of
pliers, disconnect the bumper
from its connector, as
pictured.
Point (A) Point (B)

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4- Unscrew the screws (B)
5- Unscrew the screws (C)
Note: The middle screw
is not present on all
Roomba’s.
Screws (B)
Screws (C)

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6- Unscrew the screws (D)
7- Unscrew the screws (E)
Screws (D)
Screws (E)

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8- Remove particle bin. Turn
Roomba over and pull on
the front cover.
9- If needed disconnect the
connector for Roomba’s front
cover.

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Assembly Phase
1- Reconnect to the
motherboard the connector
for the cover. Align Roomba’s
cover and press on the cover
to fit it properly. Make sure the
sides of the cover are fully
inserted, and that the top
cover matches up flush with
the robot’s frame.
2- Reconnect the connector
for the front bumper with
pliers or fingers. This step
can be omitted if you did not
disconnect the bumper in
previous steps.

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3- Align the bumper at points (A),
(B) and (C) and push on the
bumper with both hands in
order to insert the bumper into
position.
4- Reinsert the screws (B)
Point (A)
Point (B)
Point (C)
Screws (B)

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5- Reinsert the screws (C)
Note: The middle screw
is not present on all
Roomba’s.
6- Reinsert the screws (D)
Screws (C)
Screws (D)

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7- Reinsert the screws (E)
8- Reinsert the screws (A).
Reattach the dustbin, and
you have now fully
reassembled your Roomba.
Screws (E)
Screws (A)