Robotronics Toby Tire Robot User manual

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
Toby Tire RobotOperating Manual
V
ersion 6.5

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Toby Tire Operating Manual
Congratulations on your purchase of a ROBOTRONICS, Inc. robot.
Your robot has been carefully constructed of the highest quality components. Its
design is the result of years of experience building robots. You will find it an
extremely effective spokesman for your organization. It is built for ease of
operation, maintenance and repair. It is built so that you can easily expand its
functions making its usefulness grow as your needs grow.
Please read this manual carefully. It will help you make the most of your
robot. Attention to maintenance and proper training will greatly prolong the life of
your robot. Most problems you encounter will be minor and the manual will
provide an answer. Please feel free to contact us if you have unanswered questions
relating to operation, maintenance, and repair. Also, if you have technical
questions relating to expanding the functions of your robot, we would be most
happy to help.
Sincerely,
ROBOTRONICS, Inc.
ROBOTRONICS INC.
Springville, Utah 84663
www.Robotronics.com
Robotronics Inc., 2004.
Robotronics

iii
Contents
Contents
Warranty Information ..............................................................................................1
PART 1 General Operating Instructions..........................................3
Chapter 1 Getting Started......................................................................3
Operating Hints..................................................................................................... 3
Setup and How To Operate The Robot.................................................................4
Transporting The Robot........................................................................................6
PART 2 Subsystems of the Robot......................................................7
Chapter 2 Radio Control System...........................................................8
Radio Control Operating Instructions....................................................................8
Radio Control Transmitter (Diagram)....................................................................9
Radio Control Transmitter Controls.....................................................................10
NI-MH R.C. Transmitter Battery.......................................................................... 12
Charging of the NI-MH R.C. Transmitter Battery (Diagram)................................ 12
Adapter for Charging and 110 V Power Supply ..................................................13
Chapter 3 Voice System Overview......................................................14
Location of Voice Units ....................................................................................... 14
Belt Transmitter...................................................................................................15
Robot Receiver ................................................................................................... 16
151 System (Robot TX and Belt 151 Receiver) ..................................................17
Voice System Troubleshooting ...........................................................................18
Mouth Operation.................................................................................................20
Operator’s Voice Headset, Transmitter, and Receiver........................................21
Chapter 4 Cassette Tape Player System ............................................22
Cassette Tape Player (Diagram).........................................................................23
Chapter 5 Siren.....................................................................................25
Chapter 6 Robot Battery Systems.......................................................26
Robot Battery...................................................................................................... 26
Robot Battery Charger ........................................................................................27
Chapter 7 Drive Motor System ............................................................29
Chapter 8 Character Head Turning Motor System.............................31
Chapter 9 Eyelids and Eyes Left and Right........................................32
Chapter 10 Optional Accessories
Pitch Shifter (Voice Modifier)...........................................................................33

iv Contents
PART 3 Assembly & Disassembly................................................35
Chapter 11 Assembly & Disassembly..................................................35
PART 4 Maintenance................................................................................ 36
Chapter 12 Maintenance ......................................................................36
Regular Maintenance Checklist ..........................................................................36
Recommended Tool Kit.......................................................................................37
Painting of the Body............................................................................................38
Repair of the Body ..............................................................................................39
Storage................................................................................................................40
Appendixes
Appendix A..............................................................................................41
QUICK REFERENCE TROUBLESHOOTING ............................................. 42
Robot Circuit Block Diagram...............................................................................45
Appendix B Robot Parts Identification...............................................46
Inside View..........................................................................................................47
Main Box Inside...................................................................................................48
Battery Compartment..........................................................................................49
Main Board .....................................................................................................50
Fuse Block Detail................................................................................................51
Side Arm View.....................................................................................................52
Eyes Servo Board ...............................................................................................53
Eyes .....................................................................................................54
Arm Control Board ..............................................................................................55
Notes Section*.........................................................................................................56
Technical Tips Section*...........................................................................................57
* These sections can be used to place additional notes that you would like to record, during
your use of the robot.

1
Warranty Information and Getting Help
Limited Warranty
All robots and accessories have a limited 6-month warranty, which covers all parts and labor.
This period covers the normal burn-in for electronic components. Experience has shown that
this warranty period catches most component defects and other possible flaws. If you have a
problem, we are anxious to help. Our desire is to be certain you receive a quality product and
excellent service.
Warranty work is specifically limited to correction of defects by repair or replacement of faulty
equipment or parts. The robot shall be repaired or replaced at Seller's option. Equipment
returned to the factory for repair must have pre-authorization from our service department and
must be sent freight pre-paid, and will be returned freight pre-paid by UPS ground or common
carrier. If you need parts sent by air shipment you will be responsible to pay the additional
shipping charges.
In no event shall ROBOTRONICS, Inc. be liable for any incidental or consequential damages in
connection with or arising from the use of the robot, this manual or any procedures herein.
The buyer is further responsible to ensure that proper and complete training be given to those
operating the robot system as all aspects of such operation cannot be covered in a brief manual
such as this.
In no event shall ROBOTRONICS, Inc. be liable for any incidental or consequential damages in
connection with or arising from the use of this manual or any procedures contained herein.
If You Have A Problem
Call our service department and explain the problem. The phone number is (801) 489-
4466. Most difficulties are minor and can be solved easily over the phone. If possible,
have the robot near the phone when you call.
Important: Have the robot serial number and model number ready. This will help our
technician identify the model of robot you have. The serial and model number sticker is located
on the robot frame on the right side. In the Appendix, the Lower Robot - Top View shows the
location of the serial number sticker.
Record the vital information from your robot here for future access
DateReceived:
CustomerNumber:
Robot Model Number:
Robot Serial Number:
Brand of Radio Control:
Frequency of Radio Control:
Voice Frequencies
Operator Transmitter:
Operator Receiver:

2 Warranty Information and Getting Help
Upon the receipt of your product, save all packing materials to return the product if
needed.
If you must return a part or the robot for repair, pack it carefully and send it prepaid
according to instructions. You must obtain a return authorization number from the
service department before shipping the robot or a part to the factory.
Parts of the robot are best sent by a carrier such as UPS, Fed. Ex. or U.S. mail, because
shipping is based on the actual weight of the package. Be sure to insure the shipment
for the correct value. A freight company such as Roadway should be used only for the
complete robot, because their shipping charges are based on 100 pound minimums.
For international shipments, you will be responsible for paying customs duties, taxes and
other fees. The shipment must be labeled on the paperwork and on the outside of the
container that it is “For Educational Purposes”. If it is a “warranty replacement” or a
“repair return” this also must be indicated both ways on the customs documentation.
Contact your customs agency on how to document the shipment correctly to avoid
unnecessary customs charges.
After The Warranty Repair and Help
Our technical staff is always available to help with your questions. Again, most problems are
easily solved. The robot design is very modular to make removal of a part of the robot very
easy. For example the main electronics box, which houses most of the electronic circuitry, can
be removed from the frame of the robot. If you do need technical help or replacement parts, call
our Service Dept. We can usually ship them the following day you call. Please call our service
department for a return authorization number before sending a part or your robot in for repair or
modifications.
Service Department phone number: 801-489-4466.

3
Operating Hints
Part 1 General Operating Instructions
CHAPTER 1 Getting Started
OPERATING HINTS
ROBOTRONICS, Inc. robots are a unique and exciting tool in the hands of a skilled and trained
operator. The operator provides much of the excitement the robot conveys. The selection and
training of the operator should be done carefully, so as to provide a person with good judgment
and an outgoing personality. The operator is the single most important feature that the robot
has. Nevertheless, with a little practice anyone can learn to operate the robot and even those
with a shy personality can be very effective using the robot. The following points will help in
your operation of the robot.
Operate the robot with charged batteries in the transmitter and robot.
Never operate the robot out of line-of-sight.
The operator must have the radio control in their hands when the robot is on. If you need to
set the radio control down, turn the robot off first.
Always have a trained person posted near the robot to help in crowd control, and to protect
the robot from vandalism. This person is also available to answer questions and interact
with the robot.
Operating distance should never exceed 100 feet. When moving the robot through crowds,
the robot should be operated slowly and smoothly without any sudden changes of direction.
Walls, turns, and other obstacles are hazards to be avoided. Safe clearance should be
maintained between these obstacles and the robot.
Never leave the robot "ON" when unattended or in direct sunlight for extended periods of
time.
The robot is designed to be operated on hard, smooth surfaces and carpet. Avoid extra
deep shag carpet, dirt, gravel, or grass surfaces. Avoid steep inclines or large uneven
surfaces such as curbs, gutters, or uncovered electrical lines.
When using the robot on a stage, the area just in front of the stage should be clear of
children for about 10 feet.
When attempting to operate the robot for the first time, do so in a large flat area without
obstacles. The operation of the controls should be done in a smooth, fluid manner. Avoid
jerking starts and stops or overreacting to the controls. When first practicing movement, it is
sometimes helpful to follow behind the robot, as robot movement will match stick movement.
(Controls respond opposite when the robot is facing the operator.)
The robot can be a highly successful tool for education and entertainment. Appropriate jokes,
stories and general conversation can be very effective. Children of all ages are strongly
attracted to the robot. They will talk to it, hug it, kiss it, and generally treat it as a good friend.
The smaller sized robots are very effective with children. They are light in weight and just the
right size to communicate with children. The most important ingredient to the use and effective
operation of the robot is common sense. The following instructions will help you get set up and
start using the robot.

4 Setup and How to Operate the Robot
SETUP AND HOW TO OPERATE THE ROBOT
Step # 1
Read and study this manual completely before operating the robot.
Step # 2 Charge the batteries
Be certain that the robot battery and radio control transmitter battery are fully charged before
operating the robot.
Install the robot battery. Open the rear door or trunk to gain access.
1. Put the robot battery in the compartment in the back.
2. Connect the robot battery connector to the robot connector. Red will go to red and black to
black. This connection is polarity protected and can be connected only the correct way.
3. The battery is secured in place with a battery strap. Tighten the strap very tight.
!CAUTION
The robot battery posts should never contact the metal of the main electronics box or the
metal of the drive base. This will result in damage to electronic components especially
inside the main electronics box.
Step # 4 Powering up
The radio control transmitter will be referred to as “RC” in this manual.
Turn the RC "ON" first and then turn the robot "ON". Check that the RC
battery level meter reads to the right. The "ON/OFF" switch for the robot is
located inside the rear door or trunk on the main electronics panel. Push the
switch up to turn the robot on.
Step # 5 Set the Volumes
Check that the volume of the voice and tape player are at the level that your want.
The tape player volume can be changed on the tape player itself, which can be accessed
through the rear trunk or door. The volume for the Character voice is on the back of the voice
receiver also accessible through the rear door.
Step # 6 Test all the functions
Test all of the robot's functions: Character’ voice both ways, eyelids, eyes, tape, siren, lights,
and drive movement for proper operation. The robot is now ready to operate.
Step # 7 Optional Accessories Setup
For information about these, see the optional accessories section. This includes options such
as the voice modifier and water squirter. These sections will give you step by step instructions
for setup and related diagrams.
Step # 8 Powering Down
To turn off the system, turn the main switch to the “OFF” position. Finally turn off the Voice
Transmitter, 151 Voice Receiver and the Radio Control Transmitter.

5
Setup and How to Operate the Robot
Step # 9 Charge the batteries again
Connect the Robot battery to the charger and bring it back to a full charge before leaving the
robot. This battery should not be left with a partial charge. The transmitter battery should be
charged if it is low.
All of the major functions of the robot each have a section in the manual with more
details and diagrams. Refer to these for more in depth information. The Appendix
has pictures and diagrams of where various parts are in the robot. These will help
you become familiar with where the parts are located and their function.

6 Transporting the Robot
TRANSPORTING THE ROBOT
Before transporting the robot, remove the robot battery from the robot. The vehicle that you use
to transport the robot should have adequate shock absorption. Vans and cars used for
passengers would be the best. Transporting the robot in a trailer is not recommended because
trailers typically do not have the same level of shock absorption as a car or van. A good rule of
thumb to follow is that if the vehicle is adequate for transporting a computer it should also be
fine for the robot.
Double check that the upper robot is latched and secure. There are two latches. Secure the
robot in transport so that it does not roll around inside your vehicle.
!CAUTION
If the upper robot is not properly secured before transport, it could move around or tip
over in your vehicle causing damage to the robot.

7
Subsystems
Part 2 Subsystems of the Robot
Functionally, the robot is made up of the following basic subsystems:
A. Radio Control System
B. Voice System
C. Cassette Tape Player
D. Siren
E. Robot Battery Systems
F. Drive Motors
G. Eyelids and Eyes Left and Right
The systems block diagram found in the Appendix shows how the various subsystems and
their components are interrelated.
Following are explanations of each subsystem, some operating instructions, and trouble
shooting hints where appropriate.

8 Radio Control System
CHAPTER 2 Radio Control System
The Radio Control System consists of the control transmitter unit held by the operator and the
receiver with its associated components in the robot.
The Radio Control Transmitter converts movements of the control sticks and switches into a
coded radio signal, which is transmitted by radio to the Radio Control Receiver within the robot.
The signal is received and then decoded by the micro-controller, which is on the main circuit
board in the vehicle. The micro-controller controls functions based on what was sent from the
radio control transmitter.
RADIO CONTROL OPERATING INSTRUCTIONS
Refer to the diagram showing the radio control transmitter for the location of controls. Check all
of the trim adjustments on the transmitter and make sure they are in their center position.
Extend the Radio Control Transmitter Antenna 1/4 to 1/2 way. Turn the Radio Control
Transmitter on first and then turn on the main robot power switch. It is necessary for the robot to
always have an operating signal when it is on, if there is no signal you will not have full control
of the robot.
The right hand joystick controls movement of the robot's drive wheels. Pushing the stick
forward will cause the robot to move forward. Pulling the stick back will cause the robot to move
backward. Moving the stick to the right or left will cause the robot to turn to the right or left
respectively. Movement is fully proportional so any variation or combination of movement is
possible. The horizontal and vertical trim tabs to the left and below the joystick are for centering
and should be typically left in the center. The only time that you would need to move these
trims is if the robot started moving slightly on its own. In this case move them slightly until the
robot stops.
Control of the left arms is on the left joystick. The left and right arms are controlled in the
corners forward and back. There is also arm movement on one of the switches. The eyelids,
the tape, and the siren are all on a switch.
For a detail of other functions, see the radio control diagram on the next page. All of these
functions are labeled on the radio control itself.
A charge plug is provided on the transmitter for recharging its internal battery. The transmitter
power switch must be in the off position before charging the batteries. A charge light on the
charger will come on while charging.
There is a RC battery(2-3 hours) provided with all robots. There is an extra Ni-MH battery(5-6
hours) provided with the package. Each of these batteries has its own respective charger.

9
Radio Control Diagram
RADIO CONTROL TRANSMITTER
(Hi-Tec)
2
9
12
14
11
10
7
8 6
4 5
3
16
15
1
13

10 Radio Control Functions
RC TRANSMITTER CONTROLS
Note: The following information on the transmitter controls includes information for a variety of
similar robots.
1. Telescopic Transmitter Aerial.
2. Transmitter Battery Voltage Meter (Expand Scale Voltmeter)
3. Right control Stick-
Up and Down – Robot drive motors, forward and reverse.
Right and Left – Robot drive motors steering. Left and right turns.
4. Forward/Reverse Trim lever for right control stick. Normal = Center. Neutrals the drive
motors. If the robot is moving slightly slide this a few clicks until robot stops moving.
5. Left and right Trim lever for right control stick. Normal = Center. Neutrals the drive
motors. If the robot is moving slightly slide this a few clicks until robot stops moving.
6. Crystal.
7. On/Off Switch.
8. Recharge jack. Plug the RC battery charger in here to recharge the internal battery.
The charge light will come on, on the charger.
9. Forward and reverse trim lever for the left control stick. Normal = Center. Unused.
10. Left and right Trim lever for left control stick. Normal = Center. Centers the head on
robots with head movement (Character in Vehicle).
11. Left Control Stick
Left and right movement- not used
Up – Left arm and Right arm up and down

11
Top Switch Functions
12. Tape player
13. Blink eyes
14. Dance and Handshake
15. Unused
16. Siren

12 RC Transmitter Battery
THE NICKEL METAL HYDRIDE (NI-MH) RC TRANSMITTER BATTERY
The NI-MH RC transmitter battery will last about 5-6 hours on a full charge. Charge the battery
for 16 hours. A charge jack is provided on the transmitter for recharging its internal batteries.
This round jack is located on the right side of the radio control. (See the radio control diagram)
The RC power switch must be in the off position when the charger is plugged into it and must
remain in the off position while charging. A light on the charger will be on, when charging.
Charging Jack for
the RC Battery
Caution: Do not overcharge the batteries as this could cause permanent damage to the
transmitter batteries. (Doubling the normal charging time is the type of over charging that is
meant here, and the battery getting hot.) When the battery level needle goes in the red, the
robot should be turned off because the robot could act erratic without the transmitter signal.
To avoid a RC battery going dead during a presentation, start the program with a fully charged
battery or be aware of how much charge there is left in the battery. If you have an extra battery
or the optional 110 Volt RC Power Supply, you can connect one of these and keep going.
To install the NI-MH battery pack you need to take the battery cover off the RC. Disconnect the
RC battery and put the NI-MH battery in its place.
RC Battery and Charger Specifications
RC transmitter battery 9.6 Volts 700mAH
RC transmitter battery charger 11.6 Volts 70mA
NI-MH RC Battery and Charger Specifications
NI-MH RC transmitter battery 9.6 Volts 1300mAH
NI-MH RC transmitter battery charger 11.6 Volts 130mA

13
Adapter and 110 V Supply
Adapter for Charging an Extra NI-MH RC Transmitter Battery
If you have an extra NI-MH RC battery, you can charge this outside the RC. You may want to
do this while you are using the robot or if you need to charge both batteries at the same time.
The adapter needed to do this is in the control case or it is on your charger. It has a white
connector on one side and a connection on the other end that will go directly to your battery.
The charging time is still 16 hours.
110 Volt RC Transmitter Power Supply Option
The 110V RC Power Supply is a power unit that plugs into a standard electrical outlet and in to
the RC transmitter. This allows you to have continuous power without using batteries. This
connects into the same connection as the battery. To make the connection you need to take
the back cover off the RC. The wire feeds through a slot in the RC case. When you re-close
the case be sure that the wire is not pinched. With this option, you do need to stand near an
electrical outlet or have an extension cord.

14 Voice System
CHAPTER 3 Voice System
The Voice System consists of two separate communication links. One link transmits the
operator's voice to the robot. When you speak into the headset mic, this audio goes to a
transmitter on your belt. This audio is transmitted to a receiver in the robot. The audio signal
then goes from the receiver through a mixing circuit on the main board. It is then is fed into the
amplifier which amplifies the signal through the robot's speakers.
The second voice link transmits the audio detected by the Mic element (located in the front of
the robot) to the 151 receiver (which is worn by the operator). This is amplified and sent to the
speaker in the operator's headset.
Important: The operator’s transmitter and receiver should be kept as far separate as possible,
such as on opposite sides of the operator's waist. Do not attach the units together, this may
cause interference effects. The antennas should not be wrapped around each other or around
the headset wire but should hang freely.
Location of Voice Units
Voice Transmitter- Operator wears
Voice Receiver- On the main electronics box in the lower robot.
151 Transmitter- On the frame in the robot. The robot mic connects to it.
151 Receiver- Operator wears
Operator’s Voice Transmitter, Receiver, and Headset
3.5 mm headphones
Plu
g
151 Receiver Transmitter
3.5 mm
mic plug
On some models the mic
plug is a 3 Pin Mini XLR

15
Voice System
How to Operate the Operator’s Transmitter
1. Open the battery door.
2. Use a 9 Volt alkaline battery and insert it according to the diagram inside the battery
compartment.
3. Place the headset on your head and adjust the microphone to approximately 1 inch from
your mouth.
4. Plug the round connector from the headset into the top of the transmitter.
5. Move slide switches to the "ON" position.
6. On the UB-10 there is a volume adjust on the unit.
Function of the LED
When turning on the power switch, with a fresh alkaline 9-Volt, the battery light will blink on
momentarily and go out. This indicates that it is powering up and that the battery is good.
Because the light is a low battery indicator, when the light is on constant, this indicates the
battery is too low-below 7 Volts. Replace with a new alkaline battery.
Tip: The operator’s voice units both have metal clips that contact the posts of the 9-
volt battery. These must be bent out from time to time to keep this contact good.
18. Battery Compartment
19. 9 V Alkaline Battery
20. Input Selector Switch ( Leave On 3 Lavalier)
21. 3.5 mm jack
25. Off/Standby/On switch
26. Battery Indicator LED
27. Volume- Input Level Control
28. Belt Clip

16 Voice System
How to Operate the Receiver (in Robot)
There are two adjustments on the receiver. The volume is on the back of the receiver, which
you may set to the desired volume. On the UHF UB-10 you can change the volume on your belt
transmitter on the fly. The other adjustment is the sensitivity. This is factory preset to
maximum sensitivity. This effects how sensitive the receiver is to the transmitter signal.
Typically you would never need to adjust this. The only exception would be if you get squelch
when the transmitter is off. You can deal with this by simply turning on the belt transmitter
whenever the robot is turned on. You could turn the sensitivity down slightly but turn the
adjustment as little as possible, because adjusting it will affect the range.
Function of the LEDs
TX LED- This indicates that you are receiving a signal from the transmitter. On some units it is
a single TX light. On other units it may have an A or B that it will alternate between.
AF LED- This light indicates that audio is going through the receiver. It will flash as you speak
into your headset mic.
Tip: For best range extend the receiver antenna(s) as much as possible, not allowing it
to touch metal.
1. Power On LED Indicator
2. Diversity LED Indicators
3. AF Peak LED Indicator
4. Antennas
5. Power Switch (Leave On)
6. DC Input Jack
7. Frequency Label
8. Squelch Control
9. Aux. Volume Control
10. Audio Output
11 Balanced Mic Audio Output XLR