Table of contents

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General Information

This repair guide covers the disassembly, repair, assembly, and testing procedures for the Cozmo robot manufactured by Anki. The procedures apply to both Cozmo and Vector robots with minor variations.

• Always power off the robot before beginning any repair
• Use proper ESD protection when handling electronic components
• Keep track of screw locations and types during disassembly
• Organize parts in order of removal for easier reassembly

Robot Compatibility

There are two main types of Cozmo robots:

• Older models: No button on back LED (parts specific to this model only)
• Newer models: Button-style back LED (white, liquid metal, and limited blue editions - parts are interchangeable)

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Disassembly Procedures

Step 1: Remove Upper Arms

1. Use a small flat-tip screwdriver to gently pry one upper arm off the plastic rod
2. Insert the screwdriver underneath the remaining attached arm
3. Press the tip against the underside to push the arm off the rod
4. Pull the plastic rod out of the body

Step 2: Remove Lower Arms

1. Raise the lower arms to their fully upright position
2. Wiggle the arms side to side while maintaining the raised position
3. Pop the arms out of their keyed slots on the sides of the body
   • Note: Arms will only release when fully raised

Step 3: Remove Tire Treads

1. Pull the rubber treads off each wheel

Step 4: Remove Tire Caps

1. Insert flat-tip screwdriver into the sides of the wheel caps
2. Work around each of the 3 slots, prying carefully
3. Apply gentle pressure to multiple sides until caps release
   • Caution: Plastic is thin and can break with excessive force

Step 5: Remove Wheel Base Pieces

1. Use small Phillips head screwdriver to remove screws from each wheel base
2. If screws are stripped, use angled pliers to grip screw heads and twist out
3. Remove wheel base pieces once screws are out

Step 6: Remove Head Components

Remove Ears

1. Insert flat-tip screwdriver along the front edge of each ear
2. Use gentle up-and-down motions toward the edges to release tabs
3. Avoid excessive force to prevent plastic damage

Remove Head Shell Screws

1. Remove two screws from each side of the head (4 total)
2. Note the orientation of plastic rods and spring placement:
   • Plastic rods have flat edges that insert into specific head shell halves
   • Spring sits in center of head shell half without teeth along back edge

Step 7: Disconnect Screen/Speaker Assembly

1. Locate the connector plugged into the back of the screen
2. Gently grip the connector (not the wires) and wiggle to release
3. If connector feels stuck, leave it connected to avoid damage

Step 8: Remove Body Components

Remove Front and Back Pieces

1. Front piece: Remove two screws from sides and lift off
2. Back piece: Remove two screws, then use fingernail or screwdriver to pop out upper edge

Split Body Halves

1. Remove three body screws:
   • Front screw (short)
   • Rear screw (short)
   • Upper center screw (longer than the other two)
2. Pop off the back shell
3. Separate body halves carefully while supporting the main board
4. Note weight placement in lower rear for reassembly

Step 9: Disconnect Gear Cases

1. Gently pull connectors out of main board (one for each gear case)
2. Do not pull on wires - grip connectors only
3. If connectors feel stuck, leave them connected

Step 10: Remove Gear Cases

1. Lift gear case: Remove two screws from right body half
2. Head gear case: Remove two screws from left body half

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Assembly Procedures

Step 1: Attach Gear Cases

1. Secure head gear case to left body half with two screws
2. Secure lift gear case to right body half with two screws

Step 2: Connect Gear Cases to Main Board

1. Insert both connectors into main board (different sizes prevent incorrect connection)

Step 3: Position Weight and Main Board

1. Place weight in lower rear position (fits only one way)
2. Insert main board into right body half
3. Route screen wire through upper channel before closing body halves
   • Important: Wire must be properly routed before assembly

Step 4: Close Body Assembly

1. Close body halves carefully, ensuring weight stays in position
2. Watch for wire routing - avoid pinching wires between shell pieces
3. Snap back shell onto body halves
4. Check that back wires are not pinched

Step 5: Attach Body Components

1. Install front piece with two screws
2. Install back piece with two screws
3. Install three main body screws (remember longer screw goes in upper center)

Step 6: Connect and Test Screen

1. Connect screen connector to wire from main board
2. If back LED lights up spontaneously, solder joints may be too high and touching weight

Step 7: Assemble Head

1. Insert plastic rods into correct head shell half (flat edge orientation)
2. Position spring in center of appropriate head shell half
3. With robot on its side, carefully align all components:
   • Head shell halves
   • Spring (keep centered)
   • Plastic rods
   • Screen connector
4. Press head halves together

Step 8: Quick Functional Test

1. Power on robot and connect to app
2. Verify motor movement (wheels, head, lift)
   
3. Listen for normal gear sounds
4. Power off

Step 9: Install Remaining Components

1. Pop ears onto head sides
2. Install wheel base pieces with screws
3. Install wheel caps (snap onto base pieces)
4. Insert lower arms in fully raised position only
5. Insert center rod through body and attach upper arms
6. Install tire treads