irobot roomba 694 just beeps and says "error" then stops. what do i do?

Diagnosis

The Roomba 694 utilizes a system of voice prompts and LED patterns to communicate hardware failures. When the unit beeps and says "Error," it is indicating that a critical component—usually a brush, wheel, or sensor—has encountered too much resistance or has failed a self-test. This is rarely a software glitch and is typically a physical obstruction preventing the motor from completing its rotation. To confirm the root cause, you must listen for the specific number following the word "Error." For example, "Error 2" indicates a stuck brush, while "Error 7" indicates a cliff sensor issue. If the robot simply says "Error" without a number, it is often a general power-rail failure or a stalled drive motor. You can confirm a physical jam by flipping the robot over and attempting to spin the side brush and the main EZ-Clean brush manually; if they resist or feel "gritty," you have found your culprit.

How to Fix It

Follow these steps in order to clear the most common mechanical failures associated with the 694 model:

1. Perform a Hard Reset: Press and hold the CLEAN, SPOT, and DOCK buttons simultaneously for 10 seconds. Release them and wait for the robot to reboot. This clears the temporary cache and resets the sensor calibration.
2. Clear the Main Brush Roll: Flip the robot over. Press the two tabs on the side of the brush module to pop it out. Remove the two green EZ-Clean brushes. Use a pair of scissors to cut away hair, string, or carpet fibers wrapped around the ends of the rollers. Check the brush bearings (the plastic caps) and remove any debris lodged inside the bearing housing.
3. Inspect the Side Brush: Pull the side brush (the spinning bristle arm) straight up to remove it. Check for hair wrapped tightly around the axle. If the axle is bent or the bristles are melted, replace the brush (Part # 4410).
4. Clean the Cliff Sensors: Locate the five small rectangular windows on the underside of the chassis. Use a clean, dry microfiber cloth or a cotton swab dipped in a tiny amount of isopropyl alcohol to wipe these sensors. Dust buildup here often triggers a false "Error" by making the robot think it is about to fall down stairs.
5. Check the Drive Wheels: Gently push the two large main wheels inward and pull them outward. They should spring back instantly. If one feels "stuck" or doesn't bounce, use a can of compressed air to blow out any pebbles or debris lodged in the wheel assembly.

If That Didn't Work

• Battery Terminal Oxidation: Remove the bottom cover by unscrewing the screws on the base. Remove the battery pack and inspect the gold contact pins. If they look dull or have a white powdery residue, clean them with a pencil eraser or a cotton swab with rubbing alcohol. A voltage drop during a high-torque move can trigger a generic error.
• Caster Wheel Jam: Remove the small front swivel wheel by pulling it straight up. Check for a "hair donut" wrapped around the axle of the caster. If the wheel doesn't spin freely in all directions, the robot may trigger a drive error because it is fighting the friction of the stuck wheel.
• Charging Contact Cleaning: Use a magic eraser or a rough cloth to scrub the two silver charging contacts on the bottom of the robot and the corresponding plates on the Home Base. If the robot cannot maintain a steady current, it may error out during the start-up sequence.
• Factory Reset via App: Open the iRobot HOME App, go to Product Settings > About Roomba > Reset. This will wipe all mapped data and Wi-Fi settings, which can resolve deep-seated firmware conflicts that a button-reset cannot fix.

Heads Up

• Avoid Wet Cleaning: Never use liquid cleaners on the sensors; a single drop of soapy water can cloud the infrared lens, leading to permanent "Error 7" or "Error 1" messages.
• Hair Maintenance: The EZ-Clean brushes are designed to be tangle-free, but they still collect hair at the ends. Clear the end-caps every two weeks to prevent motor strain.
• Surface Warning: High-pile shag carpets can cause the 694 to trigger a "stuck" error. If this happens frequently, use Virtual Wall barriers to keep the robot on low-pile rugs or hard floors.
• Battery Storage: If storing the robot for more than a month, remove the battery entirely to prevent deep-discharge cycles that can lead to erratic power errors.