Robomow Service Manual Rl2018
. ® Robomower Service Guide Read carefully and thoroughly all relevant sections before servicing Robomower. It is very important to read and follow all warning and safety instructions in this manual and in the Robomower Operating Manual. All maintenance procedures and troubleshooting must be carried out exactly as given in this manual. Table of contents Introduction Chapter 1- Robomower Layout & IPL’s (Illustrated Parts List) Chapter 2 - Menu Items Chapter 3 - Troubleshooting Chapter 4 - Repair and Maintenance Procedures Chapter 5 - Diagnostics Chapter 6 – General Procedures Chapter 7 - Service Bulletins. Introduction The purpose of this Service Guide is to allow trained and certified technicians to efficiently inspect, diagnose and repair the Robomower. If you have not completed training, please contact your manager or supervisor to arrange training completion.
The Service Guide is divided into various sections to allow access to information in an easy to use format. Robomow Layout & Spare Parts This first section is dedicated to the layout of the Robomow, how it is constructed, part numbers and identification of parts.
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Important: Be sure to review section 1.1 (Orientation). It explains what is referred to as “right”, “left”. 1.1 Robomow layout and main components 1.1.1 Robomow top view Charging contacts RL Model Stickers (for Charging Front Bumper RL350 – STC0057A Station) SPP0026A MSB0106B RL800 – STC0051A RL550 – STC0048A RL850 – STC0049A RL1000 – STC0056A RL Yellow Cover GEN0094A RL Green Cover GEN0227A Left Right. 1.1.2 Robomow bottom view Note: Mower sides are determined by its top view Front Bumper MSB0106B Front Wheel Snap lock (curved) SPP0011A GEN0163A (x4) High cut blades MRK0002A Mowing Motor Low cut blades MSB0065B (x3) MRK0003A Knobby drive wheel MSB0099A Snap lock (straight) GEN0162A (x6) RL plastic base. 1.1.3 Robomow internal views & Front wheel stopper Front right Drop-off Board GEN0207A Wire sensor SPP0005B Front left & Spring GEN0208A SPP0018A Wire sensor SPP0018A Right Mowing Motor Left Mowing MSB0065B Motor MSB0065B Center Mowing Motor MSB0065B Main Board SPP0019B Cover-base seal ring GEN0182A Odometer board L.
1.1.4 Charging Station views Charging Station Cover SPP0030A Charging Station contacts assembly SPP0031A Charging Station Base SPP0029A Charging Charging Station Fence Station Drive GEN0215B Wheel support Figure 1.1.4 Charging Station view. 1.2 IPL’s / Exploded views 1.2.1 Robomow – bottom view.7 1.2.2 Base – top view.8 1.2.3 Cover – top view.9 1.2.4 Charging Station.10 1.2.5 Gear Case.11 1.2.6 Power Pack & Power Supply.12 1.2.7 Fuses.13 1.2.8 Perimeter Switch.14 1.2.9 Bumpers.14 1.2.10 Front Wheel.15 1.2.11 Thermistors.16 1.2.12 Add-on Items.16. 1.2.1 Robomow bottom view DETAIL A DETAIL A SEE DETAIL A. 1.2.2 Base - top view. 1.2.3 Cover – top view. 1.2.4 Charging Station. 1.2.5 Gear Case.
1.2.6 Power Pack & Power Supply NOTE: for Power Pack wiring P/N’s refer to ‘Power Pack wiring diagram’ (Section 1.5.2) PWS0001A 230VAC power supply -Europe 230VAC Out Door Power PWS0004A PWS0002A 230VAC power supply - UK Supply for RL1000 (EUR) PWS0003A 115VAC power supply - US 115VAC Out Door Power PWS0005A. CBL0037A External charger cord - UK CBL0038A External charger cord - US CBL0039A External charger cord - EUR UNT0016A Power Pack external charging adaptor 1.2.7 Fuses FUS0021A Fuse 5x20 10A 125V (External Charger) FUS0015A Fuse mini blade 5A FUS0003A Fuse AT blade 30A 32V FUS0012A Fuse AT blade 1A 32V. 1.2.8 Perimeter Switch 1.2.9 Bumpers. 1.2.10 Front Wheel.
1.2.11 Thermistors SPP0020A Thermistors kit (Includes NIT0009A & HSN0003A) NIT0009A Pop rivet/D3.2x6 HSN0003A Heat sink silicone insulator 1.2.12 Add-On Items Low cut blades High cut blades DOC0015D – RL Operating Manual (En) DOC0076B – RL1000 (Standard Manual Con.) + Docking Manual. GEN0211A Charging plug rubber cover GEN0210A Charging socket rubber cover TOL0001A Mowing motor removal tool 1.2.13 Decals. 1.2.14 Old configuration spare parts The parts below are available spare parts, which are not part of the ’05 configuration, but are still required to support the previous RL configurations. Flash Software v 3.2a (Main ESB0031A Rear Right Wire Sensor Board SPP0027A Board ESB 0019) Perimeter wire to.
1.3 Fuse location 1A Lamp fuse 5A Charging fuse Figure 1.3.1 Robomow fuse location 30A Power Pack fuse (-) Terminal (+) Terminal Figure 1.3.2 Power Pack fuse location Figure 1.3.3 External Charger fuse location. 1.4 Board identification 1.4.1 Main Board The Mowing motor cable is available as a separate part to support old configuration models. 12 - Soldered to the mowing motor 98 – Only cable 1.4.2 Connector Board. 1.4.3 Odometer Board Right odometer board Left odometer board 1.4.4 Drop-off Board. 1.5 Wiring layout 1.5.1 Robomow schematic wiring diagram.
1.5.2 Power Pack wiring diagram Fuse holder & cable (Red) Fuse holder & cable (Red) Fuse Fuse Fuse WSB0046B WSB0046B Holder Holder Holder Battery jumper cable Battery jumper cable WSB0049B WSB0049B Battery Battery Battery Contact Contact Contact Grey Grey Left (+) Left (+) Left (+) Negative battery cable (Black). 1.6 Spare Parts List 1.6.1 Spare Parts – sorted by item number Appears in Friendly P/N No. Of Friendly P/N Part Description Exploded views (2005) (2006) parts 1.1.1 GEN0094A GEN0094A RL Yellow cover GEN0227A GEN0227A RL Green cover 1.1.1 1.1.1 & 1.2.3 MSB0112A MSB0112A Manual controller- Europe (tones) MSB0114A. 1.6.1 Spare Parts – sorted by item number (con.) Appears in Friendly P /N No. Of Friendly P /N Part Description Exploded views (2005) (2006) parts GEN0104A GEN0104A Wheel Cup (gray) 1.2.1 GEN0201A GEN0201A Wheel Cup (black) 1.1.3 & 1.2.1 1.2.2 GEN0146A GEN0146A Main board rubber holder.
1.6.1 Spare Parts – sorted by item number (con.) Appears in Friendly P/N No. Of Friendly P/N Part Description Exploded views (2005) (2006) parts GEN0116A GEN0116A Drop off flag 1.2.10 NIT0009A NIT0009A Pop rivet/D3.2x6 (Thermistors) 1.2.11 HSN0003A HSN0003A Heat sink silicone insulator (Thermistors) 1.2.11 DOC0015D DOC0015C RL Operating Manual (En). 1.6.2 Spare Parts – sorted by Friendly part number Appears in Friendly P/N No. Of Friendly P/N Part Description Exploded views (2005) (2006) parts BAT0003A BAT0003A Battery holder for perim.switch with screws 1.2.8 CBL0037A CBL0037A External charger cord - UK 1.2.6 CBL0038A CBL0038A. 1.6.2 Spare Parts – sorted by Friendly part number (con.) Appears in Friendly P /N No. Of Friendly P /N Part Description Exploded views (2005) (2006) parts GEN0215C GEN0215B Docking Station Fence (Green) 1.2.4 1.2.4 GEN0217B GEN0217B D. Station Connectors Cover (Green) GEN0218A GEN0218A Push button for Docking Board 1.2.4.
1.6.2 Spare Parts – sorted by Friendly part number (con.) Appears in Friendly P /N No. Of Friendly P /N Part Description Exploded views (2005) parts (2006) 1.2.14 SPP0027A SPP0027A Flash Software v3.2a+ (ESB0019C) Charging Station Board (includes screws, tact switch SPP0028B SPP0028A 1.2.4.
1.7 Parts Compatibility Table Service Description Compatible with Bulletin GEN0094A RL Cover #RL0536-04 All models GEN0118A Front Wheel Click Spring #RL0536-05 S/N IRL02340100 and older S/N IRL02340100 and older GEN0148A Navigator keypad - (M. Controller without ‘GO’ printed on the green button) GEN0182A Cover-base seal ring -. Menu Items The menu items section gives an explanation and description of the options and messages displayed on the LCD Display. Use this section to navigate around the menu and find the required option. Following is the layout of the menu as a whole. In section 2.2 you will find detailed explanations for each of the menu items.
1.0 User Preferences: Zones setup Press GO Dock zone Press GO Work time Press GO Dock zone: Press GO Dock zone: MAX Confirm Zone B Press GO 1.1.1 Work time Press GO Zone B: Press GO Zone B: MAX Confirm 1.1.2 Learn Edge Press GO. 1.10 Anti theft Press GO Anti theft Press GO Anti theft Confirm Set new password Press GO 0000 next digit Key 1965 confirm Change password Press GO Set old password Press GO 0000 next digit Key 1965 confirm Set new password Press GO 0000 next digit. 3.0 Docking Options (RL1000 only): Weekly program Press GO Set program Press GO M T W T F S S Press GO Entry point: 1 Confirm Work time 2:20 Confirm Depart 11:30 next digit Mode: Edge+Mow Confirm M T W T F S S Press GO Display program Press GO. Service (Password required): Password req. Press GO 00000 (00) next digit 12321 Confirm Calibrations Press GO 6.1.1 Learn wire snsrs Press GO wait Confirm was:x Now:x No:a confirm 6.1.2 Edge calibration Press GO Edge calibration xxx done 6.1.3 Set Country Press GO Confirm 6.1.4. Service (con.) 6.2.5 Mowing motors Press GO to test activate motors confirm test passed Confirm 6.2.6 Thermistors Press GO to test Drive Pass Pass 6.2.7 Docking tests Press GO Dock detection Press GO to test Test results: 01 Press GO 6.2.8 Edge tests Press GO.
Service (con.) Settings Press GO 6.3.1 Docking options Press GO 6.3.1.1 Edge to dock Press GO Edge to dock Confirm 6.3.1.2 Docking search vlt. Press GO Confirm 6.3.1.3 Dock bumper Press GO Dock edge Confirm 6.3.1.4 Islands Press GO Islands Confirm 6.3.2 Small wheels off. 2.2 Menu Items Explanation They following section explain the different menu items appeared in section 2.1 above: 1.0 User Preferences 1.1 Zones Setup Allows user to set the parameters that are specific per zone 1.1.1 Work Time Allows the user the option of setting the operating time from the ‘MAX’ default setting to times ranging from 20 minutes up to 2:40 hours. 1.6 Fast Edge Fast edge enables Robomow tracking the Perimeter Wire in faster drive speed. This option is enabled in Dock zone only. The fast speed has two speed levels, when the faster level is used when the mowing motors are witched off and Robomow tracks the Perimeter Wire in ‘Searching dock’. 2.0 Information 2.1 Total time A very important information menu item, this shows the total operating time of the mower.
This is valuable information used for warranty and repair services. It can also indicate the usage model of the mower, for example using the mower on multiple properties instead of for homeowner use as it is designed. 3.0 Docking Options (RL1000 only) 3.1 Weekly Program 3.1.1 Set Weekly Program One of the advantages of having a docking station for the Robomow is the ability to set an automatic weekly program. The user can set the weekly program at the beginning of a season and not worry about mowing again all season long. 3.5 Skip Next Depart Allows user to skip the next scheduled operation.
4.0 Child Guard Child Guard is an option that allows disabling operation of the buttons of the Manual Controller unless a pre-set two step button sequence is pressed first. While locked, the up arrow key and then the ‘C’. 6.1.3 Set Country When a mower is first placed in operation, by default the customer is required to ‘Set Country’ prior to the mower operation.
This setting helps define the area of the world in which the mower is operating in order to better define the magnetic field of the earth, which is used by the Robomow for navigation. 6.2.5 Mowing Motors Mowing motors is the process of testing the mowing motor system of the mower. It has one basic level of testing. Under the basic testing it is a ‘pass-fail’ test with a fault code listed for the failure message. Poor Storage – poor storage counter indicates how many times the mower was put into operation where the power pack capacity was less than 80% of fully charged.
This essentially indicates how often the mower was used prior to the power pack being fully re-charged, where the count will not start until there is a 20% capacity loss from fully charged. 6.3.3 Enable DK Enable DK is a feature that is helpful when operating the mower in an area where magnetic interference is suspected in a certain lawn or when the Robomow is operated indoors, i.e. At an exhibition. Indoors exhibitions are typically on concrete floors that contain a great deal of metals.
This large amount of metal will skew the magnetic field causing the mower to run in curved lines rather than straight lines. 6.3.9 Auto Restart This option enables to set the cases in which Robomow restarts the operation automatically within an hour after it has stopped during the operation. 6.3.9.1 Drive Overload If the mower stops with the following ‘Drive overload - cooling, wait’(10 min above 100 or 1 sec above 105), it will stay awake for up to 60 minutes with the displayed message and blinking operating light. Docking state. If the charging is done through the charging socket (placed in the Manual Controller Holder) then ‘00’ is displayed in the docking state. If the charging is done through the Docking Station, one of the following numbers is displayed: 01 - Charging through the docking station 02 - Problem in charging through the docking station. 6.3.10.2 Wire Sensors In this display the LCD will display the following information: 1.Front left reading 1.Front left reading 1.Front left reading 2.Front right reading 2.Front right reading 2.Front right reading 3.Bit rate 3.Bit rate 3.Bit rate 4.Rear left reading 4.Rear left reading 4.Rear left reading 5.Rear right reading.
Ambience temperature (ºC). Ambience temperature in ºC. Mow temperature (a2d). Mow temperature in a2d. Otherwise - over current. Right drive temperature (a2d).
Right drive temperature in a2d. Charging FET temperature (ºC). Charging FET temperature in ºC. 6.3.10.4 Edge In this display the LCD will display the following information: 1.DK angle (degrees). 6.3.10.5 Drive motors In this display the LCD will display the following information: 1.Left drive current (A2D) 1.Left drive current (A2D) 1.Left drive current (A2D) 2.Right drive current (A2D) 2.Right drive current (A2D) 2.Right drive current (A2D) 3.Right drive temperature (ºC) 3.Right drive temperature (ºC) 3.Right drive temperature (ºC) 4.Over current counter. Hardware over current. Indicates if mow over current is detected by Hardware current limiter.
0 – Over current not detected. 1 - Over current detected 6. Mow temperature (ºC) or over current event counter The display will switch every 3 seconds between: 1) Mow temperature in ºC. Troubleshooting 3.1 Error Messages This is a comprehensive list of all error messages that may be displayed on the Robomow LCD. It lists the message, what it means and possible cause and corrective action required to solve the problem. In every case, which the mower stops it is recommended to see the ‘Last stop cause’. Probable Cause/Event Message Displayed Corrective/User Action - There is no need to do anything – Robomow Drive Overload - The drive motors have been working will renew automatically the operation after the under a severe load for too long.
Drive motors will cool down to temperature Cooling, Wait. Message Displayed Probable Cause/Event Corrective/User Action - Mower is searching for the Docking - Drive the mower manually for charging in the Low battery Station but the battery voltage is too Docking Station low to continue the searching process - Robomow charging is not allowed when the - Robomow is charged through the plug ambience temperature is going down below Low temp. An unknown fault has occurred and - Manually drive the mower away from this user help is required particular area and restart operation Start Elsewhere - Wheel drive motors have been working - Check to insure the mower is not stuck, under a severe load allowing the wheels to slip - Faulty / disconnected Thermistors. Problem analysis flow charts – Table of Contents 3.2.1 Installation and Setup 3.2.1.1 Wire disc (P. Switch) 3.2.1.2 Replace battery (P. Switch) 3.2.1.3 P.
Switch does not operate 3.2.2 Power & Charging 3.2.2.1 Robomower does not 'Wake up' 3.2.2.2 Charging Failure 3.2.2.3 Check Power 3.2.2.4 No Charging indication 3.2.2.5 Short run time. 3.2.10 Wire Sensors 3.2.10.1 ‘No wire Signal’ message 3.2.10.2 ‘Move from wire’ message 3.2.11 Docking Station/Zone 3.2.11.1 Robomower does not leave the Docking Station for operation at the time set in the Weekly Program 3.2.11.2 Robomower does not detect the Docking Station contacts and/or ‘Front wheel problem’. 2 screws It is not a Friendly Robotics product Cut a short wire and strip 0.5cm of and Friendly Robotics did not test insulation from each wire end. 3.2.1 Setup Problems (con.) 3.2.1.1 Is it a Secondary search Check each zone separately and find the multiple problematic zone (by cutting the wires for the zone set between the zones to separate them) disconnected wire Choose an area/wire to be tested (see detailed explanation below) Disconnect the p. 3.2.1 Setup Problems (con.) 3.2.1.2 Install new C-cell batteries ‘Replace battery’ in the Perimeter Switch indicator is (alkaline batteries are blinking recommended) ‘Replace battery’ Separate plot installation indicator is Turn-on the Perimeter Switch increases the P. Switch blinking with by pressing the ‘ON’ button total operation time relatively new (shorter wire). 3.2.1 Setup Problems (con.) 3.2.1.3 Perimeter Switch does not operate / dead Is the buzzer Press the ‘on’ heard and Perimeter switch button of the ‘ ’ is OK perimeter switch blinking?
Open the perimeter switch: Verify batteries are in place and at the right polarity Standard Confirm the battery holder is not broken. 3.2.2 Power & Charging Problems Does not ‘wake up’ Remove power Robomow when ‘GO’ is pack and re-insert awake? Pressed after 10 seconds 3.2.2.1 Confirm battery contacts on both sides (Bat.
And Robomower) are not loose/damaged Check battery fuse (30A) is not blown (located in Voltage battery case) Replace manual. 3.2.2 Power & Charging Problems (con.) 3.2.2.2 Is the message Disconnect the Power displayed Supply, perform reset by ‘Charging immediately as the Immediately lifting the Power Pack from Failure’ mower is connected mower and re-insert it after message to the charger or 10 seconds and reconnect after a few hours of the Power Supply.
3.2.2 Power & Charging Problems (con.) Confirm the Power Supply is plugged into the main power receptacle Does the Check for power to this main receptacle ‘Check Power’ message by plugging in another appliance message appear during Confirm the Power Supply connector is charging? Fully inserted into the charging socket Check if the Power Supply plug is. 3.2.2 Power & Charging Problems (con.) In any case of charging problem or failure, it is There is no 3.2.2.4 recommended first to Charging indication perform the charging although the Power Supply is test as explained in connected section 5.4.9 (page 5.13). 3.2.2 Power & Charging Problems (con.) Is the operation Short run time, time shorter than The time is ok. Confirm user operates less previous follows Charging Policy. Time then normal operations?
3.2.2.5 Was battery fully charged Fully charge the battery prior to –. 3.2.3 Mowing Problems Important Safety Information!!! PRIOR TO ANY OF THE ACTIONS SUGGESTED BELOW REMOVE THE POWER PACK. Always wear thick protective gloves when handling or cleaning around the blades 3.2.3.3 3.2.3.2 3.2.3.1 Mowing motors do Uncut lane left ‘Check mow not start but the behind the height’. 3.2.3 Mowing Problems (con.) 3.2.3.5 Cannot start mowing motors in manual mode Confirm the ‘C’ and the Confirm the user performs the right ‘Mow’ buttons in the sequence: manual controller are Step 1 – Press and hold down ‘C’ Are the responsive (Choose Step 2 –. 3.2.4 Edge Problems 3.2.4.1 Stops displaying Does the an error Refer to the error Robomow does Robomow leave message in the LCD not complete the the edge or stop (See paragraph 3.1) displaying an error Edge message? Leaves the edge and If the problem appears in starts to mow Dock zone, please refer to.
3.2.4 Edge Problems (con.) 3.2.4.2 Does it happen in In narrow passes the wire Robomow is not areas where the sensors readings are affected centered on the distance between by the other wire – this causes perimeter wire the two perimeter the mower to shift (up to 2 wires is less than inches/5cm) outside the. 3.2.5 Automatic Mowing Problems Many patches of uncut grass 3.2.5.1 remain on the lawn after the Robomower had How much Less than Check the reason why the finished working time does the 2 hours Robomower works less than Robomower 2 hours (refer to flowchart work before it 3.2.2.5 –. 3.2.5 Automatic Mowing Problems (con.) 3.2.5.3 If the Manual Controller Make sure that prior to cord is misplaced in the Robomow had inserting the Manual cavity it may push the stopped and is Controller to its place, Manual Controller during found with no error the cord is stored well operation and stop the. 3.2.5 Automatic Mowing Problems (con.) Important Safety Information!!! PRIOR TO ANY OF THE ACTIONS SUGGESTED BELOW REMOVE THE POWER PACK.
Always wear thick protective gloves when handling or cleaning around the blades 3.2.5.4 3.2.5.5 Robomow keeps Confirm the Front Wheel Poor direction going back and turns freely both on the. 3.2.5 Automatic Mowing Problems (con.) 3.2.5.6 The minimum distance Change the setup to Robomow crosses between 2 adjacent min. 5ft/1.5m between Perimeter Wire plots activated by the 2 perimeter wires in (stops with ‘Start same P.
Switch should the same plot elsewhere’. 3.2.6 Manual Controller Problems 3.2.6.1 Is it a new One or more of Robomower or is the Manual it the first Controller buttons operation after an do not respond extended storage period (winter)? Electrical equipment stored for a long period of time starts to oxidize. 3.2.7 Drive Problems 3.2.7.1 The drive motors have been working under a Check to insure the Robomow stops severe load for too long – mower is not stuck, There is no need to do with ‘Drive allowing the wheels to anything –.
3.2.7 Drive Problems (con.) Confirm that nothing Drive the Robomow Drive is interfering with the manually on a flat Problem wheel rotation surface 3.2.7.3 Test the ‘Drive motors’ in Does it the ‘Service’ menu and Robomow is OK – move in a refer to Fault Code Table continue the straight. 3.2.8 Front Wheel Problems 3.2.8.1 The Front Wheel has left Confirm the Front Front Wheel the ground for too long Wheel is on the There is a problem with Problem ground the Drop-off Board Confirm the lawn slope is not greater than 15 degrees Does it Usually pits filling in bumpy happen in.
3.2.9 Bumpers Problems Attention 3.2.9.1 Item pressed against the bumpers or Robomower positioned “standing” Take the Power Pack on any of the bumpers while in Front /Rear out of the mower and storage can change the shape of the Bumper re-insert bumper and cause problems to the Pressed. 3.2.9 Bumpers Problems (con.) Is the Take the Power ‘Front /Rear ‘Bumper disc.’ Robomow Pack out of the Bumper disc.’ Message still mower and re-insert message displayed? 3.2.9.2 Remove the Top Cover: Confirm jumper position on the Main Board (refer to Service Bulletin ‘RL0536-01 Main Board’. 3.2.9 Bumpers Problems (con.) The bumper has an activation area.
If the Robomower hits an obstacle (such 3.2.9.4 as slanted tree) and the bumper’s active area is not pressed, the Robomower will continue to work Bumper is not against the obstacle for max 2 minutes Press the suspected responding –. 3.2.10 Wire Sensors Problems Is the ‘No wire Turn on the Perimeter Perimeter signal’ Switch by pressing the Switch/Docking message ‘on’ button Board turned 3.2.10.1 Is any LED Refer to flowchart 3.1.3 blinking on – ‘Perimeter Switch the Perimeter does not operate’ Switch?
Move the Robomow towards the wire and. 3.2.10 Wire Sensors Problems (con.) 3.2.10.2 Position the mower Were the Main ‘Move from inside an active plot Board or Wire wire’ and perform ‘Learn Sensors message wire sensors’ (refer replaced? To section 5.3.1) On the wire or very close Where is Move the Robomow at to it. 3.2.11 Charging Station Problems Problem Encountered Probable Cause/Event Corrective/User Action - Confirm the time in the mower is set - Set the time (See paragraph 4.2 in the correctly (day and hour) Operating and Safety Manual) - Confirm there are minimum 16 hours of Robomower does not leave - Low battery voltage charging in the Docking Station before the. Problem Encountered Probable Cause/Event Corrective/User Action ‘Docking test’ Perform (refer to section 5.4.7).
This test checks the detection of the Docking Station by the Robomower. Power supply/charger is not plugged - Confirm power supply is plugged into the main into the main power supply power receptacle. Measure the voltage (using voltmeter) on the docking contacts while the mower contacts touch the docking contacts (should be around 36V). If it is less then 36V continue to step 4. Disassemble the docking cover (figure 3.2.11.1) and measure the voltage on the two cables of the Power Supply where they are connected to the Docking Board (at the points showed by the red arrows in figure 3.2.11.2). 3.2.12 Excessive noise Note: Excessive noise from the Robomow, which does not decrease the performances, is an aesthetic issue only. Important Safety Information!!!
3.2.12.1 Excessive Drive the mower REMOVE THE POWER PACK. Noise comes manually on a flat Always wear thick protective gloves when from the surface without mowing handling or cleaning around the blades. Repair and Maintenance Procedures The Repair and Maintenance Procedures Section is broadly divided into two areas, External and Internal.
The External procedures include all those procedures that can be completed without the removal of the cover and conversely all Internal procedures require the removal of the cover of the unit. Table Of Contents.
Repair and Maintenance procedures 4.1 Robomow External procedures. 4.1.1 Fuse replacement.
4.1.2 Operating lamp replacement. 4.4 4.1.3 Manual Controller replacement. 4.1.4 Front Wheel Procedures.
4.6 4.1.5 Drive wheel replacement. 4.1.6 Blades replacement.
4.9 4.1.7 Charging Station contacts (Robomow side) replacement. 4.10 4.2 Robomow Internal procedures. 4.1 Robomow External procedures 4.1.1 Fuses replacement Required tools: None Procedure duration: 5 minutes Power Pack Fuse Replacement (30A) – FUS0003A A. Remove the Power Pack from the Robomow. Pull the burnt fuse directly downwards to extract.
Fully insert a new 30A fuse (FUS0003A). 4.1.2 Operating lamp replacement (LMP0004A) Required tools: Flat screwdriver Procedure duration: 5 minutes A. Remove the Power Pack from the Robomow. Insert the screwdriver into the notch of the lamp cover and lift, as illustrated in Figure 4.1.2.1.
Be cautious not to pinch or damage the seal ring. Squeeze the two tabs of the fuse cover, while pulling up the fuse cover (Figure 4.1.3.3). To replace the M. Controller holder assembly, disconnect the yellow charging cable from the Connector Board (3 pins). Replace the defective M. Controller holder assembly with a new one and repeat previous steps in reverse order, ensuring correct routing of wires, as illustrated in Figure 4.1.3.4.
4.1.4 Front Wheel with axle replacement (SPP0011A) Required tools: Flat screwdriver Procedure duration: 10 minutes A. Remove the Power Pack from the Robomow. Turn the Robomow on its back and place it on a soft surface to protect it from scratches.
Replace the faulty part: either the egg wheel with shaft (SPP0011A), the adjusting plastic bolt (GEN0117A) or the flag (GEN0116A). Return the adjusting bolt onto the shaft remembering to place the metal washer first. Replace the flag to the metal shaft. 4.1.5 Drive wheel replacement Required tools: Flat screwdriver Procedure duration: 5 minutes External circlip pliers A. Remove the Power Pack from the Robomow. Prop the Robomow on a stand so that the drive wheels will not be touching the ground. Figure 4.1.5.3 Figure 4.1.5.4 Drive wheel circlip removal Disassembled drive wheel I.
Replace the damaged wheel with a new one (it is recommended to replace both wheels in order to ensure the unit is balanced during the operation). Push the new drive wheel over the shaft and the spline until it rests against the support in the spline. 4.1.7 Charging Station contacts (Robomow side) replacement Required tools: Pliers Procedure duration: 10 minutes A.
Remove the Power Pack from the Robomow. Identify the two contacts on the Robomow front cover and unscrew them by hand or using pliers, as illustrated in Figure 4.1.7.1 below. 4.2 Robomow Internal procedures NOTE: The procedures duration appears at the top of each procedure and at the table in section 6.1.3 are the net time required to perform the specific replacement. When calculating the total repair time, you should add 20 minutes to cover the time of the removing and returning the cover. 4.2.1 Removing the cover Required tools: Wide flat screwdriver Procedure duration. Repeat step I for the other nine lockers. Turn the Robomow back on its wheels.
Grab the front lift handle in one hand and the bumper below it in another hand and jerk the two parts apart, as illustrated in Figure 4.2.1.3. Push both battery contacts to sit firmly in their place on the base, ensuring correct polarity – red lead (+) on the left side (See Figure 4.2.2.2) D.
Take the cover and place it gently over the base. Make sure the lamp cable is inserted into the manual controller cavity. Insert the locker with the two large legs sliding down the side yellow legs of the cover. Figure 4.2.2.6 Fitting a locker inside its cavity K.
Turn the Robomow back on its wheels. Insert the 5A and 1A fuses into their right locations (see Figure 4.2.1.1) M. 4.2.3 Main Board Replacement Required tools: Wide flat screwdriver Procedure duration: 10 minutes Flash extracting tool A. Remove the Power Pack from the Robomow. Remove the cover, as outlined in section 4.2.1.
Disconnect all the cables leading to the main board. Identify the flat inside corner and marking triangle next to it inside the socket, as illustrated in Figure 4.2.3.5. Carefully and methodically place the flash over the socket cavity making sure the flat corners and marking dot/triangle are one above the other. Verify that every lead in the flash is sitting against a lead in the socket, as illustrated in Figure 4.2.3.6.
Battery cable Black / Flat cable Drive motors Green White Black Right - Center - Left Front Bumper (Red – up Green – down) Jumper Mowing motors connector Wire Sensors Drop - Bumpers Odometers Thermistors Figure 4.2.3.9 Cable connection to the Main Board. Replace the cover as outlined in section 4.2.2. Place the unit inside the simulated garden, as explained in section 5.1 and turn the Perimeter Switch on.
Perform ‘Factory defaults’ under the ‘Service’’Settings’ menu (section 5.5.6) M. Perform the following under the ‘Service’’Calibration’ menu: ‘Learn wire sensors’. 4.2.4.2 Drop-off Board Replacement Required tools: Wide flat screwdriver Procedure duration: 15 minutes A.
Remove the Power Pack from the Robomow. Remove the cover, as outlined in section 4.2.1. Unscrew the Front Wheel all the way until the highest mowing position, ass illustrated in Figure 4.2.4.2.1. Screw the front wheel into its place to the proper height position. Connect the drop-off board cable to the Main Board. Close the cover, as outlined in section 4.2.2.
Perform the ‘Front wheel test’ under the ‘Safety tests’ menu. Clean the mowing deck from grass residues and dirt.
Take the mowing motor special tool provided by Friendly Robotics and identify its five pins and five holes in the mowing motor flange they will fit into (Figure 4.2.5.1). Replace the defective mowing unit with a new one. Insert the mowing unit into its hole and connect the wires to the main board.
NOTE: If a Thermistor is attached to the shield of the defective motor, remove the shield and replace it on the new motor. Right odometer Drive motors cable cable Rear right wire sensor cable Figure 4.2.6.1.1 Cable around the gear case Left odometer Rear left wire sensor cable & bumper cables K.
Place the ground clearance adjustment lever on top of the rear bumper from the chassis. Insert the slider into the cavity of the base wall, as illustrated in Figure 4.2.6.1.4 below. Repeat this step for the other side of the unit. Straighten the slider and position it as illustrated in Figure 4.2.6.1.5 below.
Figure 4.2.6.1.4 Figure 4.2.6.1.5 Inserting the slider into place. 4.2.6.2 Drive motor magnet replacement Required tools: Wide flat screwdriver Procedure duration: 5 minutes External circlip pliers A. Remove the Power Pack from the Robomow. Remove the drive wheels, as outlined in section 4.1.5. Remove the cover, as outlined in section 4.2.1. Return the drive wheels, as outlined in section 4.1.5. Return the cover as outlined in section 4.2.2.
Perform the ‘Drive motor test’ outlined in section 5.4.4. Complete the General Test as outlined in section 5.1. 4.2.6.3 Odometer Board replacement Required tools: Wide flat screwdriver Procedure duration: 10 minutes External circlip pliers. Figure 4.2.6.3.3 Figure 4.2.6.3.4 Releasing the board using Insertion of a new odometer board the screwdriver and the pliers G. Connect the odometer cable.
Return the drive wheels, as outlined in section 4.1.5. Return the cover as outlined in section 4.2.2. Figure 4.2.6.4.1 Figure 4.2.6.4.2 A complete gearbox out of the Robomow A gearbox without the spline and slider Figure 4.2.6.4.3 Figure 4.2.6.4.4 Removing the shaft clips Extracting the long shaft out of a gearbox on supporting blocks G. Turn the gearbox so the drive motors will face towards the table. Use a plastic hammer to hit on each side of the short shaft, as illustrated in Figure 4.2.6.3.5.
Figure 4.2.6.4.5 Figure 4.2.6.4.6 Extracting the long shaft out of a gearbox Short shaft placement in the gear frame groove Figure 4.2.6.4.7 Figure 4.2.6.4.8 Short shaft placement Short shaft placement K. Take the long shaft, 2 gears and 4 rings and place them on the long shaft, 2 rings between the gears and 2 rings outside the gears, as illustrated in Figure 4.2.6.3.9. Center the new long shaft in its groove using a caliper. The measure from the shaft end to the gear is 101 mm, as illustrated in Figure 4.2.6.3.11. Once the long shaft has been centered, use the plastic hammer to force the shaft into its groove, as illustrated in Figure 4.2.6.3.12. 4.2.6.5 Drive Motor replacement Required tools: Wide flat screwdriver Procedure 45 minutes External circlip pliers and TORX T-20 duration: A. Remove the cover and both drive wheels, as outlined in section 4.1.5.
Remove the gearbox and both shafts, as outlined in section 4.2.6.4. Secure the motor to the gear frame using the four screws that used to hold the defected motor. Make sure to use only screws that were supplied by Friendly from the spare part list as the screws have a unique design. Apply 150 lb-in torques to tighten each screw.
4.2.7 Wire Sensors replacement Required tools: Wide flat screwdriver Procedure duration: 10 minutes NOTE: When servicing Robomow with old configuration Wire Sensors (See Figure 4.2.7.1 below) S/N IRL02340100 and below. Read Service Bulletin #RL0536-03- Wire Sensors/Cable replacement (Section 7.1) before starting this procedure. Figure 4.2.7.1 Old configuration Wire Sensors. Verify that both gray plastic retaining clips are back in place and are holding the wire sensor holder, as illustrated in Figure 4.2.7.5. Figure 4.2.7.4 Figure 4.2.7.5 Proper direction to place wire sensor holder Proper position of wire sensor holder in its place I.
Remove the Power Pack from the Robomow. Remove the cover, as outlined in section 4.2.1 and expose the power pack contacts, as illustrated in Figure 4.2.8.2.
Disconnect the damaged power pack contact from its lead and replace it with a new one. Ensure the leads are connected correctly –. 4.2.9 Rear bumper replacement Required tools: Wide and long flat screwdriver Procedure duration: 30 minutes Soap and water solution A.
Remove the Power Pack from the Robomow. Remove the cover, as outlined in section 4.2.1 and expose the rear bumper, as illustrated in Figure 4.2.9.1 below. Push the second side of the protrusion, as illustrated in Figure 4.2.9.4. Pull down the two ‘T’ holders located next to each of the drive wheels. The faulty bumper will become detached from the gray plastic base.
Figure 4.2.9.4 Pushing the protrusion –. Once the first side of the protrusion is in the rectangular hole, press with your thumb the rest of the protrusion into the rectangular hole, as illustrated in Figure 4.2.9.8. Figure 4.2.9.7 Figure 4.2.9.8 Thumb pressing on one side of the protrusion Thumb pressing the entire protrusion O. Stretch the bumper upwards all the way around, as illustrated in Figure 4.2.9.11.
Place the entire top bumper edge, including the “ears”, over the gray plastic base, as illustrated in Figure 4.2.9.12 below. Make sure the bumper cables, on both sides are not pinched and well connected to their tabs. Disconnect both left and right bumper cables (white or purple) that are coming out of the front bumper. Peel off the “ears” that touch the slider seal on both sides of the Robomow, as illustrated in Figure 4.2.10.2 below and the rest of the front bumper’s top edge. Bumper assembly: I.
Support the Robomow on its rear bumper but be careful not to damage any of its exposed internal parts. Make sure the front metal strip is properly located all the way around, as illustrated in Figure 4.2.10.6. Make sure the bumper’s rubber rib with the metal spring is not caught under the plastic rib that holds the metal strip, as illustrated in Figures 4.2.10.9 and 4.2.10.10 Plastic rib Figure 4.2.10.9 Figure 4.2.10.10 Improperly seated contact spring Placement of the front bumper in N. Make sure the bumper cables are coming through the designated notch on both sides of the bumper, as illustrated in Figure 4.2.10.13. Connect both (white or purple) wires. Figure 4.2.10.12 Figure 4.2.10.13 Properly seated front bumper Properly routed front bumper cables holding protrusions R. 4.2.11 Thermistors assembly/replacement Required tools: Wide flat screwdriver Procedure duration: 30 minutes External circlip pliers + Driller NOTE: Read Service Bulletin #RL0340-10 - Thermistors Kit (SPP0020A) Installation Instructions (Section 7.1) before starting this procedure.
Before starting the assembly of Thermistor to the Robomow, confirm the Main Board has the connector to support the Thermistors connection. The Thermistor cable color is white. There is one side with black marking on the white cable, as illustrated in Figure 4.2.11.4 below. Make sure the side with the black marking is attached to the right mowing motor.
Attach the pop rivet with the Thermistor to the motor shading, as illustrated in Figure 4.2.11.5. Mowing side Figure 4.2.11.4 Figure 4.2.11.5. 4.2.12 Front wheel spring/locker replacement Required tools: Wide flat screwdriver Procedure duration: 10 minutes NOTE: Read Service Bulletin #RL0536-05 - Front Wheel Detent Change (Section 7.1) before starting this procedure. Remove the Power Pack from the Robomow.
Remove the cover, as outlined in section 4.2.1. 4.3 Power Pack Procedures The Power Pack is not designed to be opened for service or repair as it does not contain either moving parts or parts that are expected to fail. However, procedures are included to allow access if necessary. 4.3.1 Power Pack opening and cable layout Required tools: Flat screwdriver Procedure duration: 10 minutes. 4.3.2 Power Pack terminal replacement Required tools: Small flat screwdriver Procedure duration: 10 minutes A.
Remove the Power Pack from the Robomow. Open the Power Pack as outlined in procedure 4.3.1. Identify the defective terminal you would like to replace and disconnect both cables attached to it. Connect both cables to the power pack terminal, as illustrated in Figure 4.3.2.1. Ensure correct polarity.
Verify the functionality of the repair by placing the power pack in a Robomow and observing it turning on. Close the case cover as illustrated in procedure 4.3.1. 4.4 Charging Station Procedures 4.4.1 Charging Station contacts replacement Required tools: Philips screwdriver Procedure duration: 5 minutes A. Remove the Robomow from the Charging Station.
Disconnect the Power Supply from the wall socket. Disconnect the two cables (Red and Green) from the tabs on the Charging Station contacts, as illustrated in Figure 4.4.1.1 below. Connect the contacts cables (Red and Green) back to the taps as illustrated in Figure 4.4.1.1 above (confirm the Red is connected to the RH side and the Green to the LH side). Connect the Power supply to the wall socket and switch on the Charging Station board to check the functionality of the Charging Station.
Figure 4.4.2.3 Figure 4.4.2.4 The track of the Power Supply cable Proper polarity of Power Supply connection G. Confirm proper layout of the Power Supply cable from the cover, as illustrated in Figure 4.4.2.5 below.
Connect the Power supply to the wall socket and switch on the Charging Station board to check the functionality of the Charging Station. 4.4.3 Docking Board replacement Required tools: Philips screwdriver Procedure duration: 15 minutes A. Remove the Robomow from the Charging Station. Disconnect the Power Supply from the wall socket. Remove the cover and disconnect the Power Supply from the Docking Board, as explained in section 4.4.2. Diagnostics The Diagnostics section of the Service Guide refers directly to the ‘Service’ menu accessed on the Robomow Manual controller.
The Robomow has a series of self-diagnostic tests that allow it to pinpoint problems or test systems affecting the operation. By entering the ‘Service’ menu and selecting the specific system or component test, the Robomow will display either a ‘Pass’. 5.1 General Test The General Test is a basic test that should be performed whenever a technician initiates a service repair on a Robomow.
The test is designed so that most common problems found in normal operation will be readily apparent. The General Test should be performed regardless of whether any work was actually performed out on a unit. Clean the unit using compressed air; particularly inside the Power Pack well and Manual controller well drain holes. A damp cloth and a wooden stick can also be used to remove stubborn dirt and debris. Do not wash with a hose. (RL500: On Manual/settings press green button, scroll up to Service key, insert 12321, green button, Confirm, green button and the menu will jump to Diagnostics. Green button to get into diagnostic mode and now scroll down or up to the wanted test).
Calibration, Tests and Settings Various calibrations, tests and settings are found under the ‘Service’. 5.3 Calibration Procedures 5.3.1 Learn wire sensors.5.5 5.3.2 Edge Calibration.5.6 5.3.3 Set country.5.7 5.3.4 DK Calibration.5.7 5.3.1 Learn Wire Sensors This is a calibration of the wire sensors. This must always be performed after replacement of a wire sensor or main board. IMORTANT: if this procedure is not performed the message ‘Move from wire’. 5.3.2 Edge Calibration Edge Calibration determines the position of the Robomow relative to the wire in edge mode. Verify that the perimeter switch/docking board switch is on.
There are two options to perform the Edge Calibration: 1. If the wire is visible, position the Robomow over a perimeter wire. The Robomow should be positioned on the wire facing in a counter-clockwise position when viewed from the inside of the perimeter. 5.3.3 Set Country It used for positioning the Robomow globally. This operation is important, as the Robomow needs to be able to adjust the sensitivity of the magnetic navigation system to its location on the globe. This process should be done only once, prior to the first automatic operation. 5.4 Tests Procedures 5.4.1 Wire sensors.5.9 5.4.2 Rain Sensor.5.10 5.4.3 Direction keeper.5.10 5.4.4 Drive motors.5.11 5.4.5 Mowing motors.5.11 5.4.6 Thermistors.5.12 5.4.7 Docking.5.12 5.4.8 Edge.5.13 5.4.9 Bat.
5.4.1 Wire Sensors The test is used to check the operation of the wire sensors. ‘Wire sensors’ is a diagnostic process that tests the operation of the four wire sensors on the mower. It has two levels of testing, basic and advanced.
Under the basic testing it is a ‘pass-fail’ test with a fault code listed for the failure message. 5.4.2 Rain Sensor This test checks the rain sensor reading. As pressing the GO button to perform the test, the following is displayed: Rain sensor Rain sensor. The left number indicates the actual reading of the rain sensor, which is updated every 5 seconds. 5.4.4 Drive Motor This test checks the operation of the drive motors.
This test should be performed when the Robomow is securely propped up on a stand so that the drive wheels will not touch the ground. The front wheel must be firmly on the ground.
Insure the cutting height and ground clearance settings are on the highest setting. Enter Mowing Motors in the ‘Service’ menu. Press the GO button for testing the motors. Press the GO button again to confirm activation of the motors for the test - the mowing motors will run. Press GO; the mower will start to move towards the Charging Station. The mower will try to connect to the Charging Station contacts and at the end Test result: X Test result: X of the test the following message will be displayed: Press GO Press GO when X can be one of the following values.
Maintenance Battery Maintenance is a multiple menu selection. It can provide valuable information on the charging maintenance habits of the customer as well as to help in identifying a faulty power pack.
Last Battery Voltage – this selection will tell you the last measured voltage of the power pack. 5.5 Settings Procedures 5.5.1 Docking Options.5.16 5.5.1.1 Edge to dock.5.16 5.5.1.2 Docking search vlt.5.16 5.5.1.3 Dock bumper5.16 5.5.1.4 Island.5.16 5.5.2 Small wheels.5.16 5.5.3 Enable DK.5.16 5.5.4 Max leg distance.5.17 5.5.5 Thermistors.5.17 5.5.6 Mowing.5.17 5.5.7 Drv. Overcurrent.5.17 5.5.8 Mow overcurrent.5.17 5.5.9 Auto restart.5.18 5.5.9.1 Drive overload.5.18 5.5.9.2 Mow overload. 5.5.1 Docking Options General comment: There is no need to change the settings under the ‘Docking Options’, unless there is an exception case, which prevent the mower to works normally.
These options appeared in the menu as a backup only. 5.5.1.1 Edge to Dock The ‘Edge to dock’. Enable DK is divided into 2 modes: ‘edge’ and ‘scan’ and it is possible to disable the DK either in edge or scan. Disabling the DK in the 2 modes enables to operate the mower without compass at all (or when the compass is faulty).
5.5.4 Max leg distance Enable to set the max distance between the perimeter wires in every zone. 5.5.9 Auto Restart This option enables to set the cases in which Robomow restarts the operation automatically within an hour after it has stopped during the operation. 5.5.9.1 Drive Overload If the mower stops with the following ‘Drive overload - cooling, wait’(10 min above 100 or 1 sec above 105), it will stay awake for up to 60 minutes with the displayed message and blinking operating light. Docking state. If the charging is done through the charging socket (placed in the Manual Controller Holder) then ‘00’ is displayed in the docking state. If the charging is done through the Docking Station, one of the following numbers is displayed: 01 - Charging through the docking station 02 - Problem in charging through the docking station.
5.5.10.2 Wire Sensors In this display the LCD will display the following information: 1.Front left reading 1.Front left reading 1.Front left reading 2.Front right reading 2.Front right reading 2.Front right reading 3.Bit rate 3.Bit rate 3.Bit rate 4.Rear left reading 4.Rear left reading 4.Rear left reading 5.Rear right reading. Ambience temperature (ºC).
Ambience temperature in ºC. Mow temperature (a2d). Mow temperature in a2d. Otherwise - over current. Right drive temperature (a2d).
Robomow Service Manual Rl20180
Right drive temperature in a2d. Charging FET temperature (ºC).
Evinrude Service Manual
Charging FET temperature in ºC. 5.5.10.4 Edge In this display the LCD will display the following information: 1.DK angle (degrees). 5.5.10.5 Drive motors In this display the LCD will display the following information: 1.Left drive current (A2D) 1.Left drive current (A2D) 1.Left drive current (A2D) 2.Right drive current (A2D) 2.Right drive current (A2D) 2.Right drive current (A2D) 3.Right drive temperature (ºC) 3.Right drive temperature (ºC) 3.Right drive temperature (ºC) 4.Over current counter. Hardware over current. Indicates if mow over current is detected by Hardware current limiter. 0 – Over current not detected.
1 - Over current detected 6. Mow temperature (ºC) or over current event counter The display will switch every 3 seconds between: 1) Mow temperature in ºC.
Probotics is a division of Cyperceptions, Inc. For information Robomower Repair and Service If you are looking for someone to get your Robomower back into top shape, you have come to the right place.
We are the Primary factory warranty and non-warranty Robomower repair center for all Robomower models (including Toro iMow). Our factory trained technicians on staff have more repair experience than anyone in the US. Since we run these mowers ourselves, we know how hard it is to be without our robotic friends.
The most complete parts inventory in the US and state of the art repair center ensure that your Robomower will be back to you and mowing your lawn as soon as possible. What we offer:.
Free Repair Evaluation. Factory Trained Technicians. Warranty and Non-Warranty Service and Repair. Full Testing. Upgrade plans and refurbishment for all models.
Option for 'from your door' prepaid shipping pick up tags (discounted). Replacement Shipping Boxes We are familiar with all models from the RL-500 to the latest RL-1000 and can recommend the best repair path to help you get the most from you mower. We even offer tips to avoid future problems and resulting repairs! If you are experiencing problems and you are not sure if your mower needs to be sent in for service, please give us a call. We can help you with troubleshooting your problems and have 'ready to email' instructions for most user correctable issues.
If your mower is still covered by the warranty, please be sure to contact us or Friendly Robotics support before sending it in. If the problem turns out not to be a faulty mower, or the problem was something that was user serviceable, shipping costs may not be covered. If you are already sure that you Robomower needs repair, you can purchase a box online if you do not have your original box. Original Friendly Robotics boxes fall below UPS surcharge size limits (plain brown over-box must be removed if present). You can also use your own packaging.
Service Manual
There is no need to contact us. Just download and read the instructions below. For your convenience, we have provided the following online information: Using your own non-original shipping box? Note: You want level 2 on the calculator.
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