Friendly Robotics robomower RL1000 Service Manual Download Page 5

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1.1 Robomow layout and main components

1.1.1 Robomow top view

Charging contacts

(for Charging

Station) SPP0026A

Knobby drive wheel

MSB0099A

Smooth drive wheel

MSB0078A

Manual Controllers

MSB0112A (tones)

MSB0114A (speech)

MSB0118A (E)

MSB0119A (Enhanced)

Manual Controller

holder assembly

MSB0105B

Operation lamp

cover

SPP0032A

Front Bumper

MSB0106B

RL Model Stickers

RL350 – STC0057A
RL800 – STC0051A
RL550 – STC0048A
RL850 – STC0049A

RL1000 – STC0056A

RL Yellow Cover GEN0094A

RL Green Cover GEN0227A

Left

Side

Right

side

Power Pack
UNT0009A

Rear

Rear Bumper

MSB0107A

Figure 1.1.1

Top view

Summary of Contents for robomower RL1000

Page 1: ...nic or mechanical including photocopying recording taping or by any electronic information storage and retrieval systems without a prior written consent of F Robotics Acquisitions Ltd This book was ca...

Page 2: ...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 C...

Page 3: ...ways meet these standards and to surpass them wherever possible All units inspected by a technician MUST as a minimum standard pass the General Test prior to return to the customer Units which were ac...

Page 4: ...1 1 Orientation It explains what is referred to as right left etc Failure to understand this can result in a mistake or problem in the analysis or repair of the product Table of Contents 1 1 Robomow...

Page 5: ...tones MSB0114A speech MSB0118A ESBC050B MSB0119A Enhanced Manual Controller holder assembly MSB0105B Operation lamp cover SPP0032A Front Bumper MSB0106B RL Model Stickers RL350 STC0057A RL800 STC0051...

Page 6: ...rved GEN0163A x4 Snap lock straight GEN0162A x6 11 Front Wheel SPP0011A Front Bumper MSB0106B 12 Mowing Motor MSB0065B x3 15 High cut blades MRK0002A Low cut blades MRK0003A 14 5 Rear Bumper MSB0107B...

Page 7: ...left Wire sensor SPP0018A Cover base seal ring GEN0182A Ground clearance limiter GEN0202A Main Board SPP0019B Drop off Board SPP0005B Battery contacts RL side SPP0014A Front wheel stopper GEN0207A Sp...

Page 8: ...0 Charging Station Base SPP0029A Charging Station contacts assembly SPP0031A 32 Charging Station Cover SPP0030A 29 Charging Station Drive Wheel support 123 122 Charging Station Fence GEN0215B 31 Figur...

Page 9: ...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...

Page 10: ...1 1 2 1 Robomow bottom view 7 DETAIL A 34 35 36 12 16 14 SEE DETAIL A 39 37 38 3 34 DETAIL A 15 7...

Page 11: ...1 8 1 2 2 Base top view 41 42 28 25 44 21 27 40 43 17 22 10 5 18 20 8...

Page 12: ...1 9 1 2 3 Cover top view 45 3 46 2 4 105 7 10 9 6 47 9...

Page 13: ...1 2 4 Charging Station 10 53 30 48 29 31 54 122 123 29 32 48 49 50 127 51 52 1 10...

Page 14: ...1 2 5 Gear Case 5 5 42 21 44 57 56 58 22 23 59 61 60 1 11...

Page 15: ...ring diagram Section 1 5 2 65 66 PWS0001A 230VAC power supply Europe PWS0002A 230VAC power supply UK PWS0003A 115VAC power supply US PWS0004A 230VAC Out Door Power Supply for RL1000 EUR PWS0005A 115VA...

Page 16: ...er cord US 67 CBL0039A External charger cord EUR 68 UNT0016A Power Pack external charging adaptor 1 2 7 Fuses 69 70 71 72 69 FUS0021A Fuse 5x20 10A 125V External Charger 70 FUS0015A Fuse mini blade 5A...

Page 17: ...1 14 1 2 8 Perimeter Switch 73 74 75 76 77 1 2 9 Bumpers 78 10 79 5...

Page 18: ...15 1 2 10 Front Wheel 83 82 81 80 11 1...

Page 19: ...s kit Includes NIT0009A HSN0003A 84 NIT0009A Pop rivet D3 2x6 85 HSN0003A Heat sink silicone insulator 1 2 12 Add On Items 15 15 Low cut blades High cut blades 86 DOC0015D RL Operating Manual En DOC00...

Page 20: ...1 GEN0211A Charging plug rubber cover 87 26 GEN0210A Charging socket rubber cover 88 TOL0001A Mowing motor removal tool 1 2 13 Decals 91 90 89 17 92 93...

Page 21: ...tion but are still required to support the previous RL configurations ESB0031A Rear Right Wire Sensor Board GEN0148A Navigator keypad GEN0118A Front Wheel Click Spring WSB0053A Mowing motors cable WSB...

Page 22: ...cation 72 1A Lamp fuse 5A Charging fuse 70 Figure 1 3 1 Robomow fuse location 71 30A Power Pack fuse Terminal 64 Terminal Figure 1 3 2 Power Pack fuse location 69 Figure 1 3 3 External Charger fuse lo...

Page 23: ...1 4 1 Main Board 100 101 25 104 17 82 21 103 102 12 12 12 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...

Page 24: ...1 1 4 3 Odometer Board 19 24 Right odometer board Left odometer board 1 4 4 Drop off Board 82 21...

Page 25: ...1 5 Wiring layout 1 22 1 5 1 Robomow schematic wiring diagram 109...

Page 26: ...attery jumper cable WSB0049B Grey Red Negative battery cable Black WSB0048B Red Fuse Holder Fuse Holder Battery Contact Left Battery Contact Left Battery Contact Right Battery Contact Right Fuse holde...

Page 27: ...k straight 1 1 2 6 15 SPP0012A SPP0012A Single high cut blade 1 1 2 1 2 11 3 15 SPP0013A SPP0013A Single low cut blade 1 1 2 1 2 11 3 16 GEN0163A GEN0163A Snap lock curved 1 1 2 4 17 SPP0018A SPP0018A...

Page 28: ...2 60 GEN0101A GEN0101A Odometer magnet 1 2 5 4 61 SCR0025A SCR0025A Screw for RL motors 1 2 5 8 62 GEN0132A GEN0132A Battery cover 1 2 6 1 63 GEN0131A GEN0131A Battery Case 1 2 6 1 64 GEN0130A GEN013...

Page 29: ...5 WSB0044A WSB0044A Lamp board cable 1 2 3 1 5 1 1 106 WSB0046B WSB0046A Fuse holder battery pack cable 1 5 2 1 107 WSB0048B WSB0048A spring battery cable 1 5 2 1 108 WSB0049B WSB0049A Battery jumper...

Page 30: ...7A GEN0067A Fast charger 115 230V without cord 1 2 6 1 GEN0094A GEN0094A RL Yellow cover 1 1 1 1 13 GEN0095A GEN0095A RL plastic base 1 1 2 1 60 GEN0101A GEN0101A Odometer magnet 1 2 5 4 39 GEN0104A G...

Page 31: ...Controller 1 1 1 1 2 3 1 84 NIT0009A NIT0009A Pop rivet D3 2x6 Thermistors 1 2 11 2 114 PRG0005A PRG0005A Flash Software v3 2i Service version 03 models NA 66 PWS0001A PWS0001A 230VAC power supply Eu...

Page 32: ...STC0012A STC0012A Rear warning sticker 1 2 13 1 89 STC0018A STC0018A Danger sticker 1 2 13 2 90 STC0022A STC0022A Front caution sticker 1 2 13 1 92 STC0036B STC0036B Battery charging decal En 1 2 13 1...

Page 33: ...al controller tones M Controller US speech RL0456 09 All models MSB0118A MSB0119A Standard Manual controllers 05 Enhanced Manual Controller RL0536 09 Main Board ESBC050B and onwards SPP0004B Spare par...

Page 34: ...en the Manual Controller is out of its place the following display is appeared Manual User Options Manual User Options As pressing the GO button when the Manual Controller in user s hand the following...

Page 35: ...ess GO to set Zone C Press GO Zone D Press GO 1 2 sound on Press GO Sound on Confirm 1 3 Wire position Press GO Wire position Press GO to test 1 4 language Press GO English Confirm 1 5 Wide scan off P...

Page 36: ...irm 2 0 Information 2 1 Total Time Press GO Total Time 196h34m 2 2 Bat run time Press GO Battery run time 2h25m 26 2V 2 3 Battery Voltage Press GO Battery Voltage 25 6 V 2 4 Temperature Press GO Tempe...

Page 37: ...1 Docking Pres GO for next Entry 2 of 4 Press GO to set Entry 3 of 4 Press GO to set Entry 4 of 4 Press GO to set learn completed Back to default Press GO Back to default Confirm Entry Points on Pres...

Page 38: ...m failed K 18 xxx xx xxxx retry elsewher 6 1 2 Edge calibration Press GO 6 1 3 Set Country Press GO 6 1 4 DK calibration Press GO e 6 2 Tests Press GO 6 2 1 Wire sensors Press GO to test wait test pas...

Page 39: ...mistors Press GO to test Drive Mow 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 6 2 9 Bat Maintenance Press GO Edge termina...

Page 40: ...edge off Confirm 6 3 1 4 Islands on Press GO Islands off Confirm Small Wheels on Confirm 6 3 3 1 Scan DK on Press GO Scan DK on Confirm 6 3 3 2 Edge DK on Press GO Edge DK on Confirm Dock zone Press G...

Page 41: ...as one full round This can increase the efficiency by minimizing the time spent on edge mowing In some rare cases because of some unique geometry of the lawn a mower may not complete edge under the no...

Page 42: ...in sensor menu Rain sensor on off allows turning the rain sensor feature off to enable operation in rain and wet grass conditions Reading Shows the actual reading of the rain sensor Set sensitivity En...

Page 43: ...e beginning of the operation measured when the GO is pressed 2 3 Battery voltage Displays the current voltage of the power pack 2 4 Temperature Displays the ambience temperature in the mower 2 5 Main...

Page 44: ...time day of the week and time hours minutes Note that the clock is on a 24 hour military time scale This feature is relevant only if a weekly program has been set While the mower is docked the current...

Page 45: ...al Controller By entering this menu the customer can select which system to test and following the screen prompts test each of the systems 6 0 Service The Service menu while accessed under the User Op...

Page 46: ...ading of each of the four wire sensors which on occasion may be helpful is troubleshooting Typically the basic test is sufficient 6 2 2 Rain Sensor Rain sensor is a diagnostics process that tests the...

Page 47: ...formation of the customers maintenance habits regarding the mower as well as help in identifying a faulty power pack Last Battery Voltage the last measured voltage of the power pack will be displayed...

Page 48: ...ry parameters back to zero when a new power pack has been put in service or possibly if a service repair was done which may have affected the counters 6 3 SETTINGS 6 3 1 Docking Options 6 3 1 1 Edge t...

Page 49: ...For example in lawn 10 by 30 the mower will not drive more than 10 meters with the same readings but in lawn 40 by 90 it may drive for 60 meters with no changes in the wire sensors readings If during...

Page 50: ...signal comes back within 60 minutes from the stop the mower will restart the operation automatically otherwise it will stop with No wire signal press GO The Operating Lamp is blinking all the time tha...

Page 51: ...ry voltage is too high during charging 09 Disconnected from charging in order to heat up when needed 10 Disconnect from charging in order to perform the Learn entry points sequence 11 Disconnected fro...

Page 52: ...left sensors outside the garden 7 forward left forward right and backward left sensors outside the garden 8 backward right sensor outside the garden 9 forward right and backward right sensors outside...

Page 53: ...high speed during edge is enabled 0 Disabled 1 Enabled 4 Moving towards ds Indicates if we are moving towards the Charging Station 0 No 1 Yes 5 Wire sensors state 0 all wire sensors are inside the ga...

Page 54: ...rdware over current Indicates if drive over current is detected by Hardware current limiter 0 Over current not detected 1 Over current detected 6 Right drive temperature a2d Right drive temperature in...

Page 55: ...tant 0 will be displayed 2 Should be 0 otherwise represents the mowing disable reason 3 Operation state 4 Last stop cause reason 5 Current movement id 6 Should be 0 otherwise represents the mowing dis...

Page 56: ...d grass clippings using a wooden stick Check P Switch Mower is trying to depart from Docking Station and the perimeter switch is not responding There is a perimeter wire disconnection detected at depa...

Page 57: ...the ground for more than 8 10 seconds The ground contains large holes or indentions where the front wheel can drop into when passing across Fill these areas with dirt and level off High temp Disc cha...

Page 58: ...to mow Make sure the Perimeter Switch is connected to the correct zone and is turned on Rain detected Go to ignore Enhanced Manual Controller only Robomow detects rain upon GO pressing Do not operate...

Page 59: ...2 Problem analysis flow charts To use this section efficiently follow this procedure A Using the Table of Contents locate the sub section for the area of the unit to be checked B Identify the type of...

Page 60: ...igzagging as it edges weaves left and right 19 3 2 5 Automatic Mowing 20 3 2 5 1 Many patches of uncut grass remain on the lawn 20 3 2 5 2 Robomower ignores areas 20 3 2 5 3 Stops with no message 21 3...

Page 61: ...eel problem is displayed when the mower is in the Docking Station 33 3 2 11 3 Robomower reached the Docking Station when its contacts are above the Docking Station contacts 33 3 2 11 4 Robomower is op...

Page 62: ...ding from the perimeter switch to the lawn Walk along the wire including perimeter islands and look closely for a cut in the wire or a loose connection Check all wire connections carefully Make sure t...

Page 63: ...der to divide the zone Twist the two ends of wires to the points you want to check on the perimeter wire Turn on the p switch and check for disconnection in the specific wire If there is no indication...

Page 64: ...broken into separate zones Does the Cut wire indicator flash once as the P Switch is turned on Separate plot installation increases the P Switch total operation time shorter wire 3 2 1 2 Is it a mult...

Page 65: ...king Station Cover by unscrewing the screws and check the connection of the power cable Black White to the connector and for the right polarity Look for a damaged or cut cable from the power supply to...

Page 66: ...ecting a standard 12 volt 1 3 amp automotive type charger to the connectors on the outside of the power pack and charging for 12 hours will usually bring the voltage up to 14 volts enough to wake up t...

Page 67: ...f charging NO Is the message still displayed YES NO Mower is ok Replace Main Board SPP0019B and follow the instructions attached to the spare part board Service Bulletin use the most updated S W versi...

Page 68: ...NO YES Is there corrosion rust inside the Charging Socket Confirm the Power Supply is plugged into the main power receptacle Check for power to this main receptacle by plugging in another appliance C...

Page 69: ...r Supply connector is fully inserted into the charging socket Confirm that the charger plug is not corroded rusty Unplug and plug the charger from the Robomower Confirm that there is no corrosion insi...

Page 70: ...ttery then try again Recharge battery Is the grass very high dense and or wet NO YES Instruct the user regarding the Charging Policy and replace the Power Pack UNT0009A Did the user properly maintain...

Page 71: ...GO then press the GO button to continue the operation 3 2 3 4 Mow overload Cooling wait message NO YES Carefully remove the grass clippings and allow the lawn dry before commencing mowing Clippings a...

Page 72: ...g reasons decrease mulching quality Mowing deck is full with grass clippings and debris Blunt blades Wet grass High grass Refer to flowchart 3 3 previous page To ensure high mulching quality confirm t...

Page 73: ...e distance Observe mower on edge is wire properly placed to prevent bumper activation while in edge Leaves the edge and starts to mow Perform Edge termination test under the Service Tests menu it shou...

Page 74: ...dges weaves left and right NO Is there another adjacent zone connected to the same perimeter switch NO YES The minimum distance between 2 adjacent zones activated by the same p switch should be greate...

Page 75: ...uncut area Confirm the distance between 2 adjacent wires is inside the allowed limit 5 5ft 1 7m Does the lawn have a complex shape slopping area or many obstacles and Perimeter Islands in the lawn YE...

Page 76: ...Power Pack contacts on both sides bat and RL are not loose damaged Remove Connectors Board cover and confirm the fuses are not free to move and there is no corrosion on the fuse housing Confirm good...

Page 77: ...smooth and level area away from metal objects and power lines Confirm the slope is not more than 15 degrees Confirm the Front Wheel turns freely both on the horizontal and vertical axes clean out all...

Page 78: ...g corners sharper than 90 degrees in the Perimeter Wire Perform Edge calibration Usually a zigzagging motion is preceding the wire crossing please refer to section 5 3 2 During Scan Perimeter Island P...

Page 79: ...does not respond several times continuously up to 30 times NO YES Is it a new Robomower or is it the first operation after an extended storage period winter Check the suspected faulty button Choose B...

Page 80: ...k allowing the wheels to rotate but unable to move 3 2 7 2 The drive motors have been working under a severe load for too long There is no need to do anything Robomow will renew automatically the oper...

Page 81: ...escription What does the failure code refer to Inspect wire connections on motors and Main Board and secure wires where required Does the fault code indicate that only one of the drive motors is disco...

Page 82: ...check the Front Wheel wire connection to the Main Board Confirm that the front lift sensor flag GEN0116A is in place Clean the optical drop off board Replace the drop off board cable SPP0005B Replace...

Page 83: ...or bumper deformation this should be rectified by ensuring correct seating of bumper on the gray plastic base Remove Robomow away from the object Press and squeeze the appropriate pressed bumper from...

Page 84: ...Look for bumper deformations these should be rectified by ensuring correct seating of bumper on the gray plastic base Confirm metal strip is in place Replace Bumper Front MSB0106B Rear MSB0107A Replac...

Page 85: ...the bumper not always detects them Bumper is OK Take the power Pack out of the Robomower and re insert Bumper Disc Refer to section 3 9 2 What message appears on the LCD Bumper pressed Refer to secti...

Page 86: ...not too big Robomower s distance from the nearest perimeter wire should be less than 50ft 15m when the wire sensors reading are above 10 Test the wire sensors readings see section 5 4 1 Pass Fail Look...

Page 87: ...w at least 3ft 1m from the wire and retry Where is the Robomower positioned Move the Robomow 10ft 3m from its place and retry Test the wire sensors readings section 5 3 5 and refer to fault code see t...

Page 88: ...t to off C Skipped because there was no charging at the scheduled departs time although there was voltage usually when the Robomow is in the Docking Station but the Manual Controller is not in its pla...

Page 89: ...1 If the mower doesn t detect the Charging Station the failure may be found in one of the following Robomower Charging Station Power Supply 2 Testing the Robomower Connect the mower to a standard Powe...

Page 90: ...dirt and level off Robomower is operated in the zone with the Charging Station but stopped with Recharge battery or time completed message The Robomower was operated from the lawn not from the Docking...

Page 91: ...ety Information REMOVE THE POWER PACK Always wear thick protective gloves when handling or cleaning around the blades Confirm that the blades are attached firmly and are not damaged worn or dull Wear...

Page 92: ...lean dry conditions Use only correct well maintained tools At the top of each procedure the tools required are listed as well as the time needed to complete the procedure The time stated tends to be g...

Page 93: ...eplacement 4 20 4 2 5 Mowing motor replacement 4 21 4 2 6 Gear case procedures 4 22 4 2 6 1 Gear case replacement 4 23 4 2 6 2 Drive motor magnet replacement 4 25 4 2 6 3 Odometer board replacement 4...

Page 94: ...duration 5 minutes Charging Fuse Replacement 5A FUS0015A A Remove the Power Pack from the Robomow B Lift the Manual Controller to an upright position in its tray C Squeeze the two tabs of the fuse co...

Page 95: ...neral Test as outlined in section 5 1 Figure 4 1 2 1 Figure 4 1 2 2 Figure 4 1 2 3 Initial lifting of the cover Screwdriver under the seal ring Operating lamp 4 1 3 Manual Controller MSB0118A Replacem...

Page 96: ...ure 4 1 3 3 Figure 4 1 3 4 Releasing the fuse cover Correct routing of wires G To replace the Manual Controller release the cable s strain release and the plug from the socket by squeezing the latch a...

Page 97: ...wdriver into the notch and push backwards as illustrated in Figure 4 1 4 2 Figure 4 1 4 1 Figure 4 1 4 2 Unscrewing the Front Wheel Retracting the front wheel spring stopper for front wheel removal E...

Page 98: ...nap onto the plastic bolt Figure 4 1 4 5 Figure 4 1 4 6 Removal of the flag Replacing the drop off board holder L Insert the front wheel into its hole Make sure the V shape is inserted into the guide...

Page 99: ...cause damage Figure 4 1 5 1 Knobby wheels versus Smooth wheels D Remove the Power Pack from the Robomow E Identify the two notches on the wheel cup Using flat screwdriver remove the wheel cup as illus...

Page 100: ...Blades are not under warranty A Remove the Power Pack from the Robomow B Prop the Robomow on a stand or turn the Robomow on its back placing it on a soft surface to protect it from scratches C To rem...

Page 101: ...in Figure 4 1 7 2 Figure 4 1 7 1 Figure 4 1 7 2 Charging contacts RL side Screw after removing the contact D Replace the contact with a new one Confirm the magnet and the rubber are inserted into the...

Page 102: ...cavity Figure 4 1 1 2 C Remove the Manual Controller and disconnect its cable See 4 1 3 D Disconnect the charging cable from the connector board and remove the M C holder E Disconnect the lamp cable...

Page 103: ...t the cover all the way carefully as the charging contacts RL1000 only on the cover are still connected to the Connector Board P Collect both main board rubber holders that support the main board to t...

Page 104: ...their counterpart holes on the base When replacing the cover beware not to damage the connector board by observing through the Manual Controller cavity F Push the cover into place until all ten cover...

Page 105: ...heels L Insert the 5A and 1A fuses into their right locations see Figure 4 2 1 1 M Connect the lamp cable N Insert the Manual Controller and its holder See Section 4 1 3 O Connect the charging cable 3...

Page 106: ...board or with new flash from the spare parts stock b The flash is placed inside a socket and need to be extracted using the special flash extracting tool Place the two leads of the tool at the diagona...

Page 107: ...lash so that it will be pushed horizontally and uniformly into the socket cavity as illustrated in Figure 4 2 3 7 j Upon proper insertion the flash should be inside the socket cavity as illustrated in...

Page 108: ...en down Mowing motors Drive motors Red Green White Black Battery cable Black Red Flat cable Front Bumper Jumper connector Wire Sensors Drop off Odometers Thermistors Bumpers Figure 4 2 3 9 Cable conne...

Page 109: ...cover as outlined in section 4 2 1 C Remove the flat cable by pulling the two lever arms outwards D Slide the Connector Board upwards to remove as illustrated in Figure 4 2 4 1 1 below E Take the new...

Page 110: ...Retracting the stopper for front wheel removal E Remove the Holder of the Drop off board by pulling hard on the holder as illustrated in Figure 4 2 4 2 3 below until the holder is removed out of its p...

Page 111: ...n section 4 2 1 C Turn over the cover and place it on a protected surface so it will not be damaged or scratched Figure 4 2 4 3 1 Disconnection of lamp cable D Disconnect the lamp cable from the conne...

Page 112: ...entify its five pins and five holes in the mowing motor flange they will fit into Figure 4 2 5 1 G Identify the placement hole in the special tool and the triangle mark on the mowing motor flange as i...

Page 113: ...ng this procedure A Remove the Power Pack from the Robomow B Remove the drive wheels as outlined in section 4 1 5 C Remove the cover as outlined in section 4 2 1 D Disconnect the drive motor cables 4...

Page 114: ...between the left base wall and the short shaft bushing and pry them apart as illustrated in Figure 4 2 6 1 2 Lift the shaft out of the hole and place the end of the short shaft on the base wall as ill...

Page 115: ...6 1 7 T Replace the seal of the front bumper and the seal of the rear bumper so they will touch both sides of the slider as illustrated in Figure 4 2 6 1 7 Figure 4 2 6 1 6 Figure 4 2 6 1 7 Moving th...

Page 116: ...ow proper reading by the odometer Both magnets cones should point at the same direction When the notch is facing you The cones should be pointing to your left as illustrated in Figure 4 2 6 2 2 Figure...

Page 117: ...dometer cable from the board as illustrated in Figure 4 2 6 3 1 below Please note that there is a right odometer board and a left one each has a unique part number D Insert the flat screwdriver into t...

Page 118: ...e drive wheel as outlined in section 4 1 5 C Remove the gear case as outlined in section 4 2 6 1 Take the gear case out of the Robomow and place it on a flat clean surface as illustrated in Figure 4 2...

Page 119: ...2 6 3 5 H Discard of both shafts Turn the gearbox again and place it on the wooden supports so the drive motors will face up From the new shafts kit take the short shaft and place it near the gear fra...

Page 120: ...nt 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 L Place the long shaft in its g...

Page 121: ...roove O Take both clips and place them between the notches as illustrated in Figure 4 2 6 3 13 P Use a plastic hammer to tap the clips into place as illustrated in Figure 4 2 6 3 14 Figure 4 2 6 4 13...

Page 122: ...ing a TORX T 20 to open Drive Motor to the gear frame the motor screws E Remove the defect motor by sliding the holding shoulders of the gear frame to the gap between the motor and the pinion as illus...

Page 123: ...tools Wide flat screwdriver External circlip pliers TORX T 20 Procedure duration 60 minutes NOTE Read Service Bulletin RL0536 02 Gear Case Frame Modification Section 7 1 before starting this procedur...

Page 124: ...e sensor plastic in its place as illustrated in Figure 4 2 7 2 below D Remove the wire sensor holder as illustrated in Figure 4 2 7 3 below and repeat this step for all 4 wire sensors Figure 4 2 7 2 F...

Page 125: ...rform Edge calibration see section 5 3 2 L Perform Wire sensors test as outlined in section 5 4 1 M Complete the General Test as outlined in section 5 1 4 2 8 Power Pack contacts replacement Required...

Page 126: ...ct the damaged power pack contact from its lead and replace it with a new one Ensure the leads are connected correctly red wire on LH contact black on RH D Return the cover as outlined in section 4 2...

Page 127: ...the ears that are touching the slider seal on both sides of the Robomow and expose the top edge of the gray plastic base in those areas E Peel off the top edge of the bumper from the gray plastic bas...

Page 128: ...illustrated in Figure 4 2 9 5 J Take the new rear bumper and apply the soap and water solution on all seven holding protrusions K Insert the top of the T holder into its place as illustrated in Figure...

Page 129: ...of the bumper is securely placed Q Verify that all the protrusions went actually all the way as illustrated in Figure 4 2 9 9 On the left side is a properly seated protrusion and on the right side the...

Page 130: ...per edge placement Properly seated bumper and wires V Return the cover as outlined in section 4 2 2 W Perform Bumper test under the Safety test menu X Complete the General Test as outlined in section...

Page 131: ...per as illustrated in Figure 4 2 10 3 below Figure 4 2 10 2 Figure 4 2 10 3 Peeled of front bumper s top edge T holder and protrusion s under side F Using the wide flat screwdriver push down one side...

Page 132: ...on all holding protrusions Place the new front bumper in its general location as illustrated in Figure 4 2 10 7 Figure 4 2 10 6 Figure 4 2 10 7 Properly located front metal strip Placement of the fron...

Page 133: ...rside of the holding protrusions as illustrated in Figure 4 2 10 11 Use both of your thumbs and press it into its rectangular hole in the gray plastic base as illustrated in Figure 4 2 10 11 Figure 4...

Page 134: ...front bumper cables holding protrusions R Return the top edge of the bumper ears on the gray plastic base as was illustrated in Figure 4 2 10 1 S Place the entire top bumper edge over the gray plastic...

Page 135: ...ble from the Main Board C Drill the pop rivet as illustrated in Figure 4 2 11 1 to release the Thermistor from the drive motor shading Vacuum the area inside the Robomow and around the gearbox make su...

Page 136: ...the black mark is connected to the Mowing side Figure 4 2 11 5 Attaching the Thermistor to the drive motor shading using pop rivet H Repeat the same steps to attach the other Thermistor to the mowing...

Page 137: ...tion of the first side of a spring clip Figure 4 2 12 2 Insertion of the front wheel stopper to it place E Squeeze the old configuration spring clips as illustrated in Figure 4 2 12 3 below F Add the...

Page 138: ...latch E With one hand pull up on the cover just above the screwdriver while simultaneously using the screwdriver to pull the latch as illustrated in Figure 4 3 1 1 Figure 4 3 1 1 Opening the Power Pa...

Page 139: ...t F Take the new terminal and position it as illustrated in Figure 4 3 2 2 below and slide it all the way up until it is stopped when the terminal knee hits the plastic Figure 4 3 2 1 Figure 4 3 2 2 R...

Page 140: ...k terminal as illustrated in Figure 4 3 2 1 Ensure correct polarity J Verify the functionality of the repair by placing the power pack in a Robomow and observing it turning on K Close the case cover a...

Page 141: ...cts as illustrated in Figure 4 4 1 2 below and remove the contacts assembly from its place Figure 4 4 1 1 Figure 4 4 1 2 Disconnection of the contact cables Opening the contacts screws E Replace the d...

Page 142: ...on the Charging Station cover as illustrated in Figure 4 4 2 1 to remove the Charging Station Cover D Open the two screws on the Docking Board to release the Power Supply cable as illustrated in Figu...

Page 143: ...ction G Confirm proper layout of the Power Supply cable from the cover as illustrated in Figure 4 4 2 5 below H Connect the Power supply to the wall socket and switch on the Charging Station board to...

Page 144: ...y board and replace it with a new one Lay the cover on its back and confirm the push button is in its place and in the right direction flat surface towards the docking board and that the docking board...

Page 145: ...ature of the problem This section closely cross references with Section 3 Troubleshooting In Section 3 many of the troubleshooting flow charts request a specific diagnostic test to be performed The re...

Page 146: ...med correctly and that no additional problems were introduced to the unit during the service routine The General Test and certain of the other diagnostics tests need to be performed in a simulated law...

Page 147: ...est area is clear of persons and obstacles Remove all floor debris to prevent it from being thrown by the rotating blades Keep feet and hands away from the blades and the drive wheels when testing D D...

Page 148: ...functions satisfactorily The results of some tests will be a pass or fail while others will display a fault code number Refer to the fault code in Section 5 6 Diagnostics Fault Codes Please follow the...

Page 149: ...ode initiation regardless of where the unit is positioned A Place the Robomow inside an operating perimeter wire at least 1m 3ft from the nearest wire B Select Learn Wire Sensors in the Service menu C...

Page 150: ...the unit and the unit should be at least 3m 10 ft away from the nearest corner of the perimeter See Figure A below 2 If the wire is not visible position the Robomow inside the lawn perpendicular to a...

Page 151: ...Robomow is positioned on a leveled and smooth surface inside the perimeter wire It should not be placed close to anything that could alter the earth s magnetic field such as buried or overhead power...

Page 152: ...ures 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 Main...

Page 153: ...Test passed ok Failed 401 advanced failed D If the manual controller display shows Failed note the code number and refer to Section 5 6 Diagnostic Fault Codes Follow the appropriate procedure from the...

Page 154: ...at rain sensor does not exist and 2 means that rain sensor exists Note Under the User preferences Rain sensor menu there are another two options allowed Changing the rain detection sensitivity the def...

Page 155: ...long time displaying two sets of numbers The top display line will be RPM and will look like this 82 RPM 83 The number to the left indicates the left wheel drive motor speed The bottom line of the dis...

Page 156: ...d mowing motors A Insure the cutting height and ground clearance settings are on the highest setting B Select Thermistors in the Service menu C Press the GO button for testing the thermistors D The ma...

Page 157: ...st is selected the robot will enter a mode where it can be operated in any way such as normal sending to Edge mowing The display will be normal However once it detects that edge process is done finish...

Page 158: ...enance by the customer and could cause diminished power pack performance and service life While any number here is cause for concern and illustrates the need to educate the user on proper maintenance...

Page 159: ...ance 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 18 5 5 9 3 Power bre...

Page 160: ...to enter the Charging Station in case which bumper is detected as the mower enter to the Charging Station 5 5 1 4 Islands Setting this option to off allow the mower to acquire the Perimeter Wire imme...

Page 161: ...e will display However the new board supports the use of thermistors so the customer may elect to have the thermistors added to the unit at his expense as an upgrade 5 5 6 Mowing Enable The mowing fea...

Page 162: ...mes back within 60 minutes from the stop the mower will restart the operation automatically otherwise it will stop with No wire signal press GO The Operating Lamp is blinking all the time that the mow...

Page 163: ...ltage is too high during charging 09 Disconnected from charging in order to heat up when needed 10 Disconnect from charging in order to perform the Learn entry points sequence 11 Disconnected from doc...

Page 164: ...left sensors outside the garden 7 forward left forward right and backward left sensors outside the garden 8 backward right sensor outside the garden 9 forward right and backward right sensors outside...

Page 165: ...peed during edge is enabled 0 Disabled 1 Enabled 4 Moving towards Charging Station Indicates if we are moving towards the Charging Station 0 No 1 Yes 5 Wire sensors state 0 all wire sensors are inside...

Page 166: ...rdware over current Indicates if drive over current is detected by Hardware current limiter 0 Over current not detected 1 Over current detected 6 Right drive temperature a2d Right drive temperature in...

Page 167: ...Last stop cause reason 5 Current movement id 6 Should be 0 otherwise represents the mowing disable reason 5 5 11 Factory Defaults Choosing the Factory Defaults option will return all selectable setti...

Page 168: ...5 Right Left wheels friction is too high 130 Drive motors Forward Right wheel PWM Left wheel PWM Right wheel friction Left wheel friction or Right motor is slower than Left motor 131 Drive motors Forw...

Page 169: ...power units are faulty 307 Mowing motors Right Mid Left Motor current 100mA Right Mid Left Motor power units are faulty 331 Mowing motors Right Motor current 100mA Right Motor is disconnected 332 Mow...

Page 170: ...rs FR RR RL sensors 2 FR RR RL sensors are disconnected 414 Wire sensors FL RR RL sensors 2 FL RR RL sensors are disconnected 415 Wire sensors FR FL RR RL sensors 2 FR FL RR RL sensors are disconnecte...

Page 171: ...isconnected 528 Direction Keeper At least two coils cannot be zeroed cannot be zeroed Magnetic interference or coils disconnected 529 Direction Keeper Coils 1 3 cannot be zeroed Magnetic interference...

Page 172: ...pulses are not detected 11 Drive overload Drive motor overload 11 only in 2005 version Start elsewhere Time out during forward or backward movements during scanning The robot is probably stuck 12 Fron...

Page 173: ...ring from drive motors overheat during automatic operation has failed 34 Check mow height Mowing motors problem Mowing motors are off but high currents are measured This means that either the mowing m...

Page 174: ...sors readings Wire synchronization failure 63 No wire signal No wire signal 64 Set country Set country 65 Calibration req DK calibration is required 66 Enable dock on off Enable Disable docking statio...

Page 175: ...e maneuver 109 Start elsewhere Software problem 113 Replace lamp Replace lamp 114 Thermistors fail Thermistors failure 115 Bumper disc Bumper disconnected 116 Bumper disc Bumper disconnected 117 Butto...

Page 176: ...emperature Ambient temperature is too high for more than 12 hours during the charging process 136 Charging failure Charging problem 137 Charging failure Charging FET temperature is too high for more t...

Page 177: ...s 6 1 Warranty claims 6 2 6 1 1 Warranty claims procedure 6 2 6 1 2 Friendly Coding System FCS 6 9 6 2 Robomow Power Pack Charging Policy 6 17 6 2 1 Overview 6 17 6 2 2 Charging procedure 6 18 6 2 3 S...

Page 178: ...rocedure of the claims by Friendly Robotics 6 1 1 1 Claim submission procedure The complete process starting with a customer complaint and ending with a credit from Friendly is illustrated in the flow...

Page 179: ...air of every claim Dealer name Service date Product and model name Serial number Date of product purchase by the customer Warranty period end date Problem description FCS code Parts required to comple...

Page 180: ...onth The form includes the following details for each claim Dealer s claim number Product serial number Date of repair Date of sale Parts used Time claimed time cost spares cost and administration cos...

Page 181: ...of each model separately 4 Claim Period month cell N6 the month which this report is referring to One report should be sent every month for each product Do not separate the claims for more than one r...

Page 182: ...r including blades and fading of paint or plastic parts 2 Any product or part that has been altered misused abused or requires replacement or repair due to accidents or lack of proper maintenance 3 Co...

Page 183: ...In addition the FCS will allow for easier data presentation in different levels and views to measure the Robomower quality in various metrics In FCS every case customer complaint service call consists...

Page 184: ...sy 3 2 12 1 116 Operating light does not work 119 Other general issues Setup Perimeter Switch and Wire 121 3 2 1 1 122 3 2 1 2 123 Perimeter switch does not operate 3 2 1 3 129 Other issues Power Pack...

Page 185: ...nd 3 2 6 1 173 No weak display 3 2 2 1 174 No audio speech 175 Does not switch to manual automatic 3 2 6 2 176 Water and condensation inside 177 Torn fallen M Controller button 178 Display is in a for...

Page 186: ...ervation when the user observes something which causes dissatisfaction If an error message appears on the LCD the error message is the symptom In all other cases the symptom code should be derived fro...

Page 187: ...R Improperly assembled 119 Other charging parts AS Improperly connection AT Improperly installed Chassis Operating light AU Improperly maintained cared 121 Base AV Improperly setting 122 Top cover AW...

Page 188: ...Wire sensor to main b 172 Conn board to docking contacts 179 Other interconnects parts Navigation 201 360 degrees Circles 202 D K calibration 203 Inaccurate edge performance 204 Moves in curves Banana...

Page 189: ...he type of problem discovered with the component identified in the section and component codes above This problem is something that you can See visually broken damaged torn missing etc Understand from...

Page 190: ...able 10 40 95 5 578 IRL0309030017 24 04 01 03 55 Perimeter Switch 10 47 20 0 0 00 6 623 IRL0309030096 12 04 12 03 83 Gear case 90 76 32 87 Front wheel 10 13 39 7 947 IRL0309030099 23 04 04 02 0 0 00 0...

Page 191: ...282 4 0 0 00 10 5 8 0 0 47 20 53 0 0 0 00 100 58 3 0 0 89 71 148 0 0 0 00 0 0 0 17 5 0 00 17 5 0 0 00 15 8 8 0 0 48 13 56 9 0 0 00 0 0 0 0 0 0 00 0 0 0 0 00 0 0 0 0 0 0 00 0 0 0 0 00 0 0 0 0 0 0 00 0...

Page 192: ...ion H Replacement part 167 Does not move in straight lines 131 Gear case AB Broken Cracked H Replacement part 241 Bumper disconnected 233 Rear bumper AJ Disconnected F Repair 172 Buttons do not respon...

Page 193: ...ivity on the unit Repair Time should be taken from the table in appendix 1 in this document When calculating the total repair time for internal procedures where the cover is removed 20 minutes are add...

Page 194: ...sed of consisting of positive and negative plates separators electrolyte etc Charging the process of storing electrical energy in a battery in a chemical form Cycle Service The use of a battery with a...

Page 195: ...ach this voltage T1 is recorded and will be used at later stage If T1 5 minutes and battery voltage is higher than 28V we will skip stage 2 and move to the Floating stage If T1 5 minutes and battery v...

Page 196: ...are ready to be sold and that the customer will receive the unit with a charged battery Top Charging by the customer The Robomower is shipped with the power pack fuse removed in order to prevent inadv...

Page 197: ...e which will reduce the battery life and capacity In such a case the battery will dry in several days 3 Leaving the Robomower without charging after the Fully charged or Ready keep charging message is...

Page 198: ...It can be done by using the power supply through the Robomower when the battery is placed inside the Robomower or by an external charger when the battery is outside the Robomower Storage for a long p...

Page 199: ...Once again the Service Bulletins are in addition to the repair instructions of the Service Guide Carefully read the Service Bulletin and the relevant procedure in chapter 4 in the Service Guide before...

Page 200: ...ings Front Bumper Jumper J502 ESBC050B If the cable attached to the front bumper is white Leave the jumper on the board Otherwise the Robomow will warn about Bumper disconnected If the cable attached...

Page 201: ...04B and SPP0015A will have the riser removed when received as a spare part Included with these two parts is Ground Clearance Limiter part GEN0202A When using the gear frame version with the riser remo...

Page 202: ...Board 2 Disconnect the right mowing motor from the Main Board and remove the right mowing motor shading 3 Remove the faulty Gear 4 Assemble the new Gear with the mowing motor shading see Figure 1 belo...

Page 203: ...When servicing the sensors or sensor harness on units with S N IRL02340100 and older spare part SPP0018A is provided only On these units the right rear sensor board Figure 1 must be removed from the s...

Page 204: ...er drain routing This modification will not be included on the supplied spare part GEN0094A RL Top Cover spare part GEN0094A is received as shown in Figure1 If you are servicing a Robomower with a S N...

Page 205: ...cted All Front Wheel Detent Change A new front wheel detent was introduced in 2003 If the S N is IRL03010000 and onwards use the new Front Wheel detent GEN0207A with two Front Wheel detent springs GEN...

Page 206: ...t will be necessary to remove the cowling first in order to disconnect the motor wires from the main board Then remove from the blade motor from the base with special tool TOL0001A See Figure 1 IMPORT...

Page 207: ...will continue to display However at the 24 26 hour time frame the Power Pack is fully charged and ready to be used even if the Ready Keep Charging message does not display The message of Ready Keep Ch...

Page 208: ...from 2 separate springs to one spring which allows close lope control of the bumper functionality and warn about any disconnection in the Front Bumper continuity Old configuration Two separate springs...

Page 209: ...nual Controller Rain sensor 2 Old versions P N MSB0112A tones P N MSB0114A speech used in the US When servicing Robomow with S W versions 3 19 04 3 2 04 4 1 04 and later use Manual Controller P N MSB0...

Page 210: ...n to the standard procedure defined in the Service Guide 7 12 1 Thermistors should be assembled to the right motors Drive and Mow Confirm the motor shields are round if it is hexagon replace them 3 Co...

Page 211: ...compatible with Main Board ESB0019B C Main Board label is marked with ESB0019B C MSB0112A MSB0114A Does not support MSB0117A to MSB0019A PRG0005A 3 2i Service Bulletin RL0305 07 Service version suppor...

Page 212: ...ates were lose from its magnetic The current contacts you have in the Docking Station will work well but their lifetime will be shorter than the magnetic contacts Magnetic contacts were sent for repla...

Page 213: ...nst the aperture assembly F Confirm the holder is placed in the apertures and tighten the screws Ensure the contacts assembly is properly placed as illustrated in Figure 5 G Connect the contacts cable...

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