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Friendly Robotics robomower RL350 Service Manual

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®
Robomower
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.
All rights reserved. No part of this book may be reproduced or used in any form
or by any means – graphic, electronic 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 carefully prepared. However, F. Robotics Acquisitions Ltd. will
not bear any responsibility for any errors, mistakes or misunderstandings. F. Robotics
Acquisitions Ltd. shall not bear responsibility for any damage resulting from faulty
instructions in this manual.
F. Robotics Acquisitions Ltd. reserves the right to introduce changes in the
product and/or to this manual without any prior notice.
© 2006. All rights reserved to F. Robotics Acquisitions Ltd.
Service Guide
I

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  • Page 1 ® 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.
  • Page 2 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...
  • Page 3 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.

  • Page 4: Table Of Contents

    1. 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. Important: Be sure to review section 1.1 (Orientation). It explains what is referred to as “right”, “left”...

  • Page 5: Robomow Layout And Main Components

    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...
  • Page 6 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...
  • Page 7 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...
  • Page 8 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...

  • Page 9: Ipl's (Illustrated Parts List)

    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...

  • Page 10: Robomow Bottom View

    1.2.1 Robomow bottom view DETAIL A DETAIL A SEE DETAIL A...

  • Page 11: Base - Top View

    1.2.2 Base - top view...

  • Page 12: Cover - Top View

    1.2.3 Cover – top view...

  • Page 13: Charging Station

    1.2.4 Charging Station...

  • Page 14: Gear Case

    1.2.5 Gear Case...

  • Page 15: Power Pack & Power Supply

    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...

  • Page 16: Fuses

    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...

  • Page 17: Perimeter Switch

    1.2.8 Perimeter Switch 1.2.9 Bumpers...

  • Page 18: Front Wheel

    1.2.10 Front Wheel...

  • Page 19: Thermistors

    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...

  • Page 20: Decals

    GEN0211A Charging plug rubber cover GEN0210A Charging socket rubber cover TOL0001A Mowing motor removal tool 1.2.13 Decals...

  • Page 21: Old Configuration Spare Parts

    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...

  • Page 22: Fuse Location

    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...

  • Page 23: Board Identification

    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...
  • Page 24 1.4.3 Odometer Board Right odometer board Left odometer board 1.4.4 Drop-off Board...

  • Page 25: Wiring Layout

    1.5 Wiring layout 1.5.1 Robomow schematic wiring diagram...
  • Page 26 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)

  • Page 27: Parts List

    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...
  • Page 28 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...
  • Page 29 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)
  • Page 30 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...
  • Page 31 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...
  • Page 32 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...

  • Page 33: Parts Compatibility Table

    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 -----...

  • Page 34: Menu Items

    2. 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.
  • Page 35 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...
  • Page 36 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...
  • Page 37 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...
  • Page 38 6. 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...
  • Page 39 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...
  • Page 40 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...
  • Page 41 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.
  • Page 42 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’...
  • Page 43 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.
  • Page 44 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.
  • Page 45 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’...

  • Page 46: Troubleshooting

    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.
  • Page 47 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.
  • Page 48 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.
  • Page 49 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.

  • Page 50: Diagnostics

    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.
  • Page 51 4. 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...
  • Page 52 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...
  • Page 53 3. Ambience temperature (ºC). Ambience temperature in ºC. 4. Mow temperature (a2d). Mow temperature in a2d. Otherwise - over current. 5. Right drive temperature (a2d). Right drive temperature in a2d. 6. 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)
  • Page 54 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...
  • Page 55 5. 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.
  • Page 56 3. 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’...
  • Page 57 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…...
  • Page 58 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.
  • Page 59 - 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...
  • Page 60 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...
  • Page 61 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’...
  • Page 62 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...
  • Page 63 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.

  • Page 64: Important Information

    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)
  • Page 65 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...

  • Page 66: Service Bulletins

    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...
  • Page 67 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...
  • Page 68 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...
  • Page 69 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).
  • Page 70 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 –...

  • Page 71: Mowing Problems

    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’...
  • Page 72 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 –...
  • Page 73 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...
  • Page 74 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...
  • Page 75 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 –...
  • Page 76 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...
  • Page 77 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...
  • Page 78 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’...
  • Page 79 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.
  • Page 80 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 –...
  • Page 81 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...
  • Page 82 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...
  • Page 83 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...
  • Page 84 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’...
  • Page 85 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 –...
  • Page 86 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...
  • Page 87 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...
  • Page 88 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...
  • Page 89 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.
  • Page 90 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. 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).
  • Page 91 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...
  • Page 92 4. 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.
  • Page 93 Table Of Contents ………………………………. 4.1 4. 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………………………………………...

  • Page 94: Robomow External 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. B. Pull the burnt fuse directly downwards to extract. C. Fully insert a new 30A fuse (FUS0003A). D.

  • Page 95: Operating Lamp Replacement

    4.1.2 Operating lamp replacement (LMP0004A) Required tools: Flat screwdriver Procedure duration: 5 minutes A. Remove the Power Pack from the Robomow. B. 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. C.
  • Page 96 E. Squeeze the two tabs of the fuse cover, while pulling up the fuse cover (Figure 4.1.3.3). F. 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.
  • Page 97 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. B. Turn the Robomow on its back and place it on a soft surface to protect it from scratches. C.
  • Page 98 H. Replace the faulty part: either the egg wheel with shaft (SPP0011A), the adjusting plastic bolt (GEN0117A) or the flag (GEN0116A). I. Return the adjusting bolt onto the shaft remembering to place the metal washer first. J. Replace the flag to the metal shaft. K.

  • Page 99: Drive Wheel Replacement

    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. B. Prop the Robomow on a stand so that the drive wheels will not be touching the ground. C.

  • Page 100: Blades Replacement

    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). J. Push the new drive wheel over the shaft and the spline until it rests against the support in the spline.

  • Page 101: Charging Station Contacts (Robomow Side) Replacement

    4.1.7 Charging Station contacts (Robomow side) replacement Required tools: Pliers Procedure duration: 10 minutes A. Remove the Power Pack from the Robomow. B. 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. C.

  • Page 102: Robomow Internal Procedures

    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:...
  • Page 103 J. Repeat step I for the other nine lockers. K. Turn the Robomow back on its wheels. L. 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. M.
  • Page 104 C. 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.
  • Page 105 J. 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. L. Insert the 5A and 1A fuses into their right locations (see Figure 4.2.1.1) M.

  • Page 106: Main Board Replacement

    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. B. Remove the cover, as outlined in section 4.2.1. C. Disconnect all the cables leading to the main board. D.
  • Page 107 g. Identify the flat inside corner and marking triangle next to it inside the socket, as illustrated in Figure 4.2.3.5. h. 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.
  • Page 108 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...

  • Page 109: Other Boards Replacement

    J. Replace the cover as outlined in section 4.2.2. K. Place the unit inside the simulated garden, as explained in section 5.1 and turn the Perimeter Switch on. L. Perform ‘Factory defaults’ under the ‘Service’>’Settings’ menu (section 5.5.6) M. Perform the following under the ‘Service’>’Calibration’ menu: ‘Learn wire sensors’...

  • Page 110: Drop Off Board Replacement

    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. B. Remove the cover, as outlined in section 4.2.1. C. Unscrew the Front Wheel all the way until the highest mowing position, ass illustrated in Figure 4.2.4.2.1.

  • Page 111: Lamp Board Replacement

    H. Screw the front wheel into its place to the proper height position. I. Connect the drop-off board cable to the Main Board. J. Close the cover, as outlined in section 4.2.2. K. Perform the ‘Front wheel test’ under the ‘Safety tests’ menu. L.

  • Page 112: Mowing Motor Replacement

    E. Clean the mowing deck from grass residues and dirt. F. 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).

  • Page 113: Gear Case Procedures

    J. 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.
  • Page 114 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. L.
  • Page 115 P. 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. Q. 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...

  • Page 116: Drive Motor Magnet Replacement

    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. B. Remove the drive wheels, as outlined in section 4.1.5. C. Remove the cover, as outlined in section 4.2.1. D.

  • Page 117: Odometer Board Replacement

    H. Return the drive wheels, as outlined in section 4.1.5. I. Return the cover as outlined in section 4.2.2. J. Perform the ‘Drive motor test’ outlined in section 5.4.4. K. 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...

  • Page 118: Shafts Replacement

    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. H. Return the drive wheels, as outlined in section 4.1.5. I. Return the cover as outlined in section 4.2.2. J.
  • Page 119 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.
  • Page 120 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.
  • Page 121 M. 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. N. 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.

  • Page 122: Drive Motor Replacement

    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. B. Remove the gearbox and both shafts, as outlined in section 4.2.6.4. C.

  • Page 123: Gear Frame Replacement

    G. 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. H.

  • Page 124: Wire Sensors Replacement

    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...

  • Page 125: Power Pack Contact Replacement

    H. 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.
  • Page 126 A. Remove the Power Pack from the Robomow. B. Remove the cover, as outlined in section 4.2.1 and expose the power pack contacts, as illustrated in Figure 4.2.8.2. C. Disconnect the damaged power pack contact from its lead and replace it with a new one. Ensure the leads are connected correctly –...

  • Page 127: Rear Bumper Replacement

    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. B. Remove the cover, as outlined in section 4.2.1 and expose the rear bumper, as illustrated in Figure 4.2.9.1 below.
  • Page 128 G. Push the second side of the protrusion, as illustrated in Figure 4.2.9.4. H. 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 –...
  • Page 129 N. 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.

  • Page 130: Front Bumper Replacement

    T. Stretch the bumper upwards all the way around, as illustrated in Figure 4.2.9.11. U. 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.
  • Page 131 C. Disconnect both left and right bumper cables (white or purple) that are coming out of the front bumper. D. 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. E.
  • Page 132 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. J.
  • Page 133 M. 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.
  • Page 134 Q. 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.
  • Page 135 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.
  • Page 136 F. 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. G. 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...

  • Page 137: Front Wheel Spring/Locker Replacement

    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. A. Remove the Power Pack from the Robomow. B. Remove the cover, as outlined in section 4.2.1. C.

  • Page 138: Power Pack Procedures

    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...

  • Page 139: Power Pack Terminal Replacement

    4.3.2 Power Pack terminal replacement Required tools: Small flat screwdriver Procedure duration: 10 minutes A. Remove the Power Pack from the Robomow. B. Open the Power Pack as outlined in procedure 4.3.1. C. Identify the defective terminal you would like to replace and disconnect both cables attached to it.
  • Page 140 I. Connect both cables to the power pack 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 as illustrated in procedure 4.3.1.

  • Page 141: Charging Station

    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. B. Disconnect the Power Supply from the wall socket. C. Disconnect the two cables (Red and Green) from the tabs on the Charging Station contacts, as illustrated in Figure 4.4.1.1 below.
  • Page 142 G. 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). H. Connect the Power supply to the wall socket and switch on the Charging Station board to check the functionality of the Charging Station.
  • Page 143 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. H. Connect the Power supply to the wall socket and switch on the Charging Station board to check the functionality of the Charging Station.

  • Page 144: Docking Board Replacement

    4.4.3 Docking Board replacement Required tools: Philips screwdriver Procedure duration: 15 minutes A. Remove the Robomow from the Charging Station. B. Disconnect the Power Supply from the wall socket. C. Remove the cover and disconnect the Power Supply from the Docking Board, as explained in section 4.4.2.
  • Page 145 5. 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’...
  • Page 146 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.
  • Page 147 B. 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. C.
  • Page 148 (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’...
  • Page 149 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’...
  • Page 150 5.3.2 Edge Calibration Edge Calibration determines the position of the Robomow relative to the wire in edge mode. A. Verify that the perimeter switch/docking board switch is on. B. 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.
  • Page 151 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.
  • Page 152 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. Maintenance………………..…..…5.14...

  • Page 153: Wire Sensors

    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.

  • Page 154: Rain Sensor

    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.

  • Page 155: Drive Motors

    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.

  • Page 156: Thermistors

    A. Insure the cutting height and ground clearance settings are on the highest setting. B. Enter Mowing Motors in the ‘Service’ menu. C. Press the GO button for testing the motors. D. Press the GO button again to confirm activation of the motors for the test - the mowing motors will run.

  • Page 157: Edge

    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:...

  • Page 158: Bat. Maintenance

    5.4.9 Bat. 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.
  • Page 159 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 bumper………………5.16 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.

  • Page 160: Docking Options

    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’...

  • Page 161: Max Leg Distance

    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.

  • Page 162: Auto Restart

    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.
  • Page 163 4. 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...

  • Page 164: Wire Sensors

    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...

  • Page 165: Edge

    3. Ambience temperature (ºC). Ambience temperature in ºC. 4. Mow temperature (a2d). Mow temperature in a2d. Otherwise - over current. 5. Right drive temperature (a2d). Right drive temperature in a2d. 6. Charging FET temperature (ºC). Charging FET temperature in ºC. 5.5.10.4 Edge In this display the LCD will display the following information: 1.DK angle (degrees)

  • Page 166: Drive Motors

    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...

  • Page 167: Factory Defaults

    5. 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.
  • Page 168 5.6 Diagnostics Fault Codes 5.6.1 Drive motors problems………………………………..…..5.24 5.6.2 Mowing motors problems …………………………...….…5.25 5.6.3 Wire sensors problems ………………………………..….5.26 5.6.4 Direction keeping problems ……………………………..5.27 5.6.1 Drive Motors Problems Fault Diagnosed item Meaning Possible cause Right motor Drive motors (Forward) Right motor is disconnected current<100mA Left motor Drive motors (Forward)
  • Page 169 Left motor PWM>95% Drive motors (Backward) Left wheel friction is too high Right & Left motors Drive motors (Backward) Right & Left wheels friction is too high PWM>95% Right wheel PWM>Left Right wheel friction>Left wheel friction, or Drive motors (Backward) wheel PWM Right motor is slower than Left motor Left wheel PWM>Right...
  • Page 170 Mowing motors Left Motor current > 100mA Left Motor stopping is faulty Right +Left Motor current > Mowing motors Right +Left Motors stopping is faulty 100mA Mid +Left Motor current > Mowing motors Mid +Left Motors stopping is faulty 100mA Right +Mid +Left Motor Mowing motors Right +Mid +Left Motors stopping is faulty...
  • Page 171 5.6.4 Direction Keeping Problems Fault Diagnosed item Meaning Possible cause Direction Keeper Low resolution reading=0 Direction keeper is faulty Low resolution readings are Direction Keeper Direction keeper is noisy noisy Magnetic interference or coils Direction Keeper Coils 1+2 cannot be zeroed disconnected Magnetic interference or coils Direction Keeper...
  • Page 172 5.7 Last Stop Cause Every time the mower stops with an error message (+ Press GO), it is possible to look at the ‘Last stop cause’ information under the ‘Information’ menu and to have more details about the reason, which cause the mower to stop. The table below shows the description of the stop cause: Stop Message...
  • Page 173 Stop Message Description cause # Problem with the wire during Edge Start elsewhere Robomow has detected that all 4 wire sensors are outside the garden for too long Start elsewhere Problem with the wire during Edge Problem with the wire during Edge Start elsewhere Robomow unable to locate the wire for too long Start elsewhere...
  • Page 174 Stop Message Description cause # Start elsewhere Problem with the wire sensors readings Start elsewhere Software problem Start elsewhere Problem with the wire sensors readings Start elsewhere Software problem Blocked path Path is blocked No wire signal No wire signal during automatic operation Front bumper disc Front bumper disconnected Rear bumper disc...
  • Page 175 Stop Message Description cause # No wire signal No wire signal Move from wire Problem with the wire sensors readings Start elsewhere Problem with the wire sensors readings Problem with the wire sensors readings Perimeter wire might be Move from wire too close Start elsewhere Problem with the wire sensors readings...
  • Page 176 Stop Message Description cause # Robomow has reached the maximal Edge distance during the Max dist reached “Wire position test" Test result: ‘result’ Termination of the Edge termination test Test result: ‘result’ Termination of the docking station entry test Robomow has slid off the docking station more than 5 times Docking problem during the current charging process Robomow has slid off the docking station more than 5 times...
  • Page 177 6. Friendly Robotics Procedures and policies 6.1 Warranty claims……………………………………………………... 6.1.1 Warranty claims procedure………………………………………. 6.2 6.1.2 Friendly Coding System (FCS)………………………………….. 6.2 Robomow Power Pack Charging Policy……………………………. 6.17 6.2.1 Overview…………………………………….…………………… 6.17 6.2.2 Charging procedure…………………………………….………... 6.18 6.21 6.2.3 Storage and shelf life……………………………………………. 6.2.4 Closure…………………………………….……………………... 6.21...
  • Page 178 This document describes the warranty cost recognition policy for the Robomower from January 01, 2004 and beyond. It contains guidelines and explanations for filling and reporting the Warranty claim forms by Friendly authorized distributors to Friendly Robotics and the approval procedure of the claims by Friendly Robotics.
  • Page 179 Distributor no later than 60 days from the date of the repair. IMPORTANT! Claims submitted to Friendly Robotics after more than 90 days from the repair date will not be recognized. It is important to submit the claims you have on a monthly base, so the approval...
  • Page 180 The Distributor should summarize Warranty Claim received from the Dealers on a monthly basis and send the claim to Friendly Robotics every month for the month preceding it. The Claims should be submitted to Friendly no later than 90 days from the date of the repair.
  • Page 181 Robotics (see appendix A). The report should be submitted on a monthly basis. This form is identical to all distributors and is supplied by Friendly Robotics. The distributor should fill only the yellow cells in the ‘Warranty Claims Report’ spreadsheet; the second and the third spreadsheets used as data inputs to fulfill the first spreadsheet;...
  • Page 182 4. Any product that has been opened, repaired, modified or altered by anyone other than a Friendly Robotics authorized repair technician. 5. Repairs necessary due to improper battery care, electrical supply irregularities, or failure to properly prepare the mower or battery for winter storage or other extended storage periods.
  • Page 183 6.1.2 Friendly Coding System (FCS) Explanation Friendly Coding System (FCS) is Friendly’s method for recording and tracking customer complaints about the Robomower performance. The purpose of the FCS is to systematically and logically capture and organize the information coming from the customers, the evolution of every complaint and repair, in a way that will be easier to classify and analyze the data.
  • Page 184 C u s t o m e r O b s e r v a t i o n Flowchart Error Message (red) / Symptom ( black) Area coverage 3.2.4.2 101 Uncut area in the lawn edge 3.2.5.1 102 Many patches of uncut grass 3.2.5.2 103 Robomower ignores areas 109 Other coverage issues...
  • Page 185 C u s t o m e r O b s e r v a t i o n Flowchart Error Message (red) / Symptom ( black) Scan User Help Needed / Start Elsewhere message 3.2.5.6 162 Crocess wire (perimeter island) 3.2.5.6 163 Crocess wire, outside perimeter loop 164 Changes direction in the middle of the lawn...
  • Page 186 C u s t o m e r O b s e r v a t i o n Flowchart Error Message (red) / Symptom (black) Packaging 231 Missing part 232 Damaged part 233 Damaged box 239 Other packaging issues Bumpers and Sensors 3.2.9.2 Bumper disconnected...
  • Page 187 F a i l u r e C o d e Component Code Defect Code 900 Robot AA Bent 901 Software AB Broken / Cracked 902 Main Board AC Burnt AD By special instruction from Friendly Battery AE Corroded / penetrated water 101 Battery AF Damaged 102 Battery case...
  • Page 188 Component Code Component Code Setup Packaging 151 Perimeter switch 211 Operation CD 152 Battery holder for P. Switch 212 Perimeter switch 159 Othersetup parts 213 P. switch mounting stake 214 Connectors Interconnects 215 Robomower 216 RoboRuler 161 Battery contacts to main b. 217 Pegs 162 Bumpers to main board 218 Perimeter Wire...
  • Page 189 Component code The component code identifies the faulty components within a major system. In case the faulty component does not appear in the component code of the specific section, there is a code for ‘Other parts’ in every section. The ‘Environment’ section is an exception, as it does not relate to any system in the Robomower.
  • Page 190 ----- 0.00 ----- 0.00 ----- 0.00 ----- 0.00 ----- 0.00 ----- 0.00 ----- 0.00 - Friendly Robotics Internal Use Only - Total Average Approval signatures: No. of claims: 5.00 0.63 Name Date Time claimed: 175.0 21.9 Time Cost (€): 1.38 No.
  • Page 191 Part No. 3 Summary Total Total Total Total Labor Part labor Other Part Cost time cost Parts Cost Part Description time time costs (€) (€) (€) Cost (€) (min.) (min.) (€) ----- 0.00 37.9 150.92 188.8 ----- 0.00 19.35 28.1 ----- 0.00 74.34...
  • Page 192 FCS Code (1) Customer Observation (A) Component Code (B) Failure Code (C) Repair Code (D) Robomower does not 'Wake Replacement Main Board Damaged (Main board) Charging problem / Check M. Controller Corroded / Replacement Power Holder Ass. penetrated water (part) Replacement Short run time Battery...
  • Page 193 Appendix B – Claimed Time The time claimed is the time required to repair the unit. This time includes the diagnostics time needed to identify the problem, the Test time (see chapter 5.1 in the Service Guide) that should be performed after any service routine was performed on the unit and the repair time required to replace/repair the faulty part by the service/dealer.
  • Page 194 6.2 Robomow Power Pack Charging Policy 6.2.1 Overview A battery is an integral part of the electrical system for most motorcycles, snowmobiles, ATV's and watercraft. Even so, batteries often receive less care than they deserve. And improper care can lead to shortened battery life.
  • Page 195 The Robomower uses an external power supply to provide the required energy for charging while an on board computer controls the actual battery charging process. The Power Supply is manufacturing by Eng. ELECTRIC Co. LTD Friendly Robotics uses two power supply models: A – Input: 120VAC 60 Hz 38 W Output: 32VDC 900mA This model is UL approved B –...
  • Page 196 Top Charging by Friendly Robotics Friendly Robotics tests every battery prior to putting the battery into the Robomower package. If the battery voltage is less than 25.0V then the battery has to be charged prior the packaging process (the top charging process is defined in the ‘Battery assembly and testing instruction’...
  • Page 197 1. Make sure the charger is plugged into a standard 110V or 220V household outlet. 2. Connect the charging plug to the Robomower at the manual controller base. 3. Pivot it up on its hinges, connect the charger plug and pivot it back to lie flush with the surface.
  • Page 198 See section 3.2.2 in the Service Guide Battery warranty The battery warranty given by Friendly Robotics is valid when following this charging procedure. Any case in which the customer did not follow this procedure, Friendly will not accept the claim.
  • Page 199 Such cases will be specified at the top part of each bulletin. For the dealer’s convenience, most of the Service Bulletins are printed and attached to the spare parts supplied by Friendly Robotics. Once again, the Service Bulletins are in addition to the repair instructions of the Service Guide.
  • Page 200 Service Bulletin #RL0536-01 Technical Service Bulletin Date: Sep. 20, 2005 Part Number: SPP0019B Product Model: Serial Range: Main Board (SPP0019B) Replacement Instructions The following instructions are in addition to the standard procedure defined in the Service Guide. Remove the faulty Main Board with its Flash and follow the instructions in the table below. Note: Please refer to the Main Board Part Number as appeared on a white label placed on the board (the P/N in the right picture is ESBC050B).
  • Page 201 Service Bulletin #RL0536-02 Technical Service Bulletin Date: October 23, 2005 Part Number: SPP0004B / SPP0015A Product Model: Serial Range: Gear Case/ Frame Modification Two versions of the gear frame are found in the field. One version utilizes a ground clearance- limiting riser molded as part of the frame, while the other does not.
  • Page 202 Gear Case replacement Gear Case replacement A new spare part Gear, part number (SPP0004B) was introduced in 2003. The Gear includes the following parts: - Gear Case - Ground Clearance Limiter (GEN0202A) - Thermistors kit (SPP0020A) - Extra motor shading (GEN0171A) When replacing the Gear Case on all S/N units, follow the instructions below: 1.
  • Page 203 Service Bulletin #RL0536-03 Technical Service Bulletin Date: October 26, 2005 Product Model: RL500/800/550/850 Serial Range: IRL02340100 and older Part Number: SPP0018A Countries Affected: Wire Sensors/Cable (SPP0018A) A new wire sensor assembly was introduced in 2003. All four wire sensors and the harness are included as one assembly.
  • Page 204 Service Bulletin #RL0536-04 Technical Service Bulletin Date: September 20, 2005 Product Model: RL500/550/800/850 Serial Range: IRL03010000 and onwards Part Number: GEN0094A Countries Affected: RL Top Cover (GEN0094A) Water Drain Changes A modified top cover was introduced in 2003 to accommodate changes in the water drain routing.
  • Page 205 Service Bulletin #RL0536-05 Technical Service Bulletin Date: September 20, 2005 Product Model: RL500/550/800/850 Serial Range: IRL03010000 and onwards Part Number: GEN0207A / GEN0208A Countries Affected: Front Wheel Detent Change A new front wheel detent was introduced in 2003. If the S/N is IRL03010000 and onwards, the new Front Wheel detent (GEN0207A) with two Front Wheel detent springs (GEN0208A) as shown in Figure 2 below.
  • Page 206 Service Bulletin #RL0536-06 Technical Service Bulletin Date: October 25, 2002 Product Model: RL500/550/800/850 Serial Range: IRL03010000 and later Part Number: MSB0065B – Mowing Unit Countries Affected: Mowing Motor Replacement (MSB0065B) A new mowing motor, part number (MSB0065B) was introduced in 2003. The wire harness at the motor end is now soldered to the terminals for better rigidity.
  • Page 207 Service Bulletin #RL0305-07 Technical Service Bulletin Date: June 04, 2003 Product Model: RL550/800/850 Serial Range: Beginning IRL03… Part Number: Robomower Countries Affected: 2003 RL550/RL800/RL850 Operating Manual Addendum The 2003 Owner’s Operating Manual indicates that a text message, ‘Ready- Keep Charging’ will appear on the LCD screen of the manual controller when the Power Pack is fully charged and ready for use.
  • Page 208 Service Bulletin #RL0340-08 Technical Service Bulletin Date: October 02, 2002 Part Number: MSB0106B Product Model: Serial Range: RL550/850/1000 IRL0401… and later Front Bumper (MSB0196B) Replacement Instructions The following instructions are in addition to the standard procedure defined in the Service Guide.
  • Page 209 Service Bulletin #RL0536-09 Technical Service Bulletin Date: Oct 26, 2005 Part Number: MSB0117A Product Model: Countries Affected: RL350/550/800/850/1000 S.W version: Manual Controller (MSB0117A) Replacement Instructions The following instructions are in addition to the standard procedure defined in the Service Guide. Three Manual Controllers spare part are available in 2006 season: 1.
  • Page 210 Service Bulletin #RL0340-10 Technical Service Bulletin Date: October 02, 2002 Part Number: SPP0020A Product Model: Serial Range: Thermistors Kit (SPP0020A) Installation Instructions The following instructions are in addition to the standard procedure defined in the Service Guide. 1. Thermistors should be assembled to 3.
  • Page 211 Service Bulletin #RL0536-11 Technical Service Bulletin Date: Sep 20, 2005 Part Numbers: All Software Version Product Model: Countries Affected: Serial Range: S.W. version (Flash) Replacement Instructions The following instructions are in addition to the standard procedure defined in the Service Guide. Spare Part Manual Main Board...
  • Page 212 Beginning with IRL04… Charging Contacts (SPP0031A) Replacement Instructions Friendly Robotics has developed magnetic contacts for the RL1000 and the Charging Station. The magnetic contacts confirm good contact between the Robomower charging contacts and the Docking Station contacts, reduce the cases of burnt contacts and increase the lifetime of the contacts.
  • Page 213 Figure 2 Opening the contacts screws E. Replace the docking contact assembly with a new one, when the topside direction is as shown in Figure 3. Place the contacts holder above the aperture in the cover, as illustrated in Figure 4 below. Top Side Figure 3 Figure 4...

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Robomower rl1000Robomower rl550Robomower rl800Robomower rl850

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