Honda HRM500 Manual

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A Few Words About Safety

How to use this manual

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage

this Honda product or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures

require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not

recommended by Honda must determine the risks to their personal safety and the safe operation of this product.

If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer's Safety

Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight

while servicing this product can result in faulty operation, damage to the product, or injury to others.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to

be seriously hurt or killed.

Follow the procedures and precautions in this

manual and other service materials carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety

practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge

of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.

Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should

perform a given task.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or

killed.

Follow the procedures and precautions in this

manual carefully.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and

using safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills

required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around

pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

• Disconnect the power supply cable from a power outlet and make sure that the blade rests, before operation.

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Summary of Contents for Honda HRM500

Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
Page 2: Table Of Contents
dummyhead dummyhead CONTENTS GENERAL INFORMATION TECHNICAL FEATURES INSTALLATION SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER WHEEL/TRACTION MOTOR BLADE/BLADE MOTOR OTHER ELECTRICAL DOCKING STATION WIRING DIAGRAMS INDEX...
Page 3: Safety Messages
How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda HRM300/HRM500 robotic lawnmower. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.
Page 4 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
Page 5 dummyhead dummyhead MEMO...
Page 6 dummytext 1. GENERAL INFORMATION SERIAL NUMBER LOCATION ·····················1-2 RUNNING SPEED ········································· 1-3 TYPE CODE ··················································1-2 TRANSMISSION AND WORKING PART ····· 1-3 SPECIFICATIONS ·········································1-2 ELECTRICAL ················································ 1-3 NOISE ····························································1-2 DIMENSIONAL DRAWINGS························· 1-4 TRANSMISSION AND DRIVING PART ········1-3...
Page 7: General Information
Always refer to this number when making technical inquiries or ordering parts in order to obtain the correct parts. FRAME SERIAL NUMBER TYPE CODE Type REGION EU except for U.K. U.K. Switzerland SPECIFICATIONS Model HRM300 HRM500 Description code MAWF MBAF Type Overall length 645 mm (25.4 in) Overall width 550 mm (21.7 in) Overall height 275 mm (10.8 in)
Page 8 GENERAL INFORMATION TRANSMISSION AND DRIVING PART Model HRM300 HRM500 Motor Name DC motor (Geared motor) Type 3-Phase DC Brushless type Rated power 10.8 W Rated speed 38.2 min (rpm) Speed reducing ratio Service voltage 22.2 V RUNNING SPEED...
Page 9 dummyhead dummyhead GENERAL INFORMATION DIMENSIONAL DRAWINGS Unit: mm (in) 550 (21.7) 645 (25.4) 305 (12.0) 400 (15.7) 300 (11.8) 165 (6.5) 165 (6.5) 220 (8.7) 585 (23.0) 790 (31.1)
Page 10: Technical Features
dummytext 2. TECHNICAL FEATURES SYSTEM DESCRIPTION·······························2-2...
Page 11 dummyhead dummyhead TECHNICAL FEATURES SYSTEM DESCRIPTION TECHNICAL FEATURES SUMMARY This system consists of lawnmower, docking station and boundary wire. The robotic lawnmower powered by battery has sensors which detect the location of the boundary wire and docking station. The lawnmower mows automatically under the requirements set up by user. The docking station generates a pulse current to the boundary wire and transmits particular pulse signal from itself.
Page 12 dummyhead dummyhead TECHNICAL FEATURES LAWNMOWER This lawnmower consists of below core components. 3-c,d,g CATEGORY PARTS NAME FUNCTION MOTOR TRACTION MOTOR Drive the rear wheels BLADE MOTOR Drive the blade disc CONTROL MAIN ECU System control DISPLAY UNIT Display control SENSOR LIFT SENSOR Detect the top cover position changing (Moving distance of up or down)
Page 13 dummyhead dummyhead TECHNICAL FEATURES DOCKING STATION/BOUNDARY WIRE/TRANSFORMER Docking station/Boundary wire/Transformer consists of below core components. POWER CORD BOUNDARY WIRE TRANSFORMER DOCKING STATION PULSE GENERATOR CHARGING PLUG UNIT PARTS FUNCTION DOCKING STATION PULSE GENERATOR Output the pulse current to detect the boundary wire and location of the docking station by lawnmower CHARGING PLUG...
Page 14: Installation
dummyhead dummyhead TECHNICAL FEATURES BASIC OPERATION OF THE LAWNMOWER BOUNDARY WIRE FUNCTION The boundary wire is in loop shape and starts from the docking station. The boundary wire can utilize the below three functions by changing the shape. 1. Avoid the obstacle. 2.
Page 15 dummyhead dummyhead TECHNICAL FEATURES 3. Returning guide to the docking station: When the lawnmower returns to the docking station, it will follow the boundary wire until it receives the docking station signal. The short cut wire is effective in ensuring a rapid returning back to the docking station. STATION SIGNAL RANGE Short cut wire is installed (One line): Short cut wire is installed (Two lines):...
Page 16 dummyhead dummyhead TECHNICAL FEATURES MOVING TO THE MOWING ZONE Under the programmed timing and requirements below, the lawnmower will move away from the docking station and will run along the boundary wire and eventually enter the mowing zone. 1. Moving direction (From the docking station, clockwise or anti-clockwise) 2.
Page 17 dummyhead dummyhead TECHNICAL FEATURES DETECTION OF THE BOUNDARY WIRE The overlap distance of the lawnmower from the boundary wire is possible to set up (20 - 45cm). The lawnmower detects the boundary wire by using three area sensors. If one of the area sensors goes beyond the boundary wire and overlap distance is reached, the lawnmower will stop instantly, move backward and rotates until all of the sensor confirm that the lawnmower is inside of the boundary wire.
Page 18 dummyhead dummyhead TECHNICAL FEATURES RUNNING SPEED ADJUSTMENT To maintain uniform blade rotation frequency the ECU monitors the current load placed on the battery. The ECU will adapt the wheel rotation speed to the load applied to the blades. NORMAL SLOW NORMAL The blade rotates 360 degrees as to reduce the impact when hitting an obstruction.
Page 19 dummyhead dummyhead TECHNICAL FEATURES MOVEMENT OF THE LAWNMOWER WHEN IT HITS AN OBSTRUCTION When the lawnmower hit obstructions, the obstruction sensor detects the crosswise movement of the top cover, the lawnmower stops and changes direction. The display will show a message or sound an alarm depending on the repetition of hitting the obstruction.
Page 20 dummyhead dummyhead TECHNICAL FEATURES MOVEMENT OF THE LAWNMOWER WHEN IT ENCOUNTERS AN OBSTRUCTION OR IS LIFTED UP When the lawnmower encounters an obstructions or is lifted up, the lift sensor detect the top cover moving. The lawnmower will stop the blade motor and change direction, rotate, or stop with showing the message on the display or sound an alarm depending on the continuing time of run up or lifted up.
Page 21 dummyhead dummyhead TECHNICAL FEATURES MOVEMENT OF THE LAWNMOWER WHEN IT TILTS OR ROLL OVER The tilt sensor and roll over sensor on the ECU detect the angle of the lawnmower. Depending on the angle, the lawnmower will escape from slope or stop with showing the message on the display or sound an alarm. •...
Page 22 dummyhead dummyhead TECHNICAL FEATURES RETURN TO THE DOCKING STATION The lawnmower generally runs along the boundary wire and required time to return to station will depends on the shape and length of the boundary wire. 1. When the timer is ending or battery voltage is low, the lawnmower will start searching the docking station‘s signal and return directly for 5 minutes.
Page 23 dummyhead dummyhead MEMO...
Page 24 dummytext 3. INSTALLATION SAFETY INSTRUCTIONS ·····························3-2 PROGRAMING············································ 3-15 BEFORE INSTALLATION·····························3-4 SETTING METHODE ·································· 3-18 BOUNDARY WIRE INSTALLATION·············3-9...
Page 25: Maintenance
dummyhead dummyhead INSTALLATION SAFETY INSTRUCTIONS INSTALLATION PRECAUTIONS Carefully observe the following precautions. • Make sure to keep your hands, feet and any other body parts away from the rotating blades. • Do not touch sharp components such as the blades or blade disc other than when performing maintenance. •...
Page 26 dummyhead dummyhead INSTALLATION OBSERVE THE FOLLOWING POINTS FOR YOUR SAFETY Carefully observe the following precautions. • When carrying the lawnmower, turn it off and carry it as explained in this manual (see Owner‘s Manual:32VP7600 page 46) with the blades facing away from you. •...
Page 27 INSTALLATION BEFORE INSTALLATION PARTS LIST The Honda Miimo robotic lawnmower box will contain the following parts: PARTS No. Q’ty PARTS NAME HRM300 HRM500 HRM300 HRM500 DOCKING STATION 31220-VP7-000 LAWNMOWER TRANSFORMER EAE TYPE 31786-VP7-003 EAB TYPE 31786-VP7-631 EAS TYPE...
Page 28 dummyhead dummyhead INSTALLATION BATTERY CHARGING Before the installation, the battery will need to be charged. After the initial setup of the lawnmower (page 3-15), follow the below steps. Set the charging socket of the lawnmower to the plug of the station. Ensure that the charging socket on the mower and docking station are in a well ventilated area that is protected from the weather.
Page 29 dummyhead dummyhead INSTALLATION PLANNING THE MOWING ZONE CHECK THE MOWING ZONE CONDITION • Confirm that the height of the grass is 7cm or less. If the grass is taller than 7cm, cut the grass using a standard lawnmower. 7 cm or less •...
Page 30 dummyhead dummyhead INSTALLATION BASIC INSTALLATION PATTERN OF THE BOUNDARY WIRE Make a loop shape by the boundary wire starting from the docking station. Maximum length between the boundary wire and the lawnmower is 30m. If the lawnmower is more than 30m away from the boundary wire, the lawnmower cannot detect the signal (pulse current). Total length of the boundary wire should be less than 500m.
Page 31 SHORT CUT WIRE: TWO LINES 1m or more (The lawnmower can not go Distance from the letter "N" from "HONDA" logo to through the passage less than 1m in width) the end of the short cut wires should be 80 - 85cm...
Page 32 dummyhead dummyhead INSTALLATION BOUNDARY WIRE INSTALLATION To ensure safe operation of the lawnmower, it is necessary to tune below settings with each other. 1. The optimum sensitivity (High, Middle, Low) of the lawnmower (= signal receivable range). 2. The distance between the lawnmower and boundary wire when the lawnmower traces the boundary wire (=passage width). 3.
Page 33 dummyhead dummyhead INSTALLATION 2. The distance between the lawnmower and boundary wire when the lawnmower traces the boundary wire (=passage width) The lawnmower detects the magnetic field from the boundary wire, and moves between the boundary wire and the specified value (See below) at random as it goes toward the mowing start point ("passage width (out)"...
Page 34 dummyhead dummyhead INSTALLATION 3. The shape of the mowing zone. A mowing area can be divided into some zones (when using the custom mode setting). If the mowing area is a simple shape, it is not necessary to divide the area except when the result of the performing test have failed (page 3-14).
Page 35 dummyhead dummyhead INSTALLATION BOUNDARY WIRE INSTALLATION • Leave enough wire to ensure that small adjustments can be made, double backing outside of the loop is acceptable. • Do not fix the wire until finish the layout. • Boundary wire should be laid so that there is no excess wire. Set the boundary wire by using the "LAWN DIAGRAM"...
Page 36 dummyhead dummyhead INSTALLATION From the inside of working zone, facing the docking station, install the right RIGHT SIDE WIRE CONNECTOR side wire connector to the exclusive terminal of the docking station. (EXCLUSIVE TERMINAL) TYPE2 TERMINAL Regardless of the station direction, right side wire must be connected to the TYPE1 TERMINAL exclusive terminal.
Page 37 dummyhead dummyhead INSTALLATION OPERATION TEST OF THE LAWNMOWER Test the following points by using the TEST SET UP program (page 3-34), after the working mode set up. • Return test with HOME TEST MODE (Put the lawnmower on the centre of the zone and start the test). •...
Page 38 dummyhead dummyhead INSTALLATION PROGRAMING INITIAL SETTING AND TEST FLOW STEP NAME PAGE Initial setting 3-15 System setup 3-53 Working mode selection and setup (Auto Mode) -Quick Setup 3-19 -Custom Setup 3-25 Operating test of the lawnmower 3-34 -Return test to the docking station -Running test at the installed zone Make the "DEALER CHECKSHEET"...
Page 39: Cover
Enter Key “Welcome” screen will appear. PIN Code • Locked PIN can be reset using Dr.H software. Welcome _ _ _ _ Honda Robotic lawnmower Create a PIN Input the PIN Miimo Enter Key Five seconds later Language 1.English 5.Svenska PIN activated 2.Deutsch...
Page 40 dummyhead dummyhead INSTALLATION DIAGRAM OF THE MENU MENU History Auto Mode Custom Setup Test Quick Setup System Setup Dealer Mode Dealer Mode Manual Mode Setup First Level Second Level Page Auto Mode Quick Setup Refer to Second Level of No.2. 3-19 (For selecting Custom Setup...
Page 41 dummyhead dummyhead INSTALLATION SETTING METHODE 1 Auto Mode (For selecting or disabling work modes) This setting allows to select which working mode the mower should use. Menu 1.Auto Mode 2.Quick Setup 3.Custom Setup 4.Test 5.History 6.System Setup Auto Mode Quick Setup Custom Setup Mower Inactive 3-18...
Page 42 dummyhead dummyhead INSTALLATION 1-1 Quick Setup Auto Mode Auto Mode Quick Setup :Quick Setup 1.Quick Setup 2.Custom Setup 3.Mower Inactive Enter Key Activated 1-2 Custom Setup Auto Mode Auto Mode Custom Setup :Custom Setup 1.Quick Setup 2.Custom Setup 3.Mower Inactive Enter Key Activated 1-3 Mower Inactive...
Page 43 dummyhead dummyhead INSTALLATION 2 Quick Setup (Simple setting mode) Menu Custom setup should be preferred to Quick setup in following situations. 1.Auto Mode 2.Quick Setup -More than two zones need to be setup. 3.Custom Setup -Working time has to be precisely 4.Test adjusted (e.g.
Page 44 □ 7.Sunday □ Select [0.OK] Quick Setup Start Time & End Time 1 (-) HRM300 is not designed for large areas as Timer battery life would decrease very quickly. Start End Start Time & End Time 2 Timer 1 __:__- __:__ 3.
Page 45 dummyhead dummyhead INSTALLATION 2-2 Zone 2-2-1 Wire Exit Location Quick Setup Quick Setup 1.Timer Zone 2.Zone 3.Summary 4.Reset Enter Key Quick Setup Wire Exit Location 2-2-1 Zone 2 1.Wire Exit Location 2.Zone Proportion (%) 3.Mowing Pattern 4.Area Enter Key Quick Setup Distance Zone 2 CW: Clockwise...
Page 46 dummyhead dummyhead INSTALLATION Mowing Pattern 2-2-3 Quick Setup Quick Setup 1.Timer Zone 2.Zone 3.Summary 4.Reset Enter Key Mowing Pattern 2-2-3 Quick Setup Zone 2 1.Wire Exit Location 2.Zone Proportion (%) 3.Mowing Pattern 4.Area Enter Key Quick Setup • See Page 2-7 to select correct pattern. Random Directional Mixed...
Page 47 dummyhead dummyhead INSTALLATION 2-3 Summary Quick Setup Quick Setup 1.Timer Summary 2.Zone 3.Summary 4.Reset Enter Key Timer Summary Quick Setup Timer Summary Mon Tue Wed Thu Fri Sat Sun Timer 1 00:00-00:00 Timer 2 00:00-00:00 Select Button Zone Summary Quick Setup Zone Summary Zone 1 Wire Exit...
Page 48 dummyhead dummyhead INSTALLATION 3 Custom Setup (Details setting mode) Menu 1.Auto Mode 2.Quick Setup 3.Custom Setup 4.Test 5.History 6.System Setup Custom Setup Timer Zone Summary Reset 3-3-1 3-3-2 Mon-Tue-Wed-Thu-Fri-Sat-Sun Timer Zone 3-4-1 3-4-2 3-4-3 3-4-4 Reset All Zones Reset All Timers Reset All Copy Quick Setup Start Time &...
Page 49 dummyhead dummyhead INSTALLATION 3-1 Timer Custom Setup Timer Custom Setup 1.Timer 2.Zone Mon-Tue-Wed-Thu-Fri-Sat-Sun 3.Summary 4.Reset Enter Key Custom Setup Timer 0.OK 9.Select All 1.Monday □ 2.Tuesday □ 3.Wednesday □ 4.Thursday □ Select Button Custom Setup Timer :Monday 0.OK 9.Select All 5.Friday □...
Page 50 dummyhead dummyhead INSTALLATION 3-2 Zone 3-2-1 Zone1 3-2-1-1 Wire Exit Location 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-1 Custom Setup Wire Exit Location...
Page 51 dummyhead dummyhead INSTALLATION 3-2-1-2 Exit Angle 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-2 Custom Setup Exit Angle Zone 1 1.Wire Exit Location 2.Exit Angle...
Page 52 dummyhead dummyhead INSTALLATION 3-2-1-3 Mowing Pattern 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-3 Custom Setup Mowing Pattern Zone 1 1.Wire Exit Location 2.Exit Angle...
Page 53 dummyhead dummyhead INSTALLATION 3-2-1-4 Area 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-4 Custom Setup Area Zone 1 1.Wire Exit Location 2.Exit Angle 3.Mowing Pattern...
Page 54 dummyhead dummyhead INSTALLATION 3-3 Summary 3-3-1 Timer 3 Custom Setup Custom Setup 1.Timer Summary 2.Zone 3.Summary 4.Reset Enter Key Timer Custom Setup 3-3-1 Summary 1.Timer 2.Zone Enter Key Custom Setup Timer Summary :Mon Mon Tue Wed Thu Fri Sat Sun Timer 1 00:00-00:00 Zone 1...
Page 55 dummyhead dummyhead INSTALLATION 3-4 Reset 3-4-1 Reset All Zones 3 Custom Setup Custom Setup 1.Timer Reset 2.Zone 3.Summary 4.Reset Enter Key Reset All Zones Custom Setup 3-4-1 Reset 1.Reset All Zones 2.Reset All Timers 3.Reset All 4.Copy Quick Setup Enter Key Custom Setup Reset Reset All Zones...
Page 56 dummyhead dummyhead INSTALLATION 3-4-3 Reset All 3 Custom Setup Custom Setup 1.Timer Reset 2.Zone 3.Summary 4.Reset Enter Key Reset All Custom Setup 3-4-3 Reset 1.Reset All Zones 2.Reset All Timers 3.Reset All 4.Copy Quick Setup Enter Key Custom Setup Reset Reset All Confirm Reset 1.Yes...
Page 57 dummyhead dummyhead INSTALLATION 4 Test (For performing test of the lawnmower) Menu This icon shows the 1.Auto Mode present mode is in the 2.Quick Setup "dealer mode" and will 3.Custom Setup appear by pushing and 4.Test holding the key pads 2, 4, 5.History 9, and ENTER key.
Page 58 dummyhead dummyhead INSTALLATION 4-1 Check Boundary wire 4 Test Test • To perform this test, place the mower at the farthest 1.Check Area Wire point from the boundary Check Area wire 2.Test Setup wire. Enter Key • Level should not be lower Area Sensor Test than Lv1 in any case.
Page 59 dummyhead dummyhead INSTALLATION 4-3 Test Mower 4-3-1 Manual Stop Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Manual Stop 4-3-1 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Test Test Mower Manual Stop Result...
Page 60 dummyhead dummyhead INSTALLATION 4-3-2 Sensors 4-3-2-1 Lift Sensor Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Lift Sensor 4-3-2-1 Test Test Mower 1.Lift Sensor...
Page 61 dummyhead dummyhead INSTALLATION 4-3-2-2 Tilt Sensor Test Test • To perform this test, mower should be Test Mower placed on a level surface. 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm...
Page 62 dummyhead dummyhead INSTALLATION Obstruction 4-3-2-3 Sensor Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key 4-3-2-3 Obst. Sensor Test Test Mower 1.Lift Sensor 2.Tilt Sensor 3.Obstruction Sensor...
Page 63 dummyhead dummyhead INSTALLATION 4-3-2-4 Rollover Sensor Test Test • To perform this test, mower should be Test Mower placed on a level surface. 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm...
Page 64 dummyhead dummyhead INSTALLATION 4-3-3 Alarm Test Test 1.Check Area Wire Test Mower 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Alarm Test 4-3-3 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Test Test Mower Alarm Test Alarm Press ENT Key Warning will Sound 4-3-4 Display...
Page 65 dummyhead dummyhead INSTALLATION 4-3-5 Keypad Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Keypad 4-3-5 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Test Test Mower Keypad Test Start Enter Key Test •...
Page 66 dummyhead dummyhead INSTALLATION 4-4 Calibrate Sensor Test Test • To perform this operation, mower must be Calibrate Sensor placed on a level surface. 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Calibrate Tilt Sensor Test Mower Calibrate Tilt Sensor Keep Horizontal...
Page 67 dummyhead dummyhead INSTALLATION 5 History (For viewing operation and error history) Menu This icon shows the 1.Auto Mode present mode is in the 2.Quick Setup "dealer mode" and will 3.Custom Setup appear by pushing and 4.Test holding the key pads 2, 4, 5.History 9 and ENTER key.
Page 68 dummyhead dummyhead INSTALLATION 5-1 Operating History 5-1-1 Operating time History Operating History History 1.Operating History 2.Fault History Enter Key Operating time History 5-1-1 ·Cutting Time Operating History ·Charging Time 1.Operating Time 2.Work History Enter Key History Operating Time Cutting Time 0min Charging Time 0min...
Page 69 • Charge history can provide useful History indication on battery condition. Charge History • If charging time becomes excessively 0min 0min short, battery should be checked (page 0min 0min 10-8). 0min 0min 0min 0min Standard charging time: 0min 0min -HRM500: 60min -HRM300: 30min 3-46...
Page 70 dummyhead dummyhead INSTALLATION 5-2 Fault History History Fault History History History DTC code Fault History 1.Operating History ·Warning 2.Fault History 01:No loop signal Battery Voltage : 21.4[V] Enter Key Select Button History History Fault History Fault History 1.3A036 29.06.12 11:12 01:No loop signal 2.–...
Page 71 dummyhead dummyhead INSTALLATION 5-3 Operating History 5-3-1 Operating Time History History History Operating History 1.Operating History Operating Time 2.Fault History Cutting Time Directional 0min Mixed 0min Enter Key Select Button History History Operating Time 5-3-1 ·Cutting Time Operating History Operating Time ·Running Time Running Time 1.Operating Time...
Page 72 • Charge history can provide useful indication on battery condition. Charge History • If charging time becomes excessively 0min 0min short, battery should be checked (page 0min 0min 10-8). 0min 0min 0min 0min 0min 0min Standard charging time: -HRM500: 60min -HRM300: 30min 3-49...
Page 73 dummyhead dummyhead INSTALLATION 5-3-3 Zone History History History Operating History 1.Operating History 2.Fault History Enter Key History Zone History 5-3-3 ·Return History Operating History 1.Operating Time 2.Work History 3.Zone History 4.Trip 5.Activation Count Enter Key History Return History Zone 1 0min 0min 0min...
Page 74 dummyhead dummyhead INSTALLATION 5-3-4 Trip History History History Operating History 1.Operating History Trip 2 2.Fault History Start 29/6/12 11:12 Running Time 0min 0.Reset Enter Key Select Button History History Trip 5-3-4 Start Trip 3 Operating History ·Cutting Time 1.Operating Time Start 29/6/12 11:12 ·Charging Time...
Page 75 dummyhead dummyhead INSTALLATION 5-3-5 Activation Count History History Operating History 1.Operating History 2.Fault History Enter Key History Activation Count 5-3-5 ·Lift Operating History ·Bump 1.Operating Time ·Tilt 2.Work History ·Rollover ·Manual Stop 3.Zone History ·Charge Cycles 4.Trip 5.Activation Count Enter Key History Activation Count Lift...
Page 76 dummyhead dummyhead INSTALLATION 6 System Setup (System related settings) Menu 1.Auto Mode 2.Quick Setup 3.Custom Setup 4.Test 5.History 6.System Setup System Setup Station Setup Manual Mode Setup Station Signal Loop Direction Passage Return Width Mowing Pattern Area 6-1-1 6-1-2 6-1-3 6-2-1 6-2-2 Type1 Type2 Type3...
Page 77 dummyhead dummyhead INSTALLATION 6-1 Station Setup 6-1-1 Station Signal System Setup System Setup 1.Station Setup Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key Station Signal System Setup 6-1-1 Station Setup 1.Station Signal 2.Loop Direction 3.Passage Return Width Enter Key Type1 Type2 Type3 Type4...
Page 78 dummyhead dummyhead INSTALLATION 6-1-3 Passage Return Width System Setup System Setup 1.Station Setup Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key Passage Return Width 6-1-3 System Setup Station Setup 1.Station Signal 2.Loop Direction 3.Passage Return Width Enter Key •...
Page 79 dummyhead dummyhead INSTALLATION 6-2-2 Area System Setup System Setup 1.Station Setup Manual Mode Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key Area System Setup 6-2-2 Manual Mode Setup 1.Mowing Pattern 2.Area Enter Key Wire Overlap System Setup Manual Mode Setup Area Wire Overlap...
Page 80 dummyhead dummyhead INSTALLATION 6-4 Date and Time 6-4-1 Set Date System Setup System Setup 1.Station Setup Date and Time 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key 6-4-1 Set Date System Setup Date and Time 1.Set Date 2.Set Time Enter Key System Setup...
Page 81 dummyhead dummyhead INSTALLATION 6-5 Security 6-5-1 Alarm System Setup Security System Setup 1.Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key System Setup Security Input your PIN **** Enter Key Alarm System Setup 6-5-1 Security 1.Alarm 2.Create a PIN 3.Immobilizer Enter Key...
Page 82 dummyhead dummyhead INSTALLATION 6-5-2 Create a PIN System Setup Security System Setup 1.Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key System Setup Security Input your PIN **** Enter Key Create a PIN System Setup 6-5-2 Security 1.Alarm 2.Create a PIN...
Page 83 dummyhead dummyhead INSTALLATION boundary wire6-5-3 Immobilizer System Setup System Setup 1.Station Setup Security 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key System Setup Security Input your PIN **** Enter Key Immobilizer 6-5-3 System Setup Security 1.Alarm 2.Create a PIN 3.Immobilizer Enter Key System Setup...
Page 84 dummyhead dummyhead INSTALLATION 6-6 Sound System Setup System Setup 1.Station Setup Sound 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key • When "ON", each time keypad is pressed, System Setup a beep will sound. Sound Keypad 1.ON 2.OFF Enter Key Activated...
Page 85 dummyhead dummyhead MEMO...
Page 86 dummytext 4. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················4-2 HOW TO READ CONNECTOR DRAWINGS ··················································· 4-4 TORQUE VALUES ········································4-2 HARNESS ROUTING···································· 4-5 LUBRICATION ··············································4-3...
Page 87 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION FRAME Unit: mm (in) Part Item Standard Service limit Rotary blade Rotary blade width 17.3 – 18.7 (0.68 – 0.74) 15.0 (0.59) ELECTRIC Part Item Connector/terminal Standard No.5 (Black) - No.6 (White) Traction Winding resistance No.5 (Black) - No.7 (Red)
Page 88 dummyhead dummyhead SERVICE INFORMATION STANDARD TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Screw 5 mm 6 mm Bolt and nut 5 mm 6 mm 8 mm 10 mm 12 mm Flange bolt and nut 6 mm 8 mm 10 mm SH (Small head) flange bolt...
Page 89 dummyhead dummyhead SERVICE INFORMATION HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors.
Page 90 dummyhead dummyhead SERVICE INFORMATION HARNESS ROUTING TOP COVER (INSIDE) Route the stop switch LH STOP SWITCH harness under the rib. Terminal Wire color number Stop switch side Black Brown Yellow Orange Bu Blue Lb Light blue Green Lg Light green STOP SWITCH Pink RH STOP SWITCH...
Page 91 dummyhead dummyhead SERVICE INFORMATION UPPER FRAME (INSIDE) REAR AREA SENSOR 2P CONNECTOR DISPLAY 8P CONNECTOR REAR OBSTRUCTION SENSOR 3P CONNECTOR MAIN ECU 30P CONNECTOR RH LIFT SENSOR 3P CONNECTOR Route the main wire harness through the guide hole of the upper frame.
Page 92 dummyhead dummyhead SERVICE INFORMATION Main wire Main wire harness side harness side Terminal Wire color Terminal Wire color Terminal Wire color number number number – – Terminal Wire color Terminal Wire color number number Main wire Main wire harness side harness side Terminal Wire color...
Page 93 dummyhead dummyhead SERVICE INFORMATION BOTTOM FRAME (1/2) HRM500 shown: RH TRACTION MOTOR 8P CONNECTOR MAIN ECU 4P CONNECTOR HARNESS CLIP (2) BLADE MOTOR 8P CONNECTOR MAIN ECU 2P CONNECTOR LH TRACTION MOTOR 8P CONNECTOR MAIN ECU 4P CONNECTOR...
Page 94 dummyhead dummyhead SERVICE INFORMATION Terminal Wire color Terminal Wire color number number Sub wire harness side Sub wire harness side Terminal Wire color number G or Bu Bu or G Sub wire harness side Terminal Wire color Terminal Wire color number number Blade motor side...
Page 95 dummyhead dummyhead SERVICE INFORMATION BOTTOM FRAME (2/2) HRM500 shown: BLADE MOTOR HARNESS BOOT FRONT RH AREA SENSOR 2P CONNECTOR Route the blade motor harness under the guide rib of the blade motor housing. CHARGE SOCKET TERMINAL HARNESS GROMMET (5) BLADE MOTOR HARNESS BOOT Route between the ribs at taped FRONT LH AREA SENSOR...
Page 96 dummyhead dummyhead SERVICE INFORMATION Terminal Wire color number Sub wire harness side Terminal Wire color number G or Bu Bu or G Terminal Wire color number Sub wire harness side Terminal Wire color number Sub wire harness side Black Brown Yellow Orange Bu Blue...
Page 97 dummyhead dummyhead SERVICE INFORMATION STATION STATION ECU 5P CONNECTOR CHARGE PLUG TERMINAL STATION ECU 4P CONNECTOR Route between the ribs. CHARGE PLUG TERMINAL STATION HARNESS HARNESS GROMMET (4 HOLES) HARNESS GROMMET (5 HOLES) BOUNDARY WIRE HARNESS GROMMET TERMINAL (4 HOLES) TRANSFORMER 2P CONNECTOR BOUNDARY WIRE...
Page 98 dummyhead dummyhead SERVICE INFORMATION Terminal Wire color number Station harness side Terminal Wire color number Terminal Wire color number Station harness side Terminal Wire color number Station harness side Black Brown Yellow Orange Bu Blue Lb Light blue Green Lg Light green Pink W White Gr Gray...
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Page 100 dummytext 5. MAINTENANCE MAINTENANCE SCHEDULE························5-2 DOCKING STATION CHECK ······················· 5-5 BLADE CONDITION CHECK························5-3 DOCKING STATION CLEANING ················· 5-5 BLADE DISC CONDITION CHECK ··············5-3 DOCKING STATION SCREW CHECK ········· 5-5 MANUAL STOP BUTTON OPERATION CHECK ··························································5-4...
Page 101 dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE Maintenance interval Refer to page Perform at every indicated period or operating hour interval, whichever comes soonest. Every week Every year 500 Hours BLADES (1) Check Change BLADE DISK (1) Check Change MANUAL STOP BUTTON Check BODY PARTS (1) Check...
Page 102 dummyhead dummyhead MAINTENANCE BLADE CONDITION CHECK Damaged blades • Make sure to press the manual stop button and turn the lawnmower off before performing the following procedures. • Put on a pair of work gloves before performing the following procedures. 15 mm or less •...
Page 103 dummyhead dummyhead MAINTENANCE MANUAL STOP BUTTON OPERATION CHECK Press the power button on the control panel [1]. Check if the control panel display [1] turns off by closing the control panel cover [2] slowly when the distance between control panel cover and top cover is 10 - 20 If the control panel display does not turn off, check the clearance between stop switch bracket and top cover.
Page 104 dummyhead dummyhead MAINTENANCE DOCKING STATION CHECK Check the indicator light [1]. Refer to following chart: Color Description The docking station signal is Green correct. A signal problem. Such as the Amber boundary wire becoming (blinking) disconnected. Check the error message (page 6-4). Condition is abnormal.
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Page 106 dummytext 6. TROUBLESHOOTING SYSTEM DIAGRAM ······································6-2 GRASS CUTTING SYSTEM TROUBLESHOOTING ·································· 6-6 BEFORE TROUBLESHOOTING···················6-4 ERROR MESSAGE LIST ······························ 6-8 DOCKING SYSTEM TROUBLESHOOTING···································6-4 TROUBLESHOOTING FOR FAULT MESSAGE ··················································· 6-11 RUNNING SYSTEM TROUBLESHOOTING···································6-5 TROUBLESHOOTING FOR WARNING MESSAGE ··················································· 6-18...
Page 107 TROUBLESHOOTING SYSTEM DIAGRAM TROUBLESHOOTING TRANSFORMER TRANSFORMER TRANSFORMER (EAE type) (EAS type) (EAB type) MAIN ECU 1P BATTERY (HRM300) 2P BATTERY (HRM500) BATT(ID) BATT(TH+) BATT(−) BATT(+) G or Bu AC-IN(1) AC-IN(2) Bu or G DOCKING STATION DISPLAY ECU REPLAY(ON)
Page 108 dummyhead dummyhead TROUBLESHOOTING MAIN ECU FRONT RH AREA SENSOR AREA-SIG-FR AREA-GND-FR HIC(U)-WORK BLADE MOTOR HIC(V)-WORK HIC(W)-WORK 5V-WORK S-GND-WORK FRONT LH AREA SENSOR POWER(U)-WORK POWER(V)-WORK POWER(W)-WORK AREA-SIG-FL AREA-GND-FL REAR AREA SENSOR AREA-SIG-REAR AREA-GND-REAR MAIN HIC(U)-R CIRCUIT RH TRACTION MOTOR RH LIFT SENSOR HIC(V)-R LIFT-VCC-R HIC(W)-R...
Page 109 Abnormal Normal Check the transformer (page 11-3). Remove the foreign substance of Abnormal the wheel(s). Normal Check the setting of HRM300/500 (page 3-53). Transformer trouble. Replace the transformer. Abnormal Normal Check the power supply. Set the setting again (page 3-9).
Page 110 dummyhead dummyhead TROUBLESHOOTING RUNNING SYSTEM TROUBLESHOOTING Displayed The error message is displayed (page 3-15). Check the error message and perform the troubleshooting for fault/warning message (page 6-8, 6-9, 6-10). Not displayed Rotating The traction motor(s) is rotating. Check the woodruff key (page 8-3). Not rotating Abnormal Normal...
Page 111 dummyhead dummyhead TROUBLESHOOTING GRASS CUTTING SYSTEM TROUBLESHOOTING Grass cannot be mown at all. Displayed The error message is displayed (page 3-15). Check the error message and perform the troubleshooting for fault/warning message (page 6-8, 6-9, 6-10). Not displayed Rotating The blade motor is rotating. Check the woodruff key (page 9-2).
Page 112 Check the error message and perform the troubleshooting for fault/warning message (page 6-8, 6-9, 6-10). Not displayed Continuously but jerky work HRM300/500 is working continuously. Mowing load is high and load regulation is working. Decrease the cutting height. Stop immediately Abnormal Check the condition of charge (page 3-15).
Page 113 Turn over the Mower. Manual stop One of the Manual stop switches is inactive. 3A020 6-17 Battery Error HRM300: Connect 1P battery to HRM300 3A032 6-17 HRM500: Connect 2P battery to HRM500 Motor ECU Error Main ECU trouble. 3A030...
Page 114 dummyhead dummyhead TROUBLESHOOTING WARNING MESSAGE LIST Method of checking the warning message on the display: See page 6-4 Message 1 Refer Message 2 DTC code Mode Details (using Dr.H) Message 3 page Message 4 No Operation : Wrong PIN is entered three times. 5 minutes 6-18 Clock Reset...
Page 115 dummyhead dummyhead TROUBLESHOOTING Message 1 Refer Message 2 DTC code Mode Details (using Dr.H) Message 3 page Message 4 Outside loop The main body (three area sensors) is outside of boundary wire loop. 3A037 6-22 No loop signal The main body (three area sensors) cannot receive the area signal from the station.
Page 116 dummyhead dummyhead TROUBLESHOOTING TROUBLESHOOTING FOR FAULT MESSAGE "Keypad" MESSAGE Abnormal Confirm keypad good condition by testing it Keypad trouble of the display ECU. (page 3-42). Replace the display (page 10-3). Normal Temporary failure. "Clock" MESSAGE Clock function trouble of the display ECU. Replace the display (page 10-3).
Page 117 dummyhead dummyhead TROUBLESHOOTING "Communication error" MESSAGE No continuity Check for continuity between the main ECU Replace or repair the main wire harness. 30P connector and display 8P connector of main wire harness. ·30P connector No.16 terminal (Red) - 8P connector No.1 terminal (Red) ·30P connector No.2 terminal (Red)
Page 118 dummyhead dummyhead TROUBLESHOOTING "Charging control" MESSAGE Normal Replace the transformer with a new one and Faulty original transformer. recheck the fault message in the display. Abnormal Check for continuity between the main ECU 2P Normal connector and charge socket terminal Check the charge plug and socket for damage, bent and rust.
Page 119 dummyhead dummyhead TROUBLESHOOTING "Motor sensor Blade" MESSAGE Abnormal Replace the blade motor with a new one (page Main ECU trouble. 9-2) and recheck the fault message in the Replace the main ECU (page 10-7). display. Normal Faulty original blade motor. "Wheel motor"...
Page 120 dummyhead dummyhead TROUBLESHOOTING "Area sensor" MESSAGE No continuity Check for continuity between the main ECU 4P Replace or repair the sub wire harness. connector and area sensor 2P connector of sub wire harness. ·30P connector No.3 terminal (Red) - 4P connector No.1 terminal (Red) ·30P connector No.4 terminal (Green)
Page 121 dummyhead dummyhead TROUBLESHOOTING "Tilt sensor" MESSAGE Displayed Tilt the mower and then check whether tilt Temporary failure. sensor detects it and warning screen is displayed. Not displayed Changed Angle direction does not changed in the tilt Main ECU trouble. sensor test of the test mode (page 3-38). Replace the main ECU (page 10-7).
Page 122 Main ECU trouble. Replace the main ECU (page 10-7). "Battery Error" MESSAGE Connect new battery to the mower and check message again. • HRM300: 1P battery • HRM500: 2P battery "Motor ECU Error" MESSAGE Main ECU trouble. Replace the main ECU (page 10-7).
Page 123 dummyhead dummyhead TROUBLESHOOTING TROUBLESHOOTING FOR WARNING MESSAGE "No Operation :" MESSAGE Normal Input the correct PIN code 5 minutes later Temporary failure. (page 3-16). Abnormal Cannot input Can input by the ten digits keypad. Keypad trouble of the display ECU. Replace the display (page 10-3).
Page 124 TROUBLESHOOTING "Battery voltage high" MESSAGE HRM300/500 is connected to the station. Disconnect the mower from the docking station. Turn ON the power supply and leave it for an hour. Recheck the warning message in the display. Normal Abnormal Temporary failure.
Page 125 "Battery Temp high" MESSAGE 60 °C or more Check the temperature in the frame using Cool HRM300/500 and make the temperature Dr.H. in the frame less than 60 °C. And then turn ON the power supply and leave it for an hour.
Page 126 dummyhead dummyhead TROUBLESHOOTING "Blade motor" MESSAGE Less than 85 °C The temperature of work motor driver (Main ECU) is more than 85 °C. More than 85 °C Main ECU trouble. Replace the main ECU (page 10-7). Let the mower cool down for an hour at Abnormal ambient temperature and above 5 °C.
Page 127 - 2P connector No.8 terminal (Brown) Continuity Main ECU trouble. Replace the main ECU (page 10-7). "Outside loop" MESSAGE Move HRM300/500 in the mowing zone, and Normal Temporary failure. then recheck the warning message in the display. Abnormal Other lawnmowers are near the mowing zone.
Page 128 dummyhead dummyhead TROUBLESHOOTING "No loop signal" MESSAGE LED of the station is turned on green. Recheck the warning message in the display. Normal Abnormal Temporary failure. LED of the station is blinking in umber. Other lawnmowers are near the mowing zone. Check whether the boundary wire Change the station (pulse signal) terminal is correctly connected to the...
Page 129 dummyhead dummyhead TROUBLESHOOTING "Obstruction detection" MESSAGE Normal Input the PIN code (page 3-16). Recheck the warning message in the display. Abnormal Normal Abnormal Can input by the ten digit keypad. Temporary failure. Cannot input The main cover is in the correct position. input Keypad trouble of the display ECU.
Page 130 TROUBLESHOOTING "Excessive Tilt" MESSAGE Normal Put HRM300/500 on the level surface (15 ° or Recheck the warning message in the display. less ) and input the PIN code (page 3-16). Normal Abnormal Abnormal Temporary failure. Can input by the ten digits keypad.
Page 131 dummyhead dummyhead TROUBLESHOOTING "Lifted" MESSAGE Normal Input the PIN code (page 3-16). Recheck the warning message in the display. Abnormal Normal Abnormal Can input by the ten digits keypad. Temporary failure. Cannot input The lift sensor plate is in the correct position. input Keypad trouble of the display ECU.
Page 132 TROUBLESHOOTING "Upside down" MESSAGE Normal Put HRM300/500 on the level surface (15 ° or Recheck the warning message in the display. less ) and input the PIN code (page 3-16). Normal Abnormal Abnormal Temporary failure. Can input by the ten keypad.
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Page 134 dummytext 7. COVER TOP COVER REMOVAL/INSTALLATION····7-2 MAIN COVER REMOVAL/INSTALLATION·· 7-5 TOP COVER DISASSEMBLY/ASSEMBLY ··7-3 STOP SWITCH INSPECTION ······················· 7-6...
Page 135 dummyhead dummyhead COVER TOP COVER REMOVAL/INSTALLATION COVER PUSH-PULL CLIP (2) TOP COVER REMOVAL: Be careful not to break the hooks. INSTALLATION: Set the front hook at first. STOP SWITCH 4P CONNECTOR hook (7)
Page 136 dummyhead dummyhead COVER TOP COVER DISASSEMBLY/ASSEMBLY Remove the top cover (page 7-2). Remove the two screws [1] and front cover [2]. Remove the height adjust cover [3]. Slide the control cover shaft [1] to the left and remove the right end of the control cover shaft from the hole of the top cover [2].
Page 137 dummyhead dummyhead COVER Remove the stop switch 4P connector [1] from connector holder of the top cover [2]. Remove the wire harness from groove of the top cover. Remove the screw [1], washer [2] and self-lock nut [3], and then rotate the stop switch [4]. Remove the stop switch by releasing the projections [5] of the stop switch from the groove of the top cover.
Page 138 dummyhead dummyhead COVER MAIN COVER REMOVAL/INSTALLATION Remove the top cover (page 7-2). BOLT (5 x 12 mm) (3) REMOVAL/INSTALLATION: Loosen/tighten the bolt by fixing the mount shaft using a 10 mm wrench. MAIN COVER WASHER (3) LIFT SENSOR PLATE (2) ·Do not remove the plate from main cover.
Page 139 dummyhead dummyhead COVER STOP SWITCH INSPECTION Remove the stop switch (page 7-3). RH STOP SWITCH Check for continuity between the stop switch 4P connector terminals shown in the table below. RH stop switch Switch position Terminal 1 (Black) Continuity Continuity 2 (White) LH stop switch LH STOP SWITCH...
Page 140 dummytext 8. WHEEL/TRACTION MOTOR FRONT WHEEL REAR WHEEL/TRACTION MOTOR REMOVAL/INSTALLATION··························8-2 REMOVAL/INSTALLATION ························· 8-3 TRACTION MOTOR INSPECTION ··············· 8-4...
Page 141 dummyhead dummyhead WHEEL/TRACTION MOTOR FRONT WHEEL REMOVAL/INSTALLATION WHEEL/TRACTION MOTOR Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) SPLIT PIN (2) WASHER (4) (inside) FRONT CASTER BUSH (8) FRONT WHEEL CAP FRONT CASTER FRONT CASTER ROD...
Page 142 dummyhead dummyhead WHEEL/TRACTION MOTOR REAR WHEEL/TRACTION MOTOR REMOVAL/INSTALLATION Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) – Upper frame (page 10-2) – Main ECU (page 10-7) TRACTION MOTOR WOODRUFF KEY Avoid grease on the threads. O-RING SPECIAL BOLT (6 mm) (4) 9 N·m (0.92 kgf·m, 6.6 lbf·ft)
Page 143 dummyhead dummyhead WHEEL/TRACTION MOTOR TRACTION MOTOR INSPECTION WINDING RESISTANCE INSPECTION Remove the traction motor (page 8-3). Measure the resistance between the traction motor 8P connector terminals shown in the table below. Traction motor 8P Resistance (Ω) connector (at 20 °C/68 °F) No.5 (Black) –...
Page 144 dummytext 9. BLADE/BLADE MOTOR BLADE/BLADE MOTOR REMOVAL/ BLADE MOTOR INSPECTION ····················· 9-3 INSTALLATION·············································9-2...
Page 145 dummyhead dummyhead BLADE/BLADE MOTOR BLADE/BLADE MOTOR REMOVAL/INSTALLATION BLADE/BLADE MOTOR Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) – Upper frame (page 10-2) HEIGHT ADJUST HANDLE Apply the grease to contact area INSTALLATION: of the height adjust handle and ·When handle tightened frame.
Page 146 dummyhead dummyhead BLADE/BLADE MOTOR BLADE HEIGHT ADJUSTMENT Open the height adjustment dial cover [1]. Turn the dial [2] anticlockwise to lower the blades, or turn the dial clockwise to raise the blades. Use the numbers on the dial to approximate the height of the blades.
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Page 148: Other Electrical
dummytext 10. OTHER ELECTRICAL UPPER FRAME AREA SENSOR REMOVAL/INSTALLATION························10-2 REMOVAL/INSTALLATION ······················· 10-5 DISPLAY REMOVAL/INSTALLATION ·······10-3 CHARGE SOCKET REMOVAL/INSTALLATION ······················· 10-6 OBSTRUCTION SENSOR REMOVAL/INSTALLATION························10-3 MAIN ECU REMOVAL/INSTALLATION····· 10-7 MOUNT SHAFT BATTERY REMOVAL/INSTALLATION······ 10-7 REMOVAL/INSTALLATION························10-4 BATTERY INSPECTION ····························· 10-8 LIFT SENSOR REMOVAL/INSTALLATION························10-5 10-1...
Page 149 dummyhead dummyhead OTHER ELECTRICAL UPPER FRAME REMOVAL/INSTALLATION OTHER ELECTRICAL Disconnect the battery 4P connector before disconnecting/connecting the connector from/to main ECU. Turn OFF the main switch. Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) Remove the special bolts, nuts and special nuts. Lift the upper frame slightly and disconnect the battery 4P connector.
Page 150 dummyhead dummyhead OTHER ELECTRICAL DISPLAY REMOVAL/INSTALLATION • Do the preventive measure of static electricity before removal/installation. main ECU, display, battery and sensor etc. may be damaged because of static electricity (page 3-2). • If the display is dropped, do not use it because it may have damaged.
Page 151 dummyhead dummyhead OTHER ELECTRICAL MOUNT SHAFT REMOVAL/INSTALLATION REMOVAL Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) MOUNT PLATE Front mount shaft shown: SPECIAL BOLT (6 mm) (3) MOUNT SHAFT MOUNT WASHER Right mount shaft: with magnet SPRING PLATE Front mount shaft: with magnet...
Page 152 dummyhead dummyhead OTHER ELECTRICAL LIFT SENSOR REMOVAL/INSTALLATION Do the preventive measure of static electricity before removal/installation. main ECU, display, battery and sensor etc. may be damaged because of static electricity (page 3-2). Turn OFF the main switch. LH lift sensor shown: Remove the upper frame (page 10-2).
Page 153 dummyhead dummyhead OTHER ELECTRICAL REAR AREA SENSOR Turn OFF the main switch. Remove the upper frame (page 10-2). Disconnect the 2P connector [1]. Remove the two tapping screws [2] and rear area sensor [3]. • Place the area sensor quietly with the stable position on an insulator without trash, dust, and moisture etc.
Page 154 dummyhead dummyhead OTHER ELECTRICAL MAIN ECU REMOVAL/INSTALLATION • Do the preventive measure of static electricity before removal/installation. main ECU, display, battery and sensor etc. may be damaged because of static electricity (page 3-2). • If main ECU is dropped, do not use it because it may have damaged.
Page 155: Docking Station
dummyhead dummyhead OTHER ELECTRICAL Remove the screws [1], battery upper cover [2] and HRM500 shown: lower cover [3] from the battery [4]. Remove the battery setting plates [5]. Installation is the reverse order of removal. Be careful not to damage the tabs. TORQUE: BATTERY CASE SCREW: 0.4 N·m (0.04 kgf·m, 0.3 lbf·ft)
Page 156 dummytext 11. DOCKING STATION STATION DISASSEMBLY/ASSEMBLY ·····11-2 TRANSFORMER INSPECTION ·················· 11-3 11-1...
Page 157 dummyhead dummyhead DOCKING STATION STATION DISASSEMBLY/ASSEMBLY DOCKING STATION • Do the preventive measure of static electricity before removal/installation. The station ECU may be damaged because of static electricity (page 3-2). • If the station ECU is dropped, do not use it because it may have been damaged. •...
Page 158 dummyhead dummyhead DOCKING STATION TRANSFORMER INSPECTION Check for continuity between the terminals of EAE type shown: transformer plug [1]. Check for continuity between the terminals of transformer 2P connector [2]. Measure the resistance between the terminals of transformer plug [1]. Resistance (Ω) Terminal Type...
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Page 160: Wiring Diagrams
dummytext 12. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAM ···································· 12-3 RELATED INFORMATION··························12-2 12-1...
Page 161 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a...
Page 162: Serial Number Location ·····················1
INDEX dummytext INDEX AREA SENSOR REMOVAL/INSTALLATION ···············10-5 OBSTRUCTION SENSOR REMOVAL/ BATTERY INSPECTION···············································10-8 INSTALLATION ···························································· 10-3 BATTERY REMOVAL/INSTALLATION ························10-7 PROGRAMING····························································· 3-15 BEFORE INSTALLATION···············································3-4 REAR WHEEL/TRACTION MOTOR REMOVAL/ BLADE CONDITION CHECK··········································5-3 INSTALLATION ······························································ 8-3 BLADE DISC CONDITION CHECK ································5-3 RUNNING SPEED·························································· 1-3 BLADE MOTOR INSPECTION ·······································9-3 SAFETY INSTRUCTIONS··············································...
Page 163 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
Page 164 dummyhead dummyhead CONTENTS GENERAL INFORMATION TECHNICAL FEATURES INSTALLATION SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER WHEEL/TRACTION MOTOR BLADE/BLADE MOTOR OTHER ELECTRICAL DOCKING STATION WIRING DIAGRAMS INDEX...
Page 165: Lawnmower
How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda HRM300/HRM500 robotic lawnmower. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.
Page 166 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
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Page 168 dummytext 1. GENERAL INFORMATION SERIAL NUMBER LOCATION ·····················1-2 RUNNING SPEED ········································· 1-3 TYPE CODE ··················································1-2 TRANSMISSION AND WORKING PART ····· 1-3 SPECIFICATIONS ·········································1-2 ELECTRICAL ················································ 1-3 NOISE ····························································1-2 DIMENSIONAL DRAWINGS························· 1-4 TRANSMISSION AND DRIVING PART ········1-3...
Page 169: Serial Number Location
Always refer to this number when making technical inquiries or ordering parts in order to obtain the correct parts. FRAME SERIAL NUMBER TYPE CODE Type REGION EU except for U.K. U.K. Switzerland SPECIFICATIONS Model HRM300 HRM500 Description code MAWF MBAF Type Overall length 645 mm (25.4 in) Overall width 550 mm (21.7 in) Overall height 275 mm (10.8 in)
Page 170 GENERAL INFORMATION TRANSMISSION AND DRIVING PART Model HRM300 HRM500 Motor Name DC motor (Geared motor) Type 3-Phase DC Brushless type Rated power 10.8 W Rated speed 38.2 min (rpm) Speed reducing ratio Service voltage 22.2 V RUNNING SPEED...
Page 171 dummyhead dummyhead GENERAL INFORMATION DIMENSIONAL DRAWINGS Unit: mm (in) 550 (21.7) 645 (25.4) 305 (12.0) 400 (15.7) 300 (11.8) 165 (6.5) 165 (6.5) 220 (8.7) 585 (23.0) 790 (31.1)
Page 172 dummytext 2. TECHNICAL FEATURES SYSTEM DESCRIPTION·······························2-2...
Page 173 dummyhead dummyhead TECHNICAL FEATURES SYSTEM DESCRIPTION TECHNICAL FEATURES SUMMARY This system consists of lawnmower, docking station and boundary wire. The robotic lawnmower powered by battery has sensors which detect the location of the boundary wire and docking station. The lawnmower mows automatically under the requirements set up by user. The docking station generates a pulse current to the boundary wire and transmits particular pulse signal from itself.
Page 174 dummyhead dummyhead TECHNICAL FEATURES LAWNMOWER This lawnmower consists of below core components. 3-c,d,g CATEGORY PARTS NAME FUNCTION MOTOR TRACTION MOTOR Drive the rear wheels BLADE MOTOR Drive the blade disc CONTROL MAIN ECU System control DISPLAY UNIT Display control SENSOR LIFT SENSOR Detect the top cover position changing (Moving distance of up or down)
Page 175 dummyhead dummyhead TECHNICAL FEATURES DOCKING STATION/BOUNDARY WIRE/TRANSFORMER Docking station/Boundary wire/Transformer consists of below core components. POWER CORD BOUNDARY WIRE TRANSFORMER DOCKING STATION PULSE GENERATOR CHARGING PLUG UNIT PARTS FUNCTION DOCKING STATION PULSE GENERATOR Output the pulse current to detect the boundary wire and location of the docking station by lawnmower CHARGING PLUG...
Page 176 dummyhead dummyhead TECHNICAL FEATURES BASIC OPERATION OF THE LAWNMOWER BOUNDARY WIRE FUNCTION The boundary wire is in loop shape and starts from the docking station. The boundary wire can utilize the below three functions by changing the shape. 1. Avoid the obstacle. 2.
Page 177 dummyhead dummyhead TECHNICAL FEATURES 3. Returning guide to the docking station: When the lawnmower returns to the docking station, it will follow the boundary wire until it receives the docking station signal. The short cut wire is effective in ensuring a rapid returning back to the docking station. STATION SIGNAL RANGE Short cut wire is installed (One line): Short cut wire is installed (Two lines):...
Page 178 dummyhead dummyhead TECHNICAL FEATURES MOVING TO THE MOWING ZONE Under the programmed timing and requirements below, the lawnmower will move away from the docking station and will run along the boundary wire and eventually enter the mowing zone. 1. Moving direction (From the docking station, clockwise or anti-clockwise) 2.
Page 179 dummyhead dummyhead TECHNICAL FEATURES DETECTION OF THE BOUNDARY WIRE The overlap distance of the lawnmower from the boundary wire is possible to set up (20 - 45cm). The lawnmower detects the boundary wire by using three area sensors. If one of the area sensors goes beyond the boundary wire and overlap distance is reached, the lawnmower will stop instantly, move backward and rotates until all of the sensor confirm that the lawnmower is inside of the boundary wire.
Page 180 dummyhead dummyhead TECHNICAL FEATURES RUNNING SPEED ADJUSTMENT To maintain uniform blade rotation frequency the ECU monitors the current load placed on the battery. The ECU will adapt the wheel rotation speed to the load applied to the blades. NORMAL SLOW NORMAL The blade rotates 360 degrees as to reduce the impact when hitting an obstruction.
Page 181 dummyhead dummyhead TECHNICAL FEATURES MOVEMENT OF THE LAWNMOWER WHEN IT HITS AN OBSTRUCTION When the lawnmower hit obstructions, the obstruction sensor detects the crosswise movement of the top cover, the lawnmower stops and changes direction. The display will show a message or sound an alarm depending on the repetition of hitting the obstruction.
Page 182 dummyhead dummyhead TECHNICAL FEATURES MOVEMENT OF THE LAWNMOWER WHEN IT ENCOUNTERS AN OBSTRUCTION OR IS LIFTED UP When the lawnmower encounters an obstructions or is lifted up, the lift sensor detect the top cover moving. The lawnmower will stop the blade motor and change direction, rotate, or stop with showing the message on the display or sound an alarm depending on the continuing time of run up or lifted up.
Page 183 dummyhead dummyhead TECHNICAL FEATURES MOVEMENT OF THE LAWNMOWER WHEN IT TILTS OR ROLL OVER The tilt sensor and roll over sensor on the ECU detect the angle of the lawnmower. Depending on the angle, the lawnmower will escape from slope or stop with showing the message on the display or sound an alarm. •...
Page 184 dummyhead dummyhead TECHNICAL FEATURES RETURN TO THE DOCKING STATION The lawnmower generally runs along the boundary wire and required time to return to station will depends on the shape and length of the boundary wire. 1. When the timer is ending or battery voltage is low, the lawnmower will start searching the docking station‘s signal and return directly for 5 minutes.
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Page 186 dummytext 3. INSTALLATION SAFETY INSTRUCTIONS ·····························3-2 PROGRAMING············································ 3-15 BEFORE INSTALLATION·····························3-4 SETTING METHODE ·································· 3-18 BOUNDARY WIRE INSTALLATION·············3-9...
Page 187: Safety Instructions
dummyhead dummyhead INSTALLATION SAFETY INSTRUCTIONS INSTALLATION PRECAUTIONS Carefully observe the following precautions. • Make sure to keep your hands, feet and any other body parts away from the rotating blades. • Do not touch sharp components such as the blades or blade disc other than when performing maintenance. •...
Page 188 dummyhead dummyhead INSTALLATION OBSERVE THE FOLLOWING POINTS FOR YOUR SAFETY Carefully observe the following precautions. • When carrying the lawnmower, turn it off and carry it as explained in this manual (see Owner‘s Manual:32VP7600 page 46) with the blades facing away from you. •...
Page 189 INSTALLATION BEFORE INSTALLATION PARTS LIST The Honda Miimo robotic lawnmower box will contain the following parts: PARTS No. Q’ty PARTS NAME HRM300 HRM500 HRM300 HRM500 DOCKING STATION 31220-VP7-000 LAWNMOWER TRANSFORMER EAE TYPE 31786-VP7-003 EAB TYPE 31786-VP7-631 EAS TYPE...
Page 190 dummyhead dummyhead INSTALLATION BATTERY CHARGING Before the installation, the battery will need to be charged. After the initial setup of the lawnmower (page 3-15), follow the below steps. Set the charging socket of the lawnmower to the plug of the station. Ensure that the charging socket on the mower and docking station are in a well ventilated area that is protected from the weather.
Page 191 dummyhead dummyhead INSTALLATION PLANNING THE MOWING ZONE CHECK THE MOWING ZONE CONDITION • Confirm that the height of the grass is 7cm or less. If the grass is taller than 7cm, cut the grass using a standard lawnmower. 7 cm or less •...
Page 192 dummyhead dummyhead INSTALLATION BASIC INSTALLATION PATTERN OF THE BOUNDARY WIRE Make a loop shape by the boundary wire starting from the docking station. Maximum length between the boundary wire and the lawnmower is 30m. If the lawnmower is more than 30m away from the boundary wire, the lawnmower cannot detect the signal (pulse current). Total length of the boundary wire should be less than 500m.
Page 193 SHORT CUT WIRE: TWO LINES 1m or more (The lawnmower can not go Distance from the letter "N" from "HONDA" logo to through the passage less than 1m in width) the end of the short cut wires should be 80 - 85cm...
Page 194 dummyhead dummyhead INSTALLATION BOUNDARY WIRE INSTALLATION To ensure safe operation of the lawnmower, it is necessary to tune below settings with each other. 1. The optimum sensitivity (High, Middle, Low) of the lawnmower (= signal receivable range). 2. The distance between the lawnmower and boundary wire when the lawnmower traces the boundary wire (=passage width). 3.
Page 195 dummyhead dummyhead INSTALLATION 2. The distance between the lawnmower and boundary wire when the lawnmower traces the boundary wire (=passage width) The lawnmower detects the magnetic field from the boundary wire, and moves between the boundary wire and the specified value (See below) at random as it goes toward the mowing start point ("passage width (out)"...
Page 196 dummyhead dummyhead INSTALLATION 3. The shape of the mowing zone. A mowing area can be divided into some zones (when using the custom mode setting). If the mowing area is a simple shape, it is not necessary to divide the area except when the result of the performing test have failed (page 3-14).
Page 197 dummyhead dummyhead INSTALLATION BOUNDARY WIRE INSTALLATION • Leave enough wire to ensure that small adjustments can be made, double backing outside of the loop is acceptable. • Do not fix the wire until finish the layout. • Boundary wire should be laid so that there is no excess wire. Set the boundary wire by using the "LAWN DIAGRAM"...
Page 198 dummyhead dummyhead INSTALLATION From the inside of working zone, facing the docking station, install the right RIGHT SIDE WIRE CONNECTOR side wire connector to the exclusive terminal of the docking station. (EXCLUSIVE TERMINAL) TYPE2 TERMINAL Regardless of the station direction, right side wire must be connected to the TYPE1 TERMINAL exclusive terminal.
Page 199 dummyhead dummyhead INSTALLATION OPERATION TEST OF THE LAWNMOWER Test the following points by using the TEST SET UP program (page 3-34), after the working mode set up. • Return test with HOME TEST MODE (Put the lawnmower on the centre of the zone and start the test). •...
Page 200 dummyhead dummyhead INSTALLATION PROGRAMING INITIAL SETTING AND TEST FLOW STEP NAME PAGE Initial setting 3-15 System setup 3-53 Working mode selection and setup (Auto Mode) -Quick Setup 3-19 -Custom Setup 3-25 Operating test of the lawnmower 3-34 -Return test to the docking station -Running test at the installed zone Make the "DEALER CHECKSHEET"...
Page 201 Enter Key “Welcome” screen will appear. PIN Code • Locked PIN can be reset using Dr.H software. Welcome _ _ _ _ Honda Robotic lawnmower Create a PIN Input the PIN Miimo Enter Key Five seconds later Language 1.English 5.Svenska PIN activated 2.Deutsch...
Page 202 dummyhead dummyhead INSTALLATION DIAGRAM OF THE MENU MENU History Auto Mode Custom Setup Test Quick Setup System Setup Dealer Mode Dealer Mode Manual Mode Setup First Level Second Level Page Auto Mode Quick Setup Refer to Second Level of No.2. 3-19 (For selecting Custom Setup...
Page 203 dummyhead dummyhead INSTALLATION SETTING METHODE 1 Auto Mode (For selecting or disabling work modes) This setting allows to select which working mode the mower should use. Menu 1.Auto Mode 2.Quick Setup 3.Custom Setup 4.Test 5.History 6.System Setup Auto Mode Quick Setup Custom Setup Mower Inactive 3-18...
Page 204 dummyhead dummyhead INSTALLATION 1-1 Quick Setup Auto Mode Auto Mode Quick Setup :Quick Setup 1.Quick Setup 2.Custom Setup 3.Mower Inactive Enter Key Activated 1-2 Custom Setup Auto Mode Auto Mode Custom Setup :Custom Setup 1.Quick Setup 2.Custom Setup 3.Mower Inactive Enter Key Activated 1-3 Mower Inactive...
Page 205 dummyhead dummyhead INSTALLATION 2 Quick Setup (Simple setting mode) Menu Custom setup should be preferred to Quick setup in following situations. 1.Auto Mode 2.Quick Setup -More than two zones need to be setup. 3.Custom Setup -Working time has to be precisely 4.Test adjusted (e.g.
Page 206 □ 7.Sunday □ Select [0.OK] Quick Setup Start Time & End Time 1 (-) HRM300 is not designed for large areas as Timer battery life would decrease very quickly. Start End Start Time & End Time 2 Timer 1 __:__- __:__ 3.
Page 207 dummyhead dummyhead INSTALLATION 2-2 Zone 2-2-1 Wire Exit Location Quick Setup Quick Setup 1.Timer Zone 2.Zone 3.Summary 4.Reset Enter Key Quick Setup Wire Exit Location 2-2-1 Zone 2 1.Wire Exit Location 2.Zone Proportion (%) 3.Mowing Pattern 4.Area Enter Key Quick Setup Distance Zone 2 CW: Clockwise...
Page 208 dummyhead dummyhead INSTALLATION Mowing Pattern 2-2-3 Quick Setup Quick Setup 1.Timer Zone 2.Zone 3.Summary 4.Reset Enter Key Mowing Pattern 2-2-3 Quick Setup Zone 2 1.Wire Exit Location 2.Zone Proportion (%) 3.Mowing Pattern 4.Area Enter Key Quick Setup • See Page 2-7 to select correct pattern. Random Directional Mixed...
Page 209 dummyhead dummyhead INSTALLATION 2-3 Summary Quick Setup Quick Setup 1.Timer Summary 2.Zone 3.Summary 4.Reset Enter Key Timer Summary Quick Setup Timer Summary Mon Tue Wed Thu Fri Sat Sun Timer 1 00:00-00:00 Timer 2 00:00-00:00 Select Button Zone Summary Quick Setup Zone Summary Zone 1 Wire Exit...
Page 210 dummyhead dummyhead INSTALLATION 3 Custom Setup (Details setting mode) Menu 1.Auto Mode 2.Quick Setup 3.Custom Setup 4.Test 5.History 6.System Setup Custom Setup Timer Zone Summary Reset 3-3-1 3-3-2 Mon-Tue-Wed-Thu-Fri-Sat-Sun Timer Zone 3-4-1 3-4-2 3-4-3 3-4-4 Reset All Zones Reset All Timers Reset All Copy Quick Setup Start Time &...
Page 211 dummyhead dummyhead INSTALLATION 3-1 Timer Custom Setup Timer Custom Setup 1.Timer 2.Zone Mon-Tue-Wed-Thu-Fri-Sat-Sun 3.Summary 4.Reset Enter Key Custom Setup Timer 0.OK 9.Select All 1.Monday □ 2.Tuesday □ 3.Wednesday □ 4.Thursday □ Select Button Custom Setup Timer :Monday 0.OK 9.Select All 5.Friday □...
Page 212 dummyhead dummyhead INSTALLATION 3-2 Zone 3-2-1 Zone1 3-2-1-1 Wire Exit Location 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-1 Custom Setup Wire Exit Location...
Page 213 dummyhead dummyhead INSTALLATION 3-2-1-2 Exit Angle 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-2 Custom Setup Exit Angle Zone 1 1.Wire Exit Location 2.Exit Angle...
Page 214 dummyhead dummyhead INSTALLATION 3-2-1-3 Mowing Pattern 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-3 Custom Setup Mowing Pattern Zone 1 1.Wire Exit Location 2.Exit Angle...
Page 215 dummyhead dummyhead INSTALLATION 3-2-1-4 Area 3 Custom Setup Custom Setup Zone 1.Timer 2.Zone 3.Summary 4.Reset Enter Key Custom Setup Zone1 Zone5 3-2-1 Zone 1.Zone 1 2.Zone 2 3.Zone 3 4.Zone 4 5.Zone 5 Enter Key 3-2-1-4 Custom Setup Area Zone 1 1.Wire Exit Location 2.Exit Angle 3.Mowing Pattern...
Page 216 dummyhead dummyhead INSTALLATION 3-3 Summary 3-3-1 Timer 3 Custom Setup Custom Setup 1.Timer Summary 2.Zone 3.Summary 4.Reset Enter Key Timer Custom Setup 3-3-1 Summary 1.Timer 2.Zone Enter Key Custom Setup Timer Summary :Mon Mon Tue Wed Thu Fri Sat Sun Timer 1 00:00-00:00 Zone 1...
Page 217 dummyhead dummyhead INSTALLATION 3-4 Reset 3-4-1 Reset All Zones 3 Custom Setup Custom Setup 1.Timer Reset 2.Zone 3.Summary 4.Reset Enter Key Reset All Zones Custom Setup 3-4-1 Reset 1.Reset All Zones 2.Reset All Timers 3.Reset All 4.Copy Quick Setup Enter Key Custom Setup Reset Reset All Zones...
Page 218 dummyhead dummyhead INSTALLATION 3-4-3 Reset All 3 Custom Setup Custom Setup 1.Timer Reset 2.Zone 3.Summary 4.Reset Enter Key Reset All Custom Setup 3-4-3 Reset 1.Reset All Zones 2.Reset All Timers 3.Reset All 4.Copy Quick Setup Enter Key Custom Setup Reset Reset All Confirm Reset 1.Yes...
Page 219 dummyhead dummyhead INSTALLATION 4 Test (For performing test of the lawnmower) Menu This icon shows the 1.Auto Mode present mode is in the 2.Quick Setup "dealer mode" and will 3.Custom Setup appear by pushing and 4.Test holding the key pads 2, 4, 5.History 9, and ENTER key.
Page 220 dummyhead dummyhead INSTALLATION 4-1 Check Boundary wire 4 Test Test • To perform this test, place the mower at the farthest 1.Check Area Wire point from the boundary Check Area wire 2.Test Setup wire. Enter Key • Level should not be lower Area Sensor Test than Lv1 in any case.
Page 221 dummyhead dummyhead INSTALLATION 4-3 Test Mower 4-3-1 Manual Stop Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Manual Stop 4-3-1 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Test Test Mower Manual Stop Result...
Page 222 dummyhead dummyhead INSTALLATION 4-3-2 Sensors 4-3-2-1 Lift Sensor Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Lift Sensor 4-3-2-1 Test Test Mower 1.Lift Sensor...
Page 223 dummyhead dummyhead INSTALLATION 4-3-2-2 Tilt Sensor Test Test • To perform this test, mower should be Test Mower placed on a level surface. 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm...
Page 224 dummyhead dummyhead INSTALLATION Obstruction 4-3-2-3 Sensor Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key 4-3-2-3 Obst. Sensor Test Test Mower 1.Lift Sensor 2.Tilt Sensor 3.Obstruction Sensor...
Page 225 dummyhead dummyhead INSTALLATION 4-3-2-4 Rollover Sensor Test Test • To perform this test, mower should be Test Mower placed on a level surface. 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Sensors 4-3-2 Test Mower 1.Manual Stop 2.Sensors 3.Alarm...
Page 226 dummyhead dummyhead INSTALLATION 4-3-3 Alarm Test Test 1.Check Area Wire Test Mower 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Alarm Test 4-3-3 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Test Test Mower Alarm Test Alarm Press ENT Key Warning will Sound 4-3-4 Display...
Page 227 dummyhead dummyhead INSTALLATION 4-3-5 Keypad Test Test Test Mower 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Keypad 4-3-5 Test Mower 1.Manual Stop 2.Sensors 3.Alarm 4.Display 5.Keypad Enter Key Test Test Mower Keypad Test Start Enter Key Test •...
Page 228 dummyhead dummyhead INSTALLATION 4-4 Calibrate Sensor Test Test • To perform this operation, mower must be Calibrate Sensor placed on a level surface. 1.Check Area Wire 2.Test Setup 3.Test Mower 4.Calibrate Sensor 5.Area Enter Key Test Calibrate Tilt Sensor Test Mower Calibrate Tilt Sensor Keep Horizontal...
Page 229 dummyhead dummyhead INSTALLATION 5 History (For viewing operation and error history) Menu This icon shows the 1.Auto Mode present mode is in the 2.Quick Setup "dealer mode" and will 3.Custom Setup appear by pushing and 4.Test holding the key pads 2, 4, 5.History 9 and ENTER key.
Page 230 dummyhead dummyhead INSTALLATION 5-1 Operating History 5-1-1 Operating time History Operating History History 1.Operating History 2.Fault History Enter Key Operating time History 5-1-1 ·Cutting Time Operating History ·Charging Time 1.Operating Time 2.Work History Enter Key History Operating Time Cutting Time 0min Charging Time 0min...
Page 231 • Charge history can provide useful History indication on battery condition. Charge History • If charging time becomes excessively 0min 0min short, battery should be checked (page 0min 0min 10-8). 0min 0min 0min 0min Standard charging time: 0min 0min -HRM500: 60min -HRM300: 30min 3-46...
Page 232 dummyhead dummyhead INSTALLATION 5-2 Fault History History Fault History History History DTC code Fault History 1.Operating History ·Warning 2.Fault History 01:No loop signal Battery Voltage : 21.4[V] Enter Key Select Button History History Fault History Fault History 1.3A036 29.06.12 11:12 01:No loop signal 2.–...
Page 233 dummyhead dummyhead INSTALLATION 5-3 Operating History 5-3-1 Operating Time History History History Operating History 1.Operating History Operating Time 2.Fault History Cutting Time Directional 0min Mixed 0min Enter Key Select Button History History Operating Time 5-3-1 ·Cutting Time Operating History Operating Time ·Running Time Running Time 1.Operating Time...
Page 234 • Charge history can provide useful indication on battery condition. Charge History • If charging time becomes excessively 0min 0min short, battery should be checked (page 0min 0min 10-8). 0min 0min 0min 0min 0min 0min Standard charging time: -HRM500: 60min -HRM300: 30min 3-49...
Page 235 dummyhead dummyhead INSTALLATION 5-3-3 Zone History History History Operating History 1.Operating History 2.Fault History Enter Key History Zone History 5-3-3 ·Return History Operating History 1.Operating Time 2.Work History 3.Zone History 4.Trip 5.Activation Count Enter Key History Return History Zone 1 0min 0min 0min...
Page 236 dummyhead dummyhead INSTALLATION 5-3-4 Trip History History History Operating History 1.Operating History Trip 2 2.Fault History Start 29/6/12 11:12 Running Time 0min 0.Reset Enter Key Select Button History History Trip 5-3-4 Start Trip 3 Operating History ·Cutting Time 1.Operating Time Start 29/6/12 11:12 ·Charging Time...
Page 237 dummyhead dummyhead INSTALLATION 5-3-5 Activation Count History History Operating History 1.Operating History 2.Fault History Enter Key History Activation Count 5-3-5 ·Lift Operating History ·Bump 1.Operating Time ·Tilt 2.Work History ·Rollover ·Manual Stop 3.Zone History ·Charge Cycles 4.Trip 5.Activation Count Enter Key History Activation Count Lift...
Page 238 dummyhead dummyhead INSTALLATION 6 System Setup (System related settings) Menu 1.Auto Mode 2.Quick Setup 3.Custom Setup 4.Test 5.History 6.System Setup System Setup Station Setup Manual Mode Setup Station Signal Loop Direction Passage Return Width Mowing Pattern Area 6-1-1 6-1-2 6-1-3 6-2-1 6-2-2 Type1 Type2 Type3...
Page 239 dummyhead dummyhead INSTALLATION 6-1 Station Setup 6-1-1 Station Signal System Setup System Setup 1.Station Setup Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key Station Signal System Setup 6-1-1 Station Setup 1.Station Signal 2.Loop Direction 3.Passage Return Width Enter Key Type1 Type2 Type3 Type4...
Page 240 dummyhead dummyhead INSTALLATION 6-1-3 Passage Return Width System Setup System Setup 1.Station Setup Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key Passage Return Width 6-1-3 System Setup Station Setup 1.Station Signal 2.Loop Direction 3.Passage Return Width Enter Key •...
Page 241 dummyhead dummyhead INSTALLATION 6-2-2 Area System Setup System Setup 1.Station Setup Manual Mode Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key Area System Setup 6-2-2 Manual Mode Setup 1.Mowing Pattern 2.Area Enter Key Wire Overlap System Setup Manual Mode Setup Area Wire Overlap...
Page 242 dummyhead dummyhead INSTALLATION 6-4 Date and Time 6-4-1 Set Date System Setup System Setup 1.Station Setup Date and Time 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key 6-4-1 Set Date System Setup Date and Time 1.Set Date 2.Set Time Enter Key System Setup...
Page 243 dummyhead dummyhead INSTALLATION 6-5 Security 6-5-1 Alarm System Setup Security System Setup 1.Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key System Setup Security Input your PIN **** Enter Key Alarm System Setup 6-5-1 Security 1.Alarm 2.Create a PIN 3.Immobilizer Enter Key...
Page 244 dummyhead dummyhead INSTALLATION 6-5-2 Create a PIN System Setup Security System Setup 1.Station Setup 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key System Setup Security Input your PIN **** Enter Key Create a PIN System Setup 6-5-2 Security 1.Alarm 2.Create a PIN...
Page 245 dummyhead dummyhead INSTALLATION boundary wire6-5-3 Immobilizer System Setup System Setup 1.Station Setup Security 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key System Setup Security Input your PIN **** Enter Key Immobilizer 6-5-3 System Setup Security 1.Alarm 2.Create a PIN 3.Immobilizer Enter Key System Setup...
Page 246 dummyhead dummyhead INSTALLATION 6-6 Sound System Setup System Setup 1.Station Setup Sound 2.Manual Mode Setup 3.Language 4.Date and Time 5.Security 6.Sound Enter Key • When "ON", each time keypad is pressed, System Setup a beep will sound. Sound Keypad 1.ON 2.OFF Enter Key Activated...
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Page 248 dummytext 4. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················4-2 HOW TO READ CONNECTOR DRAWINGS ··················································· 4-4 TORQUE VALUES ········································4-2 HARNESS ROUTING···································· 4-5 LUBRICATION ··············································4-3...
Page 249 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION FRAME Unit: mm (in) Part Item Standard Service limit Rotary blade Rotary blade width 17.3 – 18.7 (0.68 – 0.74) 15.0 (0.59) ELECTRIC Part Item Connector/terminal Standard No.5 (Black) - No.6 (White) Traction Winding resistance No.5 (Black) - No.7 (Red)
Page 250 dummyhead dummyhead SERVICE INFORMATION STANDARD TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Screw 5 mm 6 mm Bolt and nut 5 mm 6 mm 8 mm 10 mm 12 mm Flange bolt and nut 6 mm 8 mm 10 mm SH (Small head) flange bolt...
Page 251 dummyhead dummyhead SERVICE INFORMATION HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors.
Page 252 dummyhead dummyhead SERVICE INFORMATION HARNESS ROUTING TOP COVER (INSIDE) Route the stop switch LH STOP SWITCH harness under the rib. Terminal Wire color number Stop switch side Black Brown Yellow Orange Bu Blue Lb Light blue Green Lg Light green STOP SWITCH Pink RH STOP SWITCH...
Page 253 dummyhead dummyhead SERVICE INFORMATION UPPER FRAME (INSIDE) REAR AREA SENSOR 2P CONNECTOR DISPLAY 8P CONNECTOR REAR OBSTRUCTION SENSOR 3P CONNECTOR MAIN ECU 30P CONNECTOR RH LIFT SENSOR 3P CONNECTOR Route the main wire harness through the guide hole of the upper frame.
Page 254 dummyhead dummyhead SERVICE INFORMATION Main wire Main wire harness side harness side Terminal Wire color Terminal Wire color Terminal Wire color number number number – – Terminal Wire color Terminal Wire color number number Main wire Main wire harness side harness side Terminal Wire color...
Page 255 dummyhead dummyhead SERVICE INFORMATION BOTTOM FRAME (1/2) HRM500 shown: RH TRACTION MOTOR 8P CONNECTOR MAIN ECU 4P CONNECTOR HARNESS CLIP (2) BLADE MOTOR 8P CONNECTOR MAIN ECU 2P CONNECTOR LH TRACTION MOTOR 8P CONNECTOR MAIN ECU 4P CONNECTOR...
Page 256 dummyhead dummyhead SERVICE INFORMATION Terminal Wire color Terminal Wire color number number Sub wire harness side Sub wire harness side Terminal Wire color number G or Bu Bu or G Sub wire harness side Terminal Wire color Terminal Wire color number number Blade motor side...
Page 257 dummyhead dummyhead SERVICE INFORMATION BOTTOM FRAME (2/2) HRM500 shown: BLADE MOTOR HARNESS BOOT FRONT RH AREA SENSOR 2P CONNECTOR Route the blade motor harness under the guide rib of the blade motor housing. CHARGE SOCKET TERMINAL HARNESS GROMMET (5) BLADE MOTOR HARNESS BOOT Route between the ribs at taped FRONT LH AREA SENSOR...
Page 258 dummyhead dummyhead SERVICE INFORMATION Terminal Wire color number Sub wire harness side Terminal Wire color number G or Bu Bu or G Terminal Wire color number Sub wire harness side Terminal Wire color number Sub wire harness side Black Brown Yellow Orange Bu Blue...
Page 259 dummyhead dummyhead SERVICE INFORMATION STATION STATION ECU 5P CONNECTOR CHARGE PLUG TERMINAL STATION ECU 4P CONNECTOR Route between the ribs. CHARGE PLUG TERMINAL STATION HARNESS HARNESS GROMMET (4 HOLES) HARNESS GROMMET (5 HOLES) BOUNDARY WIRE HARNESS GROMMET TERMINAL (4 HOLES) TRANSFORMER 2P CONNECTOR BOUNDARY WIRE...
Page 260 dummyhead dummyhead SERVICE INFORMATION Terminal Wire color number Station harness side Terminal Wire color number Terminal Wire color number Station harness side Terminal Wire color number Station harness side Black Brown Yellow Orange Bu Blue Lb Light blue Green Lg Light green Pink W White Gr Gray...
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Page 262 dummytext 5. MAINTENANCE MAINTENANCE SCHEDULE························5-2 DOCKING STATION CHECK ······················· 5-5 BLADE CONDITION CHECK························5-3 DOCKING STATION CLEANING ················· 5-5 BLADE DISC CONDITION CHECK ··············5-3 DOCKING STATION SCREW CHECK ········· 5-5 MANUAL STOP BUTTON OPERATION CHECK ··························································5-4...
Page 263 dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE Maintenance interval Refer to page Perform at every indicated period or operating hour interval, whichever comes soonest. Every week Every year 500 Hours BLADES (1) Check Change BLADE DISK (1) Check Change MANUAL STOP BUTTON Check BODY PARTS (1) Check...
Page 264 dummyhead dummyhead MAINTENANCE BLADE CONDITION CHECK Damaged blades • Make sure to press the manual stop button and turn the lawnmower off before performing the following procedures. • Put on a pair of work gloves before performing the following procedures. 15 mm or less •...
Page 265 dummyhead dummyhead MAINTENANCE MANUAL STOP BUTTON OPERATION CHECK Press the power button on the control panel [1]. Check if the control panel display [1] turns off by closing the control panel cover [2] slowly when the distance between control panel cover and top cover is 10 - 20 If the control panel display does not turn off, check the clearance between stop switch bracket and top cover.
Page 266 dummyhead dummyhead MAINTENANCE DOCKING STATION CHECK Check the indicator light [1]. Refer to following chart: Color Description The docking station signal is Green correct. A signal problem. Such as the Amber boundary wire becoming (blinking) disconnected. Check the error message (page 6-4). Condition is abnormal.
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Page 268 dummytext 6. TROUBLESHOOTING SYSTEM DIAGRAM ······································6-2 GRASS CUTTING SYSTEM TROUBLESHOOTING ·································· 6-6 BEFORE TROUBLESHOOTING···················6-4 ERROR MESSAGE LIST ······························ 6-8 DOCKING SYSTEM TROUBLESHOOTING···································6-4 TROUBLESHOOTING FOR FAULT MESSAGE ··················································· 6-11 RUNNING SYSTEM TROUBLESHOOTING···································6-5 TROUBLESHOOTING FOR WARNING MESSAGE ··················································· 6-18...
Page 269 TROUBLESHOOTING SYSTEM DIAGRAM TROUBLESHOOTING TRANSFORMER TRANSFORMER TRANSFORMER (EAE type) (EAS type) (EAB type) MAIN ECU 1P BATTERY (HRM300) 2P BATTERY (HRM500) BATT(ID) BATT(TH+) BATT(−) BATT(+) G or Bu AC-IN(1) AC-IN(2) Bu or G DOCKING STATION DISPLAY ECU REPLAY(ON)
Page 270 dummyhead dummyhead TROUBLESHOOTING MAIN ECU FRONT RH AREA SENSOR AREA-SIG-FR AREA-GND-FR HIC(U)-WORK BLADE MOTOR HIC(V)-WORK HIC(W)-WORK 5V-WORK S-GND-WORK FRONT LH AREA SENSOR POWER(U)-WORK POWER(V)-WORK POWER(W)-WORK AREA-SIG-FL AREA-GND-FL REAR AREA SENSOR AREA-SIG-REAR AREA-GND-REAR MAIN HIC(U)-R CIRCUIT RH TRACTION MOTOR RH LIFT SENSOR HIC(V)-R LIFT-VCC-R HIC(W)-R...
Page 271 Abnormal Normal Check the transformer (page 11-3). Remove the foreign substance of Abnormal the wheel(s). Normal Check the setting of HRM300/500 (page 3-53). Transformer trouble. Replace the transformer. Abnormal Normal Check the power supply. Set the setting again (page 3-9).
Page 272 dummyhead dummyhead TROUBLESHOOTING RUNNING SYSTEM TROUBLESHOOTING Displayed The error message is displayed (page 3-15). Check the error message and perform the troubleshooting for fault/warning message (page 6-8, 6-9, 6-10). Not displayed Rotating The traction motor(s) is rotating. Check the woodruff key (page 8-3). Not rotating Abnormal Normal...
Page 273 dummyhead dummyhead TROUBLESHOOTING GRASS CUTTING SYSTEM TROUBLESHOOTING Grass cannot be mown at all. Displayed The error message is displayed (page 3-15). Check the error message and perform the troubleshooting for fault/warning message (page 6-8, 6-9, 6-10). Not displayed Rotating The blade motor is rotating. Check the woodruff key (page 9-2).
Page 274 Check the error message and perform the troubleshooting for fault/warning message (page 6-8, 6-9, 6-10). Not displayed Continuously but jerky work HRM300/500 is working continuously. Mowing load is high and load regulation is working. Decrease the cutting height. Stop immediately Abnormal Check the condition of charge (page 3-15).
Page 275 Turn over the Mower. Manual stop One of the Manual stop switches is inactive. 3A020 6-17 Battery Error HRM300: Connect 1P battery to HRM300 3A032 6-17 HRM500: Connect 2P battery to HRM500 Motor ECU Error Main ECU trouble. 3A030...
Page 276 dummyhead dummyhead TROUBLESHOOTING WARNING MESSAGE LIST Method of checking the warning message on the display: See page 6-4 Message 1 Refer Message 2 DTC code Mode Details (using Dr.H) Message 3 page Message 4 No Operation : Wrong PIN is entered three times. 5 minutes 6-18 Clock Reset...
Page 277 dummyhead dummyhead TROUBLESHOOTING Message 1 Refer Message 2 DTC code Mode Details (using Dr.H) Message 3 page Message 4 Outside loop The main body (three area sensors) is outside of boundary wire loop. 3A037 6-22 No loop signal The main body (three area sensors) cannot receive the area signal from the station.
Page 278 dummyhead dummyhead TROUBLESHOOTING TROUBLESHOOTING FOR FAULT MESSAGE "Keypad" MESSAGE Abnormal Confirm keypad good condition by testing it Keypad trouble of the display ECU. (page 3-42). Replace the display (page 10-3). Normal Temporary failure. "Clock" MESSAGE Clock function trouble of the display ECU. Replace the display (page 10-3).
Page 279 dummyhead dummyhead TROUBLESHOOTING "Communication error" MESSAGE No continuity Check for continuity between the main ECU Replace or repair the main wire harness. 30P connector and display 8P connector of main wire harness. ·30P connector No.16 terminal (Red) - 8P connector No.1 terminal (Red) ·30P connector No.2 terminal (Red)
Page 280 dummyhead dummyhead TROUBLESHOOTING "Charging control" MESSAGE Normal Replace the transformer with a new one and Faulty original transformer. recheck the fault message in the display. Abnormal Check for continuity between the main ECU 2P Normal connector and charge socket terminal Check the charge plug and socket for damage, bent and rust.
Page 281 dummyhead dummyhead TROUBLESHOOTING "Motor sensor Blade" MESSAGE Abnormal Replace the blade motor with a new one (page Main ECU trouble. 9-2) and recheck the fault message in the Replace the main ECU (page 10-7). display. Normal Faulty original blade motor. "Wheel motor"...
Page 282 dummyhead dummyhead TROUBLESHOOTING "Area sensor" MESSAGE No continuity Check for continuity between the main ECU 4P Replace or repair the sub wire harness. connector and area sensor 2P connector of sub wire harness. ·30P connector No.3 terminal (Red) - 4P connector No.1 terminal (Red) ·30P connector No.4 terminal (Green)
Page 283 dummyhead dummyhead TROUBLESHOOTING "Tilt sensor" MESSAGE Displayed Tilt the mower and then check whether tilt Temporary failure. sensor detects it and warning screen is displayed. Not displayed Changed Angle direction does not changed in the tilt Main ECU trouble. sensor test of the test mode (page 3-38). Replace the main ECU (page 10-7).
Page 284 Main ECU trouble. Replace the main ECU (page 10-7). "Battery Error" MESSAGE Connect new battery to the mower and check message again. • HRM300: 1P battery • HRM500: 2P battery "Motor ECU Error" MESSAGE Main ECU trouble. Replace the main ECU (page 10-7).
Page 285 dummyhead dummyhead TROUBLESHOOTING TROUBLESHOOTING FOR WARNING MESSAGE "No Operation :" MESSAGE Normal Input the correct PIN code 5 minutes later Temporary failure. (page 3-16). Abnormal Cannot input Can input by the ten digits keypad. Keypad trouble of the display ECU. Replace the display (page 10-3).
Page 286 TROUBLESHOOTING "Battery voltage high" MESSAGE HRM300/500 is connected to the station. Disconnect the mower from the docking station. Turn ON the power supply and leave it for an hour. Recheck the warning message in the display. Normal Abnormal Temporary failure.
Page 287 "Battery Temp high" MESSAGE 60 °C or more Check the temperature in the frame using Cool HRM300/500 and make the temperature Dr.H. in the frame less than 60 °C. And then turn ON the power supply and leave it for an hour.
Page 288 dummyhead dummyhead TROUBLESHOOTING "Blade motor" MESSAGE Less than 85 °C The temperature of work motor driver (Main ECU) is more than 85 °C. More than 85 °C Main ECU trouble. Replace the main ECU (page 10-7). Let the mower cool down for an hour at Abnormal ambient temperature and above 5 °C.
Page 289 - 2P connector No.8 terminal (Brown) Continuity Main ECU trouble. Replace the main ECU (page 10-7). "Outside loop" MESSAGE Move HRM300/500 in the mowing zone, and Normal Temporary failure. then recheck the warning message in the display. Abnormal Other lawnmowers are near the mowing zone.
Page 290 dummyhead dummyhead TROUBLESHOOTING "No loop signal" MESSAGE LED of the station is turned on green. Recheck the warning message in the display. Normal Abnormal Temporary failure. LED of the station is blinking in umber. Other lawnmowers are near the mowing zone. Check whether the boundary wire Change the station (pulse signal) terminal is correctly connected to the...
Page 291 dummyhead dummyhead TROUBLESHOOTING "Obstruction detection" MESSAGE Normal Input the PIN code (page 3-16). Recheck the warning message in the display. Abnormal Normal Abnormal Can input by the ten digit keypad. Temporary failure. Cannot input The main cover is in the correct position. input Keypad trouble of the display ECU.
Page 292 TROUBLESHOOTING "Excessive Tilt" MESSAGE Normal Put HRM300/500 on the level surface (15 ° or Recheck the warning message in the display. less ) and input the PIN code (page 3-16). Normal Abnormal Abnormal Temporary failure. Can input by the ten digits keypad.
Page 293 dummyhead dummyhead TROUBLESHOOTING "Lifted" MESSAGE Normal Input the PIN code (page 3-16). Recheck the warning message in the display. Abnormal Normal Abnormal Can input by the ten digits keypad. Temporary failure. Cannot input The lift sensor plate is in the correct position. input Keypad trouble of the display ECU.
Page 294 TROUBLESHOOTING "Upside down" MESSAGE Normal Put HRM300/500 on the level surface (15 ° or Recheck the warning message in the display. less ) and input the PIN code (page 3-16). Normal Abnormal Abnormal Temporary failure. Can input by the ten keypad.
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Page 296 dummytext 7. COVER TOP COVER REMOVAL/INSTALLATION····7-2 MAIN COVER REMOVAL/INSTALLATION·· 7-5 TOP COVER DISASSEMBLY/ASSEMBLY ··7-3 STOP SWITCH INSPECTION ······················· 7-6...
Page 297 dummyhead dummyhead COVER TOP COVER REMOVAL/INSTALLATION COVER PUSH-PULL CLIP (2) TOP COVER REMOVAL: Be careful not to break the hooks. INSTALLATION: Set the front hook at first. STOP SWITCH 4P CONNECTOR hook (7)
Page 298 dummyhead dummyhead COVER TOP COVER DISASSEMBLY/ASSEMBLY Remove the top cover (page 7-2). Remove the two screws [1] and front cover [2]. Remove the height adjust cover [3]. Slide the control cover shaft [1] to the left and remove the right end of the control cover shaft from the hole of the top cover [2].
Page 299 dummyhead dummyhead COVER Remove the stop switch 4P connector [1] from connector holder of the top cover [2]. Remove the wire harness from groove of the top cover. Remove the screw [1], washer [2] and self-lock nut [3], and then rotate the stop switch [4]. Remove the stop switch by releasing the projections [5] of the stop switch from the groove of the top cover.
Page 300 dummyhead dummyhead COVER MAIN COVER REMOVAL/INSTALLATION Remove the top cover (page 7-2). BOLT (5 x 12 mm) (3) REMOVAL/INSTALLATION: Loosen/tighten the bolt by fixing the mount shaft using a 10 mm wrench. MAIN COVER WASHER (3) LIFT SENSOR PLATE (2) ·Do not remove the plate from main cover.
Page 301 dummyhead dummyhead COVER STOP SWITCH INSPECTION Remove the stop switch (page 7-3). RH STOP SWITCH Check for continuity between the stop switch 4P connector terminals shown in the table below. RH stop switch Switch position Terminal 1 (Black) Continuity Continuity 2 (White) LH stop switch LH STOP SWITCH...
Page 302 dummytext 8. WHEEL/TRACTION MOTOR FRONT WHEEL REAR WHEEL/TRACTION MOTOR REMOVAL/INSTALLATION··························8-2 REMOVAL/INSTALLATION ························· 8-3 TRACTION MOTOR INSPECTION ··············· 8-4...
Page 303 dummyhead dummyhead WHEEL/TRACTION MOTOR FRONT WHEEL REMOVAL/INSTALLATION WHEEL/TRACTION MOTOR Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) SPLIT PIN (2) WASHER (4) (inside) FRONT CASTER BUSH (8) FRONT WHEEL CAP FRONT CASTER FRONT CASTER ROD...
Page 304 dummyhead dummyhead WHEEL/TRACTION MOTOR REAR WHEEL/TRACTION MOTOR REMOVAL/INSTALLATION Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) – Upper frame (page 10-2) – Main ECU (page 10-7) TRACTION MOTOR WOODRUFF KEY Avoid grease on the threads. O-RING SPECIAL BOLT (6 mm) (4) 9 N·m (0.92 kgf·m, 6.6 lbf·ft)
Page 305 dummyhead dummyhead WHEEL/TRACTION MOTOR TRACTION MOTOR INSPECTION WINDING RESISTANCE INSPECTION Remove the traction motor (page 8-3). Measure the resistance between the traction motor 8P connector terminals shown in the table below. Traction motor 8P Resistance (Ω) connector (at 20 °C/68 °F) No.5 (Black) –...
Page 306 dummytext 9. BLADE/BLADE MOTOR BLADE/BLADE MOTOR REMOVAL/ BLADE MOTOR INSPECTION ····················· 9-3 INSTALLATION·············································9-2...
Page 307 dummyhead dummyhead BLADE/BLADE MOTOR BLADE/BLADE MOTOR REMOVAL/INSTALLATION BLADE/BLADE MOTOR Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) – Upper frame (page 10-2) HEIGHT ADJUST HANDLE Apply the grease to contact area INSTALLATION: of the height adjust handle and ·When handle tightened frame.
Page 308 dummyhead dummyhead BLADE/BLADE MOTOR BLADE HEIGHT ADJUSTMENT Open the height adjustment dial cover [1]. Turn the dial [2] anticlockwise to lower the blades, or turn the dial clockwise to raise the blades. Use the numbers on the dial to approximate the height of the blades.
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Page 310 dummytext 10. OTHER ELECTRICAL UPPER FRAME AREA SENSOR REMOVAL/INSTALLATION························10-2 REMOVAL/INSTALLATION ······················· 10-5 DISPLAY REMOVAL/INSTALLATION ·······10-3 CHARGE SOCKET REMOVAL/INSTALLATION ······················· 10-6 OBSTRUCTION SENSOR REMOVAL/INSTALLATION························10-3 MAIN ECU REMOVAL/INSTALLATION····· 10-7 MOUNT SHAFT BATTERY REMOVAL/INSTALLATION······ 10-7 REMOVAL/INSTALLATION························10-4 BATTERY INSPECTION ····························· 10-8 LIFT SENSOR REMOVAL/INSTALLATION························10-5 10-1...
Page 311 dummyhead dummyhead OTHER ELECTRICAL UPPER FRAME REMOVAL/INSTALLATION OTHER ELECTRICAL Disconnect the battery 4P connector before disconnecting/connecting the connector from/to main ECU. Turn OFF the main switch. Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) Remove the special bolts, nuts and special nuts. Lift the upper frame slightly and disconnect the battery 4P connector.
Page 312 dummyhead dummyhead OTHER ELECTRICAL DISPLAY REMOVAL/INSTALLATION • Do the preventive measure of static electricity before removal/installation. main ECU, display, battery and sensor etc. may be damaged because of static electricity (page 3-2). • If the display is dropped, do not use it because it may have damaged.
Page 313 dummyhead dummyhead OTHER ELECTRICAL MOUNT SHAFT REMOVAL/INSTALLATION REMOVAL Remove the following: – Top cover (page 7-2) – Main cover (page 7-5) MOUNT PLATE Front mount shaft shown: SPECIAL BOLT (6 mm) (3) MOUNT SHAFT MOUNT WASHER Right mount shaft: with magnet SPRING PLATE Front mount shaft: with magnet...
Page 314 dummyhead dummyhead OTHER ELECTRICAL LIFT SENSOR REMOVAL/INSTALLATION Do the preventive measure of static electricity before removal/installation. main ECU, display, battery and sensor etc. may be damaged because of static electricity (page 3-2). Turn OFF the main switch. LH lift sensor shown: Remove the upper frame (page 10-2).
Page 315 dummyhead dummyhead OTHER ELECTRICAL REAR AREA SENSOR Turn OFF the main switch. Remove the upper frame (page 10-2). Disconnect the 2P connector [1]. Remove the two tapping screws [2] and rear area sensor [3]. • Place the area sensor quietly with the stable position on an insulator without trash, dust, and moisture etc.
Page 316 dummyhead dummyhead OTHER ELECTRICAL MAIN ECU REMOVAL/INSTALLATION • Do the preventive measure of static electricity before removal/installation. main ECU, display, battery and sensor etc. may be damaged because of static electricity (page 3-2). • If main ECU is dropped, do not use it because it may have damaged.
Page 317 dummyhead dummyhead OTHER ELECTRICAL Remove the screws [1], battery upper cover [2] and HRM500 shown: lower cover [3] from the battery [4]. Remove the battery setting plates [5]. Installation is the reverse order of removal. Be careful not to damage the tabs. TORQUE: BATTERY CASE SCREW: 0.4 N·m (0.04 kgf·m, 0.3 lbf·ft)
Page 318 dummytext 11. DOCKING STATION STATION DISASSEMBLY/ASSEMBLY ·····11-2 TRANSFORMER INSPECTION ·················· 11-3 11-1...
Page 319 dummyhead dummyhead DOCKING STATION STATION DISASSEMBLY/ASSEMBLY DOCKING STATION • Do the preventive measure of static electricity before removal/installation. The station ECU may be damaged because of static electricity (page 3-2). • If the station ECU is dropped, do not use it because it may have been damaged. •...
Page 320 dummyhead dummyhead DOCKING STATION TRANSFORMER INSPECTION Check for continuity between the terminals of EAE type shown: transformer plug [1]. Check for continuity between the terminals of transformer 2P connector [2]. Measure the resistance between the terminals of transformer plug [1]. Resistance (Ω) Terminal Type...
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Page 322 dummytext 12. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAM ···································· 12-3 RELATED INFORMATION··························12-2 12-1...
Page 323 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a...
Page 324 INDEX dummytext INDEX AREA SENSOR REMOVAL/INSTALLATION ···············10-5 OBSTRUCTION SENSOR REMOVAL/ BATTERY INSPECTION···············································10-8 INSTALLATION ···························································· 10-3 BATTERY REMOVAL/INSTALLATION ························10-7 PROGRAMING····························································· 3-15 BEFORE INSTALLATION···············································3-4 REAR WHEEL/TRACTION MOTOR REMOVAL/ BLADE CONDITION CHECK··········································5-3 INSTALLATION ······························································ 8-3 BLADE DISC CONDITION CHECK ································5-3 RUNNING SPEED·························································· 1-3 BLADE MOTOR INSPECTION ·······································9-3 SAFETY INSTRUCTIONS··············································...

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