Rob Om Ow Dealer Manual

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The AFFORDABLE Automatic Lawn Mower!

Robotics

RL550/800

Menu Detail

RL 550/800 Messages

Message

Blocked path

Calibration Req.

Check Power

Charging failure

Connect charger

Failed K=18

Front wheel problem

Front/Rear bumperdisconnected

Front/Rear bumperpressed

Keys locked

'X' Key pressed

Start Elsewhere

Mowing DisabledTheft Guard On

Check mow height

No wire signal

Drive Problem

Mowing OverloadCooling, Wait-Drive OverloadCooling, Wait-

Path problem

ReadyKeep charging

Recharge Battery

Retry Elsewhere

Set CountryTime Completed

Move from Wire

Max dist reached

Explanation- Bumper pressed during warm up.- Bumper pressed for 2 sec during manual mowing.

- A D.K calibration is required (only in the first operation)

- The charger is connected but not charging, usually happens upon initiatingcharging (there is no power from the power supply)

- The charger is connected but not charging (Probably faulty Main Board).

- Connect charger (displayed when the mower isnt operated and connected tothe charger).

- Appears during the D.K calibration and indicates that the coils on the electroniccompass are probably disconnected.

- The front wheel is not touching the ground for too long.- There is a problem with Drop-off board.

- An internal problem associated with the front bumper has occurred.

- Front or rear bumper is constantly pressed.

- Child guard set to 'on' - Press the scroll upper arrow and then C to enablemowing.

- One of the keys on the manual controller is pressed continuously upon reset.

- Drive motors have faced over-current for too long.- For some reason the Robomower had stopped and user assessment is

required.- Wire synchronization failed. (Very rare. Customer will have to press GO if this

appears)

- When activating motors under 'Diagnostics' but 'mowing' is set 'off'

- Anti theft set to 'on' - Insert safety password to enable mowing.

- Mowing motors have faced over-current for too long or some obstacle is stuckor wrapped around the blades.

- The Robomower cannot detect a signal from the Perimeter Wire.

- One of the odometers is not reading a signal from the magnets on the drivemotor.

- Mowing motors have faced overheating - the mower stops for cooling.

- Drive motors have faced overheating - the mower stops for cooling.

- The Robomower does not complete edge acquisition in 2 minutes.- Bumper event while the mower is exiting from the Docking Station.- Bumper as the mower leaves the edge for scanning.- Bumper as starting the turn for obstacle bypass during edge.

- Battery Is fully charged, the mower is ready to the next operation - keepcharging the battery.

- The Robomower battery needs recharging.- The Robomower battery reaches 19V under load.- There is a problem with the compass readings due to a distortion in the local

magnetic field (during DK Calibration or as pressing the 'GO' button).

- GEO location is not set

- Displayed when the time set for the operation is reached.

- The Robomower is too close to the perimeter wire or on the wire itself.- There is a reading problem while pressing the 'GO' button.- The Robomower will stop after about an hour or 800 meters, if the customer

for some reason did not stop it while learning edge. (Maximum distancereached)

RL550 User InterfaceUser Options

Press GO i

Zone A: MAX

Press GO 1lorn B: MAX

Press GO |Zone C: MAX

Press GO 1

Press GO againto skip Edge

Edge

RoboScanZ *

MowinQ ,1RoboScanZ •

Manual

Controller

•T1

Manual Controller is user's hands

ManualUser Options ]

t User PreferencesPress GO

Child guard offPress GO

Safety TestsPress GO

ServicePress GO

sound onPress GO

mowing onPress GO

languagePress GO

Work timePress GO

Child guard off A

front wheel snsrPress GO to test

BumpersPress GO to test

ButtonsPress GO to test

Password req.Press GO

Sound on A

Mowing on AConfirm

English

Zone A: MAX APress GO V

Front Wheel:On the ground

*- ok D-discon.Front: - Rear: -

Press any key

.00000 (0) Anext digit V

Zone A : MAX AConfirm

Front Wheel:Lifted

key 12321Confirm

Set CountryPress GO

USA AConfirm V

OK calibrationPress GO

activate motorsConfirm

Done scoreDK problemfailed! K-18XXX XX XXXX

retry elsewhereEdge calibration

Press GOEdge calibration

xxxdone •Learn wire snsrs i

Press GO 1wait... 1Confirm 1

was:x Now:x No:a 1confirm JE

wire sensors WfPress GO *

direction keeperPress GO

mowing motorsPress OO

Force resetPress GO

CPU version61 Class:3S.W. version:

vx.xx (date)Board versions

Press QO

total time:xxhxxm

Bat. MaintenancePress OO

Factory defaultsPress QO

Small wheels offPress QO

MiscellaneousPress QO

Enable DK onPress GO

Wide scan offPress GO

Learn EdgePress GO

(Appears only whenthe Manual Controller

in its place)

Set default edgePress GO

wait...advanced

test passedconfiiiit

-aaa +bbb-ccc +ddd

activate motorsconfirm

test passedConfirm

petim swtoh »g

Last bat Volt25

win ignored0

Poof storage0

ResetPress GO

Are you sure?Confirm

Small Wheels onConfirm

BattV:Temp C F

Enable DK onConfirm

Wide scan off AConfirm V

Learn zone BPress GO to leam

Learning EdgePress GO to leam

Learning EdgeSTOP to set

Zone A orig edge APress GO V

RL800 User InterfaceUser Options

Press 60 •

Zone A: MAX

Press GO •

Zone B: MAXPress GO B

Zone C: MAXPress GO i

Press OO againto skip Edge

Edge

RoboScan2 *

MowingRoboScanZ •

Manual

Controlled

in its cradle

Manual Controller in user's hands

ManualUser Options •

A

1

i. _ _ _

User PreferencesPress GO

Child guard offPress GO

Safety TestsPress GO

ServicePress GO

sound onPress GO

mowing onPress GO

languagePress GO

Work timePress GO

Wide scan offPress GO

Learn EdgePress GO

(Appears only whenthe Manual Controller

in its place)

Set default edgePress GO

Anti theft offPress GO

Child guard off AConfirm v

front wheel snsrPress GO to test

BumpersPress GO to test

ButtonsPress GO to test

Password req.Press GO

Sound on *

Mowing on A

English A

Zone A: MAX APress GO V

Wide scan off *Confirm V

Learn zone B APress GO to team V

Zone A orig edge A

Anti theft off AConfirm V

Front Wheel:On the ground

*-ok D-discon.Front: - Rear: -

Press any key

00000 10) Anext digit V

Zone A: MAX AConfirm V

Learning EdgePress GO to learn

Set lock passwdPress GO

Front Wheel:Lifted

Learning EdgeSTOP to set

QOOO Anext digit »

Key 1234confirm

PRICING

•FriendlyRobotics

Robomower Spare Parts Price List for the 2003 Season (in US Dollars)

#

505152535455565758596061626364656667686970717273747576777879808182838485868788899091929394959697

Friendly P/N

GEN0163AGEN0171AGEN0175AGEN0182AGEN0201AGEN0202AGEN0207AGEN0208AGEN0210AGEN0211AHSN0003ALMP0001ALMP0004AMSB0065AMSB0065BMSB0072AMSB0077AMSB0078AMSB0079AMSB0090AMSB0091BMSB0099AMSB0105AMSB0105BMSB0106AMSB0107AMSB0114ANIT0009APRG0005APRG0007APWS0003ARNG0002ARNG0005ARNG0030ASCR0024ASCR0025ASNS0004ASPP0003ASPP0004ASPP0004BSPP0005ASPP0007ASPP0008ASPP0008BSPP0009ASPP0011ASPP0012ASPP0013A

Part Description

Snap lock (curved)Motor shield, roundStake for perimeter switchWater drain sealWheel cup, blackGround clearance limiterFront wheel detentFront wheel detent springCharge socket sealCharge plug sealThermistor heat sink insulatorOperating bulb (version "A")Operating bulb (version 'B' & 'C')Mowing Motor w/mounting hub and spline

2003 Dealer Price

0.825.482.856.292.304.194.192.092.092.091.08

WSEE^BlOE'.-':.'. .i:- " --- . ' '"'-•• *.. Rffji— "Vi' T!!??™ !

5.48tasfcw

Mowing Motor w/mounting hub and spline 55.96Manual controller- USSlider assemblySmooth drive wheel + bearingGear spline + bearingContact strip front assemblyContact strip rear assembly

6.2717.1512.5020.9320.93

Knobby drive wheel + bearing J 19.95Manual Controller Holder AssyManual Controller Holder AssyFront bumper assyRear bumper assyManual Controller- USPop rivet, thermistorFlash 3.2i RL800USFlash 3.2e RL550 US1 1 5VAC power supply - USExternal zeger ring D12 DIN 471 BLKWasher D18*D12*0.5 DIN 988Washer M10 DIN 125 Z P Front wheelScrewWN1413K25*6Screw for RL motorsDouble thermistor with harnessFront wheel assembly (with board)Spare part gear caseSpare part gear caseDrop off board w/holderPS front cover w/boardDrive motor replacement kitDrive motor replacement kitGear shaft replacement kitFront wheel w/axleHigh cut blade (1) (Use accessory part #)Not Available

imp7.35

41.3034.3055.97

0.9136.7436.7424.50

0.441.100.600.600.44

U*«.*«JB

JsilelSffl lSSsBS!

118.4817.45

uUsy

"59.6844.6525.19

m1.187.844.078.993.295.995.992.992.992.991.65

BJ&MPS0Q4A 17.84

•*of6*e;ise» s,;>DuuooD79.95

8.9624.5017.8629.9029.90

_^ ^ 28.50

BMiiB • ' ' :-310.5059.0049.0079.95

1.3052.4952.4935.000.631.570.860.860.63

^ ENWISM j""""""*'" ! 6926

24.96ttOOOTB3P0038B IJIiiliil

'2 1 85.27]63.7935.99

«M* ]

•FriendlyRoboticsRobomower Spare Parts Price List for the 2003 Season (in US Dollars)

#

12345678910111213141516171819202122232425262728293031323334353637383940414243444546474849

Friendly P/N

BAT0003ACBL0038ACON0054ACPS0007ADOC0008BDOC0010ADOC0015ADOC0015BDOC0051ADOC0051BESB0018CESB0019CESB0020AESB0022BESB0031AESBC017BESBC021CESBC024BESBC025BFUS0003AFUS0012AFUS0021AFUS0015AGEN0094AGEN0095AGEN0101AGEN0103AGEN0104AGEN0111AGEN01 16AGEN0117AGEN0118AGEN0122AGEN0130AGEN0131AGEN0132AGEN0133AGEN0135AGEN0137AGEN0138AGEN0140AGEN0142AGEN0143AGEN0144AGEN0145AGEN0146AGEN0148AGEN0156AGEN0162A

Part Description

Battery holder for perim.switchExt. Charger Power CablePlot Connector (Use Accessory part #)Wire twist lockRoboRulerInstallation VideoOwner/user manual 2001-2002 500Owner/user manual 2003 500/550/800/850Service Guide (English hard-copy)

2003 Dealer Price

5.5912.47

2.193.15. . .,,,,

m"" 4.50

4.50USE OC

2003 Retail

8.0017.81

>XA a»-f-oc<=rtr\»5*«,/*cce9^wiy s3.134.50

;<-_ ' ' :' '- ' >>

kA u4.504.50

MM* >Service Guide (English hard-copy) Incl. CD ! 45.00 1 124.50Drop-off boardMain Board

t3SE$PPWJ05AUS£SPPtk)19A

Wire Sensor Board USESPPOQ18A *Lamp BoardRear RH Wire Sensor BoardCharge socket boardConnectors BoardOdometer Board ROdometer Board LFuse AT blade 30A 32VFuse AT blade 1 A 32VFuse, External Charger 10A, 125VFuse mini blade 5ARL coverRL BaseOdometer magnetGear unit frame onlyWheel Cup, grayContact leaf-baseDrop off flagAdjusting hub, front wheelFront Wheel Click SpringGear shaft clampContact leaf-batteryPower pack casePower pack coverMagnet for Manual ControllerContact base adaptorOperating lamp coverOperating Lamp SealSealing cupConnector's coverManual controller's holderCharge socket housingPivot for manual controller's trayMain board rubber holderMC navigator keypadPS back coverSnap lock (straight)

13.4610.96' -• * ' ' '

26.5414.0614.06

1.532.193.202.19

97.95105.00

0.93

2.30fuseei

: • U3KS»CM

5.4814.092.513.018.63

15.2112.723.95

• ' " ' • '*siH}f4.331.321.163.95

• HE' USE**-HHHHK; USE M*r_^^. ^

3.78—••': • mm

6.300.82

19.2515.67

""*""" 37.9520.1120.112.193.134.573.13

125.00150.00

1.33fKQMSA .,-,.,-V .;•. I

3.29>PQG14A

7.8420.143.594.31

12.3421.7518.185.64

fflK^'^''. ' ' ;6.191.881.665.64

IBQ1Q5BJBQ105B

2.195.41

9.011.18

FriendlyRoboticsRobomower Spare Parts Price List for the 2003 Season (in US Dollars)

#

9899100101102103104105106107108109110111112113114115116117118119120121122123124125126127128129130131132133

Friendly P/N

SPP0014ASPP0015ASPP0016ASPP0018ASPP0019ASPP0020ASPP0021ASTC0012ASTC0018ASTC0022ASTC0036ASTC0048ASTC0049ASTC0050ASTC0051ASTC0052ATOL0001AUNT0007AUNT0007BUNT0016AWSB0025AWSB0025BWSB0035AWSB0040AWSB0041AWSB0042AWSB0043AWSB0044AWSB0045AWSB0046AWSB0048AWSB0049AWSB0052AWSB0053AWSB0055AWSB0063A

Part Description

Battery contact assembly RL sideGear frameFlash 3.2i with US manualWire sensors assembly with harnessMain Board RL800/RL550Thermistor assy, heat pads and pop rivetsMain Board With Flash, Special RL500Rear warning stickerDanger stickerFront caution stickerFR power pack charging decalRL550 DecalRL850 DecalRL500 DecalRL800 DecalTheftGuard decal RL800Mowing motor removal toolPerimeter Switch 5HrPerimeter Switch 5 HrExternal Charger AdaptorPerim. wire to perim. switch cablePS cable, moldedMain board to battery cableWire sensors cableOdometers cableDrop-off cableBumper cableLamp board cableCharge socket cablePower pack fuse holder w/wirePower pack cable, negativePower pack cable, series jumperFlat cableMowing motors cableExternal battery charge cable

m11.2315.760.00

13.73166.2523.00

173.330.930.930.961.703.493.493.493.493.73

35.7313&E13!53.7519.55

m®*4.196.33

USES!8.294.527.082.86

yam13.713.483.489.194.97

Drive motor cable w/ferrite ring | 13.71

m16.0622.540.00

19.63237.7532.89

247.611.331.331.382.434.984.984.984.985.33

51.10

77.5027.95

Ip2ie : *

9.05*P0018A I

11.856.46

10.134.09

4.964.98

13.147.11

IA : ir:~v319.61

BULLETINS

Robotics

U.S.Service

Bulletins

riendlvRobotics Service Bulletin #RL0301-02

Technical Service BulletinDate: December 25,2002

Product Model: RL500/550/800/850 with treaded/knobby wheels

Serial Range: All

Part Number SPP004A / SPP004B / SPP0015A / GEN0103A

Countries Affected: All

Gear Case/ Frame Modification

Two versions of the gear frame are found in the field in the part numbers listed above. One versionutilizes a ground clearance-limiting riser molded as part of the frame, while the other does not.

SPP004B and SPP0015A will have the riser removed when received as a spare part. Includedwith these two parts is a Ground Clearance Limiter, part # GEN0202A. When using the gearframe version with the riser removed on units with the larger knobby/treaded wheels, it is alsonecessary to install the limiter (GEN0202A) to allow for proper clearance between the largerknobby/treaded wheels and the cowling. See Figure below. When using the frame where the riseris intact on units with knobby/treaded wheels, no additional procedure is required and the limiter(GEN0202A) is not needed.

Slick/smallwheel unitsrequire this

Knobby / treadedwheel unitsrequire this

Ground clearance limitingriser molded to gear frame.

They may be removed ifnecessary for slick wheel

unit use.

On gear frames where the riser is removed,assemble the limiter on the upper left tab of

the ground clearance adjustment tabs to blockthe lowest ground clearance position when

using knobby/treaded wheels.

Gear Case replacement

A new. spare part Gear Case assembly, part number (SPP0004B) is introduced for 2003. Theassembly includes the following parts:

- Gear Case- Ground Clearance Limiter (GEN0202A)- Thermistors kit (SPP0020A)- Extra motor shading (GEN0171 A)

When replacing the Gear Case on all S/N units, follow the instructions below:

1. Remove the faulty Gear (Thermistors cable can be cut to relieve the removal of the Gear).IMPORTANT - do not drill the pop rivet of the Thermistors inside the Robomower, as themetal pieces may cause to short in the electronics).

2. Remove the right mowing motor shield3. Assemble the new Gear with the mowing motor shield (see Rgure 1 below).

4. Use the Ground Clearance Limiter only if necessary, as explained in the first page.

5. Connect the Thermistors cable to the Main Board (only S/N IRL03... and onwards).With a serial number beginning IRLOO.../IRL01.../IRL02... leave the connectordisconnected as a future.

Right mowingmotor shield

•v?

1Connection to the

Main Board(only from S/N IRL03

and onwards)

Figure 1

• Page 2

FriendlvRobotics Service Bulletin #RL0301-03


Product Model: RL500 US & RL800 Europe

Serial Range: IRL02340100 and below

Part Number SPP0018A


Wire Sensors/Cable (SPP0018A)

A new wire sensor assembly is introduced for 2003. All four wire sensors and the harness areincluded as one assembly. Use this part for service on all units.

When servicing the sensors or sensor harness on units with S/N IRL02340100 and below onlyspare part SPP0018A is provided. On these units, the right rear sensor board (Figure 1) must beremoved from the support tower and placed in the right rear corner well of the base, as shown inFigure 2. Leave the black and white wires connected to the sensor board. All other sensor partsand wires are removed and discarded. Install part SPP0018A to complete the repair.

Figure 1

Note: Confirm the top side of thethe sensor is place as shownin Figure 3.

Figure 2

Figure 3

IvRobotics Service Bulletin 3RL0301-O4

Technical Service BulletinDate: December 25, 2002

Product Model: RL500/550/800/850

Serial Range: IRL03000000 and above

Part Number GEN0094A


RL Top Cover (GEN0094A) Water Drain Changes

A modified top cover is introduced for 2003 to accommodate changes in the water drain routing.This modification will not be included on the supplied spare part GEN0094A.

RL Top Cover spare part (GEN0094A) is received as shown in Figurel. If you are servicing aRobomower with a S/N IRL02340100 and below use the Top Cover as received withoutmodifications..

If the S/N is IRL03000000 and after, follow the modifying instructions below:

1. Cut an opening in the plastic as shown in Figure 2, to allow for water drainage.2. Notice that the opening is done on the circular side of the extension.

12 mm/0.47 inch

1

Figure 1 Figure 2

DOC0056A for SPP0004B and SPP0015A

Robotics Service Bulletin #RL0301-05


Product Model: RL500/550/800/850

Serial Range: IRL03000000 and above

Part Number GEN0207A / GEN0208A


Front Wheel Detent Change

A new front wheel detent is introduced for 2003. If the S/N is IRL03000000 and after, use the newFront Wheel detent (GEN0207A) with two Front Wheel detent springs (GEN0208A) as shown inFigure 2 below.

If you are servicing a Robomower with a S/N IRL02340100 and below, use part numberGEN0118A, front wheel detent spring, as shown in Figure 1 below.

Figure 1 Figure 2

Robotics Service Bulletin 3RL0301-06

Technical Service BulletinDate: December 25, 2002

Product Model: RL550/800/850

Serial Range: IRL03000000 and later

Part Number MSB0065B - Mowing Unit


Blade Motor Change (MSB0065B)

A new blade motor, part number (MSB0065B) is introduced for 2003. The wire harness at themotor end is now soldered to the terminals for better rigidity. When replacing the blade motor on allS/N units it will be necessary to remove the cowling first in order to disconnect the motor wiresfrom the main board. Then remove from the blade motor from the base with special toolTOL0001A. See Figure 1.

IMPORTANT - It is also necessary to remove the metal motor shield from the original motor andplace it on the new motor before installation. See Figure 2.

Inventory of the MSB0065A, which does not have soldered leads, may be used on IRL02340100and below units until depleted and does not require removal of the cowling.

Stepl Step 2 Step 3

Figure 1

Figure 2

Metal shield must be removedfrom motor and placed on new

motor before installation.

DOCforMSBOOSSB

IPL's

Robotics

RL500

IllustratedPartsList

51

1

53

:52

56 "55

54

57

65

RL500 US

RL500Operating

&Safety Manual

58

59

60

69

<M

',

ISPP0014AIBattery Contacts

RLside

Main board tobattery cable

1)TOfM3ffBfd.

SPP0005A

1Optical sensor board cable

Manual Controller

IMSBOIUAI

FUS0012AFuse 1 Amp

Flat cable

Red Fuse holder & cable

WSB0052Ai 1 .Fuse 3 Amp |

Charge boardcable

JWSB0045AI

Manual CpnWfer Battery

EH 1

WSBO046A

Connectors Board

Mowing motor cablelWSB0053AlRfldGBen(X3i / wire sensors cable

IWSBOMOA]

Lamp board

r

JBlue

I21\luf yUi*

tensorFra<RH

LWhite 1 Gray Purple

msensorFrontIK

EmmmRearW

m^sensorfearRH

Bumpers cable

short

LampBrd,

Battery jumper cable

WSB0049A

Red

Grey

i 'Battery

Negative battery cable Black

WSBO048A

long

medium

Front BumperLH

Front BumperRH

Red

Fuse 30 Amp

. Fuse, Holder I

Contact"LeftH

BumperExternal chargesocket & cable

ExternalChargeSocket

: X Number of pins on connector

RL500 US Wiring Parts List

Parts List RL500

12345678910111213141516171819

20

212223242526272829303132333435

363738394041

42

434445464748495051

GEN0146AGEN0207ACPS0007AESB0020ASPP0021AESBC021CFUS0012AFUS0015ASPP0004BESB0031ASPP0020AGEN0182AMSB0106AMSB0090AGEN0095AMSB0091BMSB0107ASPP0011AGEN0162A

GEN0171A

MSB0065BMRK0002AGEN0140AGEN0162AESB022B

GEN0133ARNG0005ARNG0002AGEN0201AMSB0099AGEN0094AGEN0142AMSB0105BGEN0145AMSB0114A

GEN0138AGEN0137ALMP0004AUNT0009AGEN0202AESBC024B

ESBC025B

SPP0008BSCR0025AGEN0101ASPP0009ASCR0025AGEN0122AMSB0077AMSB0079AUNT0007B

Main board rubber mountFront wheel detentWire twist lockWire sensor boardMain board, RL500 specialConnector boardFuse, 1A 32VFuse, mini 5AGear case assy, completeRR wire sensor boardThermistor assy w/hardwareWater drain sealFront bumperFront bumper contact stripMower baseRear bumper contact stripRear bumperFront wheel w/axleSnap lock, curved

Motor shield

Mowing motor assemblyCutting blade, set 3Sealing cupSnap lock, straightOperating lamp circuit boardMagnet, manual controllerWasher, shimRetaining ring, wheelWheel cup, blackKnobby wheel w/bearingMower cowlingConnector board coverManual controller pocketManual controller pocket pivotManual controller pocket

Operating lamp cover sealOperating lamp lens coverOperating lamp bulbPower pack assyGround clearance limiterOdometer board, RH

Odometer board, LH j

Drive motor kitScrew, drive motorOdometer magnet, pinionGear and shaft kitScrew, drive motorGear shaft clampSlider , sealGear spline w/bearingPerimeter switch only

525354555657585960616263646566676869

|

GEN0175AGEN0156ABAT0003AMRK0024AWSB0025BPWS0003ADOC0008BMRK0024ADOC0015BRNG0030AGEN0117AGEN0116ASPP0005ASPP0011AGEN0131AFUS0003AGEN0132AGEN0130A

STC0012ASTC0018ASTC0022ASTC0036ASTC0050ATOL0001AUNT0016ACBL0038ADOC0051BFUS0021A

Perimeter switch stakePerimeter switch back coverPerimeter switch battery holderConnector, perimeter switchPerimeter switch cablePower supply, chargingRoboRulerWire nut, sealing spliceOp/Safety Manual RL550/RL800Washer, front wheelFront wheel adjusting hubFlag, lift sensorLift sensor circuit board w/holderFront wheel w/axlePower pack caseFuse, power pack 30A 32VPower pack coverContact, power pack side

NOT SHOWN

Warning decal, rearBlade warning decal, sideFront lift warning decalCharging decal, power packRL500 decalMowing motor removal toolAdaptor, external optional fast chargerPower cable, optional fast chargerService manual w/CDFuse, optional fast charger 10A 125V

Note additional part numbers located on Wiring Parts List

Dealer Manual 2-2003

Robotics

RL550/800

IllustratedPartsList

CD

1

54

I56

!55

11

10

59 \

57

58

41

•74

63

60

RL550/800Operating

&Safety Manual

\64

69

70 I72

71

73

22

RL550/800 US

44

SPP0014A I

RLside

Main board tobattery cable

(tofHJffBrd,SPP0005A

0

1 Optical sensor board cableIWSB0042AI

TherrnLAsseml

[MSB0114AIManual Controller

cable

Fuse 1 Amp

Flat cableI

Manual ConMaCharge board

cableIMSB0105BI

WSB0052A

Fuse 3 Amp |

Battery

Mowing motor cableRedGreen(X3)iistofLWSB0053A|

nbly / /

Odometers cableWSB0041A

Yellow Orange!

OdometL

3E

2

er boardH

ESBC0253

mOofxnetef board

RHESBC0024B

Red Fuse holder & cable

WSBO046A

Battery jumper cable

WSB0049A

Red

Grey

Negative battery cable Black

WSB0048A

Assembly W/Hamess

Front BumperLH

Front BumperRH Bumper

Note:(x] Number of pins on connector

i Fuse I• Holder I

.BatteryContactLeft{+)

. BatteryContact

GEN0130A

RL550/800 US Wiring Parts List

Parts List RL550/RL800

12345678910111213141516171819202122232425

26272829303132333435363738394041

42434445464748495051

GEN0146AGEN0207AGEN0208ACPS0007ASPP0018ASPP0019AESBC021CFUS0012AFUS0015ASPP0004BSPP0020ASPP0014AGEN0182AMSB0106AMSB0090AGEN0095AMSB0091BMSB0107ASPP0011AGEN0162AGEN0171AMSB0065BMRK0002AGEN0140AGEN0162A

ESB022B

GEN0133ARNG0005ARNG0002AGEN0201AMSB0099AGEN0094AGEN0142AMSB0105BGEN0145AMSB0114AGEN0138AGEN0137ALMP0004AUNT0009AGEN0202A

ESBC024B

ESBC025BHSN0003ANIT0009ASPP0008BSCR0025AGEN0101ASPP0009ASPP0015AGEN0122A

Main board rubber mountFront wheel detentFront wheel detent springWire twist lockWire sensor assemblyMain board - RL550/RL800Connector boardFuse, 1 A 32VFuse, mini 5AGear case assy, completeThermistor assy w/hardwareBattery contact, RL sideWater drain sealFront bumperFront bumper contact stripMower baseRear bumper contact stripRear bumperFront wheel w/axleSnap lock, curvedMotor shieldMowing motor assemblyCutting blade, set 3Sealing cupSnap lock, straight

Operating lamp circuit board

Magnet, manual controllerWasher, shimRetaining ring, wheelWheel cup, blackKnobby wheel w/bearingMower cowlingConnector board coverManual controller pocketManual controller pocket pivotManual controller pocketOperating lamp cover sealOperating lamp lens coverOperating lamp bulbPower pack assyGround clearance limiter

Odometer board, RH |

Odometer board, LHThermistor heat sink padPop rivet, thermistorDrive motor kitScrew, drive motorOdometer magnet, pinionGear and shaft kitGear frame onlyGear shaft clamp

525354555657585960616263646566676869707172737475

|

MSB0077AMSB0079AUNT0007BGEN0175AGEN0156ABAT0003AMRK0024AWSB0025BPWS0003ADOC0008BMRK0024ADOC0015BGEN0211ARNG0030AGEN0117AGEN0116ASPP0005ASPP0011AFUS0003AGEN0132AGEN0130AGEN0131AMSB0105BGEN0210A

STC0012ASTC0018ASTC0022ASTC0036ASTC0048ASTC0050ASTC0052ATOL0001AUNT0016ACBL0038ADOC0051BFUS0021A

Slider , sealGear spline w/bearingPerimeter switch onlyPerimeter switch stakePerimeter switch back coverPerimeter switch battery holderConnector, perimeter switchPerimeter switch cablePower supply, chargingRoboRulerWire nut, sealing spliceOp/Safety Manual RL550/RL800Charge plug sealWasher, front wheelFront wheel adjusting hubFlag, lift sensorLift sensor circuit board w/holderFront wheel w/axleFuse, power pack 30A 32VPower pack coverContact, power pack sidePower pack caseManual controller pocketCharge socket seal

NOT SHOWN

Warning decal, rearBlade warning decal, sideFront lift warning decalCharging decal, power packRL550 decalRL800 decalTheftGuard decal, RL800Mowing motor removal toolAdaptor, external optional fast chargerPower cable, optional fast chargerService manual w/CDFuse, optional fast charger 10A 125V

Note additional part numbers located on Wiring Parts List

Dealer Manual 2-2003

RL500

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 ]For units serial number starting with IRLOO, IRL01, IRL02

RL500 Service Guide (2002 and prior units)o It is highly recommended to watch the service video clips, on the Dealer CD, prior to servicing a

RoboMower.o For servicing an RL550/800, see the previous document in this divider.

Table of contents Page

1. Tools, bench and work area recommendations 22. RoboMower layout and main components 3

5.1. Top view and power pack terminals polarity 35.2. Bottom view 45.3. Inside main components 5

3. Opening the RoboMower 64. Closing the RoboMower 65. Typical technical problems and their solution

5.1. Mower doesn't respond: Low voltage power pack 75.2. Charging problem: Power supply (regular mower charger) faulty ... 85.3. Charging problem: Charging fuse is faulty 85.4. Charging problem: Manual controller holder is faulty 85.5. Charging problem: Other charging problems 85.6. Charging problem: External charging problems 95.7. Manual controller problems: Keys do not respond 95.8. Manual controller problems: Keypad is torn 95.9. Manual controller problems: Magnet sensor faulty 105.10. Manual controller problems: Emits a squealing noise 105.11. Perimeter switch problems: P.Switch doesn't turn on 105.12. Perimeter switch problems: P.Switch indicates low batteries 105.13. Perimeter switch problems: P.Switch wires came out 105.14. Drive/Gear problems: Mower doesn't drive properly 115.15. Drive/Gear problems: Growling noise from rear wheels 125.16. Drive/Gear problems: Rear wheel height adjustment handle broken.. 125.17. Drive/Gear problems: Rear wheels spin, loosing track 135.18. Wire crossing in automatic mode: Main Board issues 135.19. DK calibration fails repeatedly: Main board/compass issues 145.20. Performance issues: Edge mowing is not completed 145.21. 'Wire too close' message: Learn wire sensors is needed 155.22. 'Mowing problem' message 155.23. Automatic mowing problems: Wire sensors contacts corroded 165.24. Front wheel problem: Front wheel contact 175.25. Bumper issues: Bumper is disconnected 175.26. Bumper issues: Bumper sounds without hitting an obstacle 175.27. Bumper issues: Bumper is pressed 185.28. Performance issues: RoboMower doesn't advance is scan mode... 185.29. Mower stops driving but blades run in Scan mode 195.30. Doesn't respond: Underside was exposed to excessive water 19

6. Display messages meaning 207. Diagnostics fault table and meaning 21

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 2For units serial number starting with IRLOO, IRL01, IRL02

1. Tools recommended1.1. A digital voltmeter. Could be a simple one but digital is highly recommended.1.2. A flat tip screwdriver.1.3. A mowing motor removal tool (TOL0001A).

1.4. A #20 Torx tool. (For drive motor removal only).1.5. Large tweezers1.6. A carpeted workbench with a perimeter wire and perimeter switch attached at its

base.

1.7. An indoor test area. Recommended size no less than 8x8 feet. The wire could belaid on the floor under a carpet or attached to it with tape. For wire diagnostics it isrecommended to have at least a 20x20 feet area. Advanced wire sensordiagnostics could be done on any size of plot.

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003For units serial number starting with IRLOO, IRL01, IRL02

2. RoboMower layout and main components2.1. Top view

Front

Front liftinghandle

Left side

Left rear wheel

Operating light

Power packLifting handle

Frontbumper

Manual controllerholder (cradle)

Manualcontroller

Right side

Right rear wheel

Power pack(Battery pack)

Power packterminals polarity

Negative (

Positive (+)' 30 amp fuse


2.2. Bottom viewNote: Mower sides are determined by its top view.

Front

Front locks - 4Semi curved

Right side

Right mowingmotor/blade

Center mowingmotor/blade

Right rear

Drainage

Front wheel

Manualcontroller

Left side

Leftmowing

Left rear

Rear locks - 6straight ones

Rear


2.3. Inside main components

Front

Front wire

Frontwheel lock

Left mowingmotor

Left odometerboard

Left odometerboard


Front bumperWires & tabs

Right

Main board

Right odometer

Right drive motor

Left rear

Rear wheels heightadjustment handle

Rear


3. Opening the RoboMower3.1. Remove power pack and put the RoboMower on a carpeted workbench.

Note: A carpet or a soft clean cover is needed in order to prevent scratching.3.2. Take manual controller out of its cradle.3.3. Tilt the cradle up and pull it up until pivots slide out completely.3.4. Remove the black connector board cover by pinching its tabs and pulling it up.3.5. Remove the two fuses.3.6. Unhook the white two wires connector and leave it there.3.7. Turn mower upside down and remove all three blades. Using a flat screwdriver,

remove all ten black plastic locks. It is recommended to put the four front roundones separately from the straight ones.

3.8. Put the RoboMower back on its wheels.3.9. Hold the middle of the front bumper with one hand and pry the yellow cover by

pulling it at the front handle area. It should come out as one piece and put aside.3.10. Put the battery pack contacts, mower side, back to their place on the gray wall of

the battery pack compartment. Red contact should be on the left side whenstanding behind the mower looking at its front.

4. Closing the RoboMower4.1. Make sure the rubber seals (bumper end seals) at the rear wheels slide area are

positioned properly, mounted on the lower gray part of the mower.4.2. Make sure the fuses are taken out from the connector board.4.3. Make sure all wires are connected, battery contacts positioned properly and

mowing motor cables are not above the main board.4.4. Take the top yellow part and position it above the lower part. Use the square

battery case compartment for aligning the top part with the lower gray part.4.5. Push the yellow part against the battery contacts some 1/3 of an inch forward

and look at the connector board area to make sure the yellow top part isn'tpushed against the connectors board, which should go into its hole in the yellowpart without being touched.

4.6. Once the top yellow part is positioned correctly in a way that will not harm theconnector board, push it down. You may need to guide the two yellow legs at thebattery compartment base area to guide them in the holes at the gray lower part.

4.7. Hit the top part with your open palms a few solid hits to make sure it got into thelower gray part.

4.8. Turn the mower upside down and make sure the rubber seals and the rear wheelaxle area are positioned properly and none escaped aside. If a rubber seal hasescaped and is pushed outside the plastic parts, reopen the mower and readjustit.

4.9. Lock the black plastic locks into their place. Use the four curved ones at the front.4.10. Put the mower back on its wheels and return the following parts to their original

location: Fuses, manual controller and manual controller holder.4.11 .Make sure these are done: Manual controller cable is bent down and its rubber

piece is stuck into its groove. Yellow charging lines are bent down into the frontgroove. Than close connector board cover. Make sure it locks into its place bytrying to pull it out without pressing its tabs.

4.12. Put the battery pack back into the mower and make sure it wakes up.


5. Typical technical problems and their solution5.1. Mower doesn't respond: Low voltage power packProblem• The RoboMower doesn't respond to power pack insertion or charger plug. Sometimes

it will make "clicking" noise and sometimes the display shows flickering dark squares.• Power pack voltage is below 13 volts. (Below 1-4 VDC, power pack may be beyond

revival).Resolution• Check power pack fuse. Replace it if blown. (30 amp, green automotive fuse).

(FUS0003A).» Find out why power pack voltage is so low: Was charging neglected? Is the charger

ok? Was the power pack left in the mower while not charging? Does it say 'Fullycharged' usually at the end of the charging?

• Charge externally using a power pack fast external charger. (MRK0011B).• If you do not have a power pack external charger, recharge the power pack with a

regular car battery charger, at 12 VDC overnight, at no more than 3 amperes, andthen insert the power pack to the mower, which should now wake up. Try to chargeregularly at the mower. The right hand power pack connector (when facing you) is thepositive (+) one. A regular car battery charger charges up to 13 VDC.

• If power pack cannot be revived, replace it. (UNT0009A)• Tech tip: power pack voltage levels: 25-27 VDC is fully charged. 22-23 VDC is when it

displays 'Recharge Bat.' message. Below 13 VDC the mower will not wake up orrecognize the charger. A good power supply plug voltage outcome is 38-42 VDC.Below 32 VDC - power supply is faulty.

• In rare cases, inserting the power pack lights up the operation light but there is nodisplay on the manual controller. This could indicate a faulty manual controller. Try toswap it with a new one and see if it works. Replace if needed (MSB0114A).

• If mower doesn't respond and power pack and manual controller are fine, Check andreplace at this order: Main fuse (FUS0012A), Connectors board (ESBC021C), Mainboard (SPP0021A). In case you have replaced the main board the following settingneed to be done through 'Service' menu:

1. Learn wire sensors inside an active loop of wire. (See 5.21)2. Set country to USA.3. DK calibration (In some occasions, twice).4. Edge calibration (Could be done anywhere, even in an unwired

area).

5.2. Charging problem: Power supply (regular mower charger) faultyProblem• 'Charging problem' appears on display + beeping sound, 10 seconds from plugging

the power supply plug to the charging socket.• Power supply outcome voltage is below 32 VDC.• Tech tip: A good power supply lets out 38-42 VDC. In rare cases, the reason for the

low power supply voltage could be a very low AC voltage at the wall, due to excessiveuse by other power supplies. In this case, use another wall outlet.

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 gFor units serial number starting with IRLOO, IRL01, IRL02

Resolution• Replace the power supply with a good one. (PWS0003A)• Mark the bad power supply for not using it anymore.

5.3. Charging problem: Charging fuse is faultyProblem

• 'Charging problem' appears on display + beeping sound, 10 seconds fromplugging the power supply plug to the cradle socket.

• The battery pack and power supply voltage is fine.• The charging fuse, orange, 5 amp is faulty/corroded. Tested with a voltmeter on

resistance scale, it shows 1 or no continuity at all. A good fuse gives 0.2-0.3 ohmsresistance.

ResolutionReplace the fuse and make sure mower is charging ok. (FUS0015A)

5.4. Charging problem: Manual controller holder faultyProblem• 'Charging problem' appears on display + beeping sound, 10 seconds from plugging

the power supply plug to the cradle socket.• Sometimes 'Charging' message appears when inserting the battery pack into the

mower- even without attempting to charge at all.Resolution• Replace the manual controller holder. (MSB0105B).

5.5. Charging problem: Other charging problemsProblem

• 'Charging problem' appears on display + beeping sound, 10 seconds fromplugging the power supply plug to the cradle socket.

• Power supply outcome voltage is above 32 VDC.• Charging fuse is fine.

ResolutionCheck and replace until problem is solved the following parts:

• Connectors board (ESBC021C).Flat cable wire bundle (WSB0052A).

• Main board (SPP0021A).• In case you have replaced the main board the following setting need to be done

through 'Service' menu:o Learn wire sensors inside an active loop of wire. (See 5.21)o Set country to USA.o DK calibration (In some occasions, twice).o Edge calibration (Could be done anywhere, even in an unwired

area).


5.6. Charging problem: External charging problemsProblem

• External charger lights are off even though it is connected to good AC power outletand its operating switch is on 1.

Resolution• Check the glass fuse in the charger and replace it if needed. (FUS0021 A).• If replacing the fuse doesn't fix it, replace the fast charger. (MRK0011B).

5.7. Manual controller problems: keys do not respondProblem

• One or more buttons do not respond.Resolution

• Manual controller was exposed to water or excessive humidity. Somebutton contacts have corroded. On rare cases could happen to a newmower taken out of the box.

• Get to Diagnostics, press green button, scroll up to 'Buttons', green buttonagain and play with the non responsive button many times till it responds.

• If it doesn't respond, replace manual controller. (MSB0114A).

5.8. Manual controller problems: Keypad is tornProblem

• Keypad is torn, usually at the steering pad area.Reso/t;f/on

• Replace manual controller. The new ones have a thicker, way moredurable rubber keypad that will not get torn again. (MSB0114A).

5.9. Manual controller problems: No automatic mode displayProblem

« Manual controller display remains on 'Manual settings' rather than changing toautomatic mode display when manual controller is in its cradle and flushed with themower yellow top surface.

Resolution• Make sure manual controller is flushed with the surface.• Replace manual controller. (MSB0114A).

5.10. Manual controller problems: Emits a squealing noiseProblem

• Manual controller emits a squealing noise.Resolution

• Replace it. (MSB0114A).

5.11. Perimeter switch problems: P.Switch doesn't turn onProblem

• Perimeter switch doesn't respond when green button is pressed.• Batteries inside it are fine/new.

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 JQFor units serial number starting with IRLOO, IRL01, IRL02

Resolution• Make sure the 'C' batteries inside are good. Test it with new ones.• Replace perimeter switch. (UNT0007B).• If there are watermarks or water inside the perimeter switch, check with

customer how and where was the perimeter switch mounted. It could bemounted and left outside, but it got to be mounted vertically!

• If it wasn't mounted vertically and got water penetration, it isn't covered bywarranty! The customer should purchase a new one.

5.12. Perimeter switch problems: P.Switch indicates low batteriesProblem

• Perimeter switch indicates low batteries with good/new batteries.Resolution

• Make sure the C-cell batteries inside are good. Test it with new ones.• Connect a small loop of wire to the perimeter switch green connector and

see if it keeps showing the low battery indication. If it does - replace it.(UNT0007B).

• If it behaves ok with this small loop of wire, it means there is a perimeterwire problem with the customer's installed area: The perimeter wire couldbe longer than 900 feet, a corroded or a bad splice in the perimeter wire.Check and fix the wire and splices as needed.

• There is a remote possibility that the perimeter switch is ok but showsbattery low indication by mistake, while intending to show wire cutindication. Fixing the perimeter wire will cure this problem.

5.13. Perimeter switch problems: P.Switch wires came outProblem

• Perimeter switch wires came out of the green fast connector.Resolution

• Replace these wires with new molded ones. (WSB0025B) by opening theperimeter switch and releasing the broken ones from the connectors.

5.14. Drive/Gear problems: Mower doesn't drive properlyProblem (a combination of the following)

• One or both rear wheels are not driving properly while manually orautomatically driven.

• One or both rear wheels are physically stuck - can't rotate them by hand.• One or more rear wheels are rotating loose - as if not connected to the

gears.• Unit goes in tight circles rather than a straight line.• 'Odometer problem' on the display. (Usually a good indication the main

board is faulty)Resolution

• Remove the power pack and try to rotate each of the rear wheels by hand.Try to determine whether there is a difference in feel or friction betweenthe two or whether one of them is stuck or loose.

10

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 j ]For units serial number starting with IRLOO, IRL01, IRL02

• Put the battery pack in the mower and place an object under the mower,between the rear wheels, so they will be able to rotate without touchingthe ground. The front wheel needs to remain solidly on the ground.

• Try to drive the mower manually and see the rear wheel behavior, whichone is stuck or not moving.

• Get to 'Service key', insert password 12321, press green button twice andscroll down to 'Drive motors'. Green button to activate and another toconfirm. This will result in a 'Passed' or 'Failed' message. When it fails, itwill also give an error number, which will look like this: Failed # 201. Thisis only an example and error # 201 is for Left motor disconnected. Faultserror list - see chapter 7.

• Press C and you will be back to 'Drive motors' test. If you press the greenbutton 3 times now, you will do an advanced test, which will show the rawodometers reading on each drive motor. The top line of the display willshow the MSR - measured RPM of both drive motors and the bottomdisplay line will show PWM - the current needed to get to this RPM oneach drive motor.

• These raw reading numbers can tell us a lot about the drive motors. Canthe mower equalize their speed? The MSR numbers will be identical. Isthere a different friction on one drive motor and gears? The PWM willshow it and be higher on the side the friction is larger.

• 00 or no reading at all on any of the advanced diagnostics display usuallymeans the main board is faulty.

• Open the mower and inspect drive motors pinion, gears, tabs and wires.• Make sure none of the wires is disconnected.• Replace drive motor if pinion is melted/damaged. (SPP0008B).• Replace drive motor cables id broken or darkened by heat. (WSB0063A).• Replace main board if diagnostics showed it is faulty. (SPP0021 A).• In case you have replaced the main board the following setting need to be done

through 'Service' menu:1. Learn wire sensors inside an active loop of wire. (See 5.21)2. Set country to USA.3. DK calibration (In some occasions, twice).4. Edge calibration (Could be done anywhere, even in an unwired

area).

5.15. Drive/Gear problems: Growling noise from rear wheelsProblem

• One or both rear wheels bushing type bearing needs lubrication.• Gear teeth are broken. (Very rare. In this case you will hear more of a

clicking sound)Resolution

• Remove the rear wheels using a flat screwdriver and snap ring pliers.• Use a silicone based non-flammable spray lubricant, with its nozzle on.

Insert the nozzle in between the metal wheel axle and the black plastic

11

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 |2For un'rts serial number starting with IRLOO, IRL01, IRL02

wheel spline and squirt generously. The lubricant will penetrate to the gearcase and lubricate the gear bushing which makes the noise.

• In case it doesn't help, open the mower and squirt directly on the plasticgears base/bushing. (White plastic part).

• Do not lubricate the gear teeth at all. It isn't needed.• In case the rear wheels sound is more of a clicking nature, rotate each

wheel and see if you can feel gear teeth are missing/broken.• Open the mower and replace the gear case. (SPP0004B). The gear case

will come with drive and mowing motor Thermistors attached to a cablethat can connect only to a new version main board, but can work with anold version main board without connecting to it. Thread the wires throughthe white wire holders towards the front of the mower in a way that willprevent the wires getting close to the gears or drive pinion. Replace theright mowing motor shield with the one that is attached to the Thermistorscable.

• In the future, in case a main board will be replaced on this mower with anew version one which is compatible with the Thermistors, theThermistors cable would be connected to it.

5.16. Drive/Gear problems: Rear wheels height adjustment handlebroken

Problem• Mower is lower at one side.• One or two rear wheels grind into the yellow top cover above them.• Rear handle noticed broken at the battery pack compartment.

Resolution• Open the mower and replace gear frame. (SPP0015A).• Try and find how it happened - maybe customer is doing something

wrong with it, like sitting on the mower or dropping it etc.

5.17. Drive/Gear problems: Rear wheels spin, loosing trackProblem

• Wheels are spinning while mower is stuck.• Could be slick wheels on an older generation mower.• Rear height adjustment could be set too low for the grass conditions.• Mower can be stuck against an obstacle, a ditch etc, not allowing it to

advance and too low or high for activating the bumper.• Grass could be very spongy, high, dense, wet or on a slope exceeding 15

degrees.Resolution

• If mower has sleek wheels, offer customer an upgrade to knobby wheels,which includes knobby wheels (MSB0099A), a rear wheels height limiterand the latest RL500 software version available, 3.2. (Get the brain on acase by case basis, directly from Friendly North America)

Note: This is not a warranty issue and customer should pay for it.• Raise rear wheels to highest position (handle at its lowest possible).

12

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 ] 3For units serial number starting with IRLOO, IRL01, IRL02

• Improve installation if needed.

5.18. Wire crossing in automatic mode: Wire sensors or main boardissues

Problem• Mower crosses the wire in Edge or Scan mode.

Resolution• Position the mower inside an active plot (inside the perimeter wire loop, with the

perimeter switch turned on, a few feet from the wire).• Test wire sensors through Diagnostics/wire sensors. If it fails look up the

failure code at the Error faults table. (Chapter 7).• Diagnose again at Diagnostics/wire sensors/advanced.• If one wire sensor reading is around zero or significantly lower than the

others, open the mower and play with this wire sensor connector. If thereading gets as high as the rest of them, the contact is bad/corroded.Replace wire sensors: The spare part is all four of them connected to oneharness. (SPP0018A). Perform Learn wire sensors inside an active wiredarea and Edge calibration through Service key 12321 and Diagnosticsmenu.

• The rear right wire sensor, which serves as a rear bumper connector aswell, should be left in the mower, attached to the rear bumper wires. Thebest place to put it is at the hollow corner of the gray mower base at therear right area.

• If the low wire sensor reading doesn't improve while playing with the contacts orreplacing the wire sensors, replace main board. (SPP0021 A).

» In case you have replaced the main board the following setting need to be donethrough 'Service' menu:

o Leam wire sensors inside an active loop of wire. (See 5.21)o Set country to USA.o DK calibration (In some occasions, twice).o Edge calibration (Could be done anywhere, even in an unwired

area).• In rare cases you may find the wire sensor itself is faulty. In this case replace all four

wire sensors with a new one. (SPP0018A).• In case you have replaced the wire sensors the following setting need to be done

through 'Service' menu:o Leam wire sensors inside an active loop of wire. (See 5.21)o Edge calibration (Could be done anywhere, even in an unwired

area).

5.19. DK calibration fails repeatedly: Main board/compass issuesProblem

• Mower keeps ending DK calibration with a 'Retry elsewhere' message ondisplay. Very rarely the display could say 'Failed = 18'.

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 }4For units serial number starting with IRLOO, IRL01, IRL02

Resolution• Make surer GEO location is set on USA.• Retry on smoother surfaces on the lawn or even on a sidewalk. This has nothing to

do with the perimeter wire and could be done anywhere.• Suspect a faulty main board (compass) only after trying to perform DK

calibration many times in different locations.• Diagnose the compass through 'Diagnostics/Direction keeper. Perform the

test a few times in different directions, since it is a sensitive one. Manytimes it will fail on error #530 but will pass the test in a different direction.Once it passes the test, it is a good compass.

• If it keeps failing, replace main board. (SPP0021A).• After replacing main board, you will need to do the following:

o Learn wire sensors inside an active loop of wire. (See 5.21)o Set GEO location to USA.o DK calibration.o Edge calibration (Could be done anywhere, even in an unwired

area).

5.20. Performance issues: Edge mowing is not completedProblem

• Mower leaves Edge and starts mowing the inside of the plot prior tocompleting one full circle around it.

• There isn't an obstacle on edge that makes it leave the wire. (In casethere is, it is an installation issue that could be fixed by adjusting the wire).

Resolution• Do another DK calibration. This is a compass issue and another calibration may fix

it.• If it doesn't help, replace main board. (SPP0021 A).• In case you have replaced the main board the following setting need to be done


area).• If this doesn't help, perform 'Learn edge' through 'User options' when

manual controller is in its cradle, which teaches the mower the true lengthof the edge to be done. (Available now since the new main board comeswith RL550 software).

5.21. 'Wire too close' message: 'Learn wire sensors' is neededProblem

• Mower refuses to start working in automatic mode, indicating 'Wire tooclose' while it isn't close to the wire at all.

• This is common after replacing a wire sensor or a main board. Could alsohappen to a new mower out of the box, on its first automatic operation.

14



perimeter switch turned on, a few feet from the wire).• Get to 'Service key' and insert password 12321. Green button to confirm.• In Diagnostics, scroll to 'Learn wire sensors' and perform it. When done it

will say 'Was X now Y' meaning 'Learn wire sensors' happened. Press thegreen button again (Very important!) in order to finish the process.

• Put the manual controller back into the mower and operate itautomatically.

• If you just replaced a main board on this mower, you need to set GEOlocation and do another DK calibration prior to being able to work inautomatic mode.

• If 'Learn wire sensors' didn't help, replace main board, (SPP0021 A).• In case you have replaced the main board the following setting need to be done

through 'Service' menu:o Leam wire sensors inside an active loop of wire.o Set country to USA.o DK calibration (In some occasions, twice).o Edge calibration (Could be done anywhere, even in an unwired

area).

5.22. Mowing problem messageProblem

• Mower stops mid work indicating 'Mowing problem' message on display.Resolution

• Check whether the grass is too high or dense. If it is due to grassconditions, wait 20 minutes and operate again. In some occasions thegrass should be mowed first with a heavier type mower, in order to reduceits height.

• Remove power pack and check whether grass has clogged the bladesarea. Try to rotate each blade (carefully, wearing a glove) and make sureall blades rotate easily and freely. Dull blades should be replaced.

• If a 'Mowing problem' happens without any of the above conditions, testthe mowing motors through Service password 12321, Diagnostics/Mowingmotors.

» If a mowing motor is found faulty, open the mower and replace it.(MSB0065B). If replacing it doesn't solve the problem, it could be themowing motor cables (WSB0053A) or the main board faulty.

• Check the mowing motor wires for discoloration. If they overheated youwill see wire tabs or wires with brown/black discoloration.

• In case mowing motors and wires are ok, it is a faulty main board. (SPP0021A).• In case you have replaced the main board the following setting need to be done

through 'Service' menu:1. Learn wire sensors inside an active loop of wire. (See 5.21)2. Set GEO to USA.3. DK calibration (In some occasions, twice).

15

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 ] 5For units serial number starting with IRLOO, IRL01, IRL02

4. Edge calibration (Could be done anywhere, even in an unwiredarea).

5.23. Automatic mowing problems: Wire sensors contacts corrodedProblem

• Unit stops mid work often, indicating 'User help needed'. Or• Upon initiating automatic mode, unit doesn't operate showing 'No wire

signal' on display. (Perimeter switch is turned on).Resolution

• Inside an active perimeter wire, mower positioned in the middle, test wiresensors through Diagnostics/Wire sensors/Advanced.

• If one wire sensor shows a very low reading (000-006), while other wiresensors reading are high, it probably means this wire sensor contact iscorroded or a faulty wire sensor. It could also be that one sensor readingis 20-30 while the rest of them are showing a lot higher reading, such as60-200. In both faults the remedy is replacing the wire sensors plus theirharness.

• Open the mower and play with this contact. If it cures the reading, addsome anti corrosion spray or ointment.

» Replace the wire sensors with harness (all four of them). (SPP0018A).If this doesn't help, replace main board. (SPP0021A).

• In case you have replaced the main board the following setting need to be donethrough 'Service' menu:

o Learn wire sensors inside an active loop of wire. (See 5.21)o Set country to USA.o DK calibration (In some occasions, twice).o Edge calibration (Could be done anywhere, even in an unwired

area).

5.24. Front wheel problem: Front wheel contactProblem

• Unit stops mid work often, indicating 'User help needed'. Or• Upon initiating automatic mode, unit doesn't operate, displaying 'Front

wheel problem'. Or• Unit displays 'Front wheel problem' constantly.

Resolution• Test front wheel through Diagnostics/front wheel sensor.• If it indicates 'Lifted' while the front wheel is on the ground, the front wheel

contact is corroded.• Remove battery pack, lift the mower and lean it against something so you

can reach the front wheel easily.• Using a small flat tip screwdriver unlock the front wheel plastic lock and

rotate the wheel base counter clock wise till it comes out.• Unplug the contacts and put an anti corrosion ointment on the contacts. If

you do not have any, unplug and plug the connector 20-30 times and it will

16


remove the corrosion. Test front wheel sensor again. It should say 'On theground' when not lifted.

• In case this doesn't cure the problem, open the mower and replace frontwheel drop-off board. (SPP0005A).

• If this doesn't help, replace main board. (SPP0021 A).• In case you have replaced the main board the following setting need to be done


area).

5.25. Bumper issues: Bumper is disconnectedProblem

• Unit shows 'Rear or Front bumper disc' on display constantly.Resolution

• Open the mower and find the disconnected wire.• This is more common in rear bumpers, where the white wire disconnects

from the bumper spring at the soldering.• Solder the wire to the spring. In case you cannot solder it, replace the

bumper. Use soapy water or a silicone/Teflon based lubricant at thebumper inserts for easy removal and insertion of the new one. No tool isneeded for removing and replacing the new one. Lubricate the newbumper trapeze shaped inserts prior to installing it back to the mower.Rear bumper (MSB0107A). Front bumper (MSM0106A).

5.26. Bumper issues: Bumper sounds without hitting an obstacleProblem

• Unit sounds the bumper 'Boing' sound without hitting a real obstacle.• Unit stops often with no apparent reason.

Resolution• Hit the top yellow flat part of the mower, between manual controller area and front

handle, with your open hand, to find out if this activates the bumper. (Boing sound).• If it does, the bumper is oversensitive.• Touch the bumper all around to find out which one is the sensitive one. A normal

bumper will be pushed in a 1/8 - % of an inch before activated. The sensitive areawill be where merely touching the bumper will activate it, indicating regularoperation vibrations will activate it.

• Open the mower and replace the oversensitive bumper.Rear bumper (MSB0107A). Front bumper (MSM0106A).

5.27. Bumper issues: Bumper is pressedProblem

• Unit displays 'Front or Rear bumper pressed' message constantly.

17

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 ] gFor units serial number starting with IRLOO, IRL01, IRL02

Resolution• Squeeze the appropriate pressed bumper and try to see if it is just a case of

mower stored with the bumper pressed against an obstacle, which may temporarycure the rubber in dented way pressing it all the time. (Check with the customer ifthis is the case).

• If this doesn't cure it - replace the faulty bumper.Rear bumper (MSB0107A). Front bumper (MSM0106A).

5.28. Performance issues: RoboMower doesn't advance is scan modeProblem

• Unit keeps going back and forth on the same lines without advancingsideways.

Resolution• This is a 3.2 version problem that can happen rarely.• Replace main board. (Comes with a new RL550 software version).

(SPP0021A).• Test the mower with the new software. If it problem still exists, go to User

preferences and choose 'Wide scan'. This will open wider angles betweenmowing lines and will solve the problem.



area).• In case this doesn't help, especially if mower has a magnetic interference

in the yard deviating the compass and mowing in curved lines, go toService menu and set 'Enable DK' to off.

5.29. RoboMower stops driving but blade keeps on in Scan modeProblem

• Unit stops driving and stands there with blades engaged.Resolution

• This is a 3.19 (or lower) software version problem that can happen very rarely.• Replace main board with an updated software version. (SPP0021 A).• In case you have replaced the main board the following setting need to be done


area).• If the mower has slick wheels, choose 'Small wheel' option in Service

menu.

18


19

5.30. Doesn't respond: Underside was exposed to excessive waterProblem

• Unit doesn't respond at all after being exposed to rain, sprinklers orexcessive water while being cleaned. Typical if the mower was positionedupside down and excessive water was used at the blades area.

Resolution• In most cases, the faulty part is the manual controller.• Swap the manual controller and see if mower wakes up and operates.• If this is the case, try and dry the wet manual controller by opening it and

letting it sit in a dry area for a while.• Replace manual controller if the faulty one doesn't recover. (MSB0114A).• In more severe cases, water got into the mower and got to the electronics

inside onto the main board. In this case, a new manual controller will notget it to wake up.

« Open the mower and assess the water damage.• Replace main board if needed. (SPP0021 A).• In case you have replaced the main board the following settings need to be done


area).

6. Display messages meaning

Message

Blocked path

Calibration Req.

Check Power

ChargingproblemRecharge Bat.

Failed K=18

Front wheelproblem

Explanation- Bumper pressed during warm up.- Bumper pressed for 2 sec during manual mowing.- A D.K calibration is required (only in the first operation)- The charger is connected but not charging, usually happens

upon initiating charging (there is no power from the powersupply)

- The charger is connected but not charging (Probably faultyMain Board).

- Charge the RoboMower- Appears during the D.K calibration and indicates that the

coils on the electronic compass are probably disconnected.

- The front wheel is not touching the ground for too long.

19


20

Front/RearbumperdisconnectedFront/Rearbumper pressed

Keys locked

'X' Key pressed

MowingDisabled

Mowing problem

No wire signal

Drive Problem

Motor OVC

Path problem

Retry Elsewhere

Set GEOLocationTime!

Wire too close

- There is a problem with Drop-off board.

- Bumper wire disconnected inside the RoboMower.


- Child guard set to 'on' - Press the scroll upper arrow andthen C to enable mowing.

- One of the keys on the manual controller is pressedcontinuously upon reset.

- When activating motors under 'Diagnostics' but 'mowing' isset 'off

- Mowing motors have faced over-current for too long or someobstacle is stuck or wrapped around the blades.

- The RoboMower cannot detect a signal from the PerimeterWire.

- One of the odometers is not reading a signal from the magnetson the drive motor.- Drive motors have faced overheating - the mower stops forcooling.-Bumper hits an obstacle in less than 2 feet from mowing initiatioi- There is a problem with the compass readings (during DK

Calibration or as pressing the 'GO' button).

- GEO location is not set (Set your country)

- Displayed when the time set on 'Work time' is reached.- The RoboMower is too close to the perimeter wire or on thewire itself. Or, a 'Learn wire sensors' needs to be performed.

7. Diagnostics fault table and meaning.

Fault*100

101

102

110

111

DiagnosedDrivemotors(Forward)Drivemotors

JForward)Drivemotors(Forward)Drivemotors(Forward)Drive

MeaningRight motorcurrent< 100mA

Left motorcurrents 100mA

Right & Left motorscurrent< 100mA

Right odometerreading=0

Left odometer

Possible causeRight motor is disconnected

Left motor is disconnected

Right & Left motors aredisconnected

Right odometer is disconnected

Left odometer is disconnected

20


21

112

120

121

121

130

131

140

141

142

Fault*143

200

201

202

210

motors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)

TestedDrivemotors(Forward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors^Backward)Drivemotors(Backward)

reading=0

Right & Left odometerreading=0

Right motor pwm>95%

Left motor pwm>95%

Right & Left motorspwm>95%

Right wheel pwm>Leftwheel pwm

Left wheel pwm>Rightwheel pwm

Right pwm<78 or >82

Left pwm<78 or >82

Right & Left pwm<78or>82

MeaningMeasured PWMdifference >2

Right motorcurrent< 100mA

Left motorcurrent< 100mA



Right & Left odometers aredisconnected

Right wheel friction is too high

Left wheel friction is too high

Right & Left wheels friction is toohigh

Right wheel friction>Left wheelfriction, or Right motor is slower thanLeft motorLeft wheel friction>Right wheelfriction, or Left motor is slower thanRight motorTest again

Test again

Test again

Possible causeTest again

Right motor is disconnected



Right odometer are disconnected

21


22

_^

s~

211

212

220

221

222

230

231

240

241

242

Fault*243

301

302

303

304 <

305

306

307

Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors

JBackwardJ^Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)TestedDrive motors(Backward)

MowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowing

Left odometerreading=0

Right & Left odometerreading=0

Right motor pwm>95%

Left motor pwm>95%


Right wheel pwm>Leftwheel pwm

Left wheel pwm>Rightwheel pwm

Right pwm<78 or >82

Left pwm<78 or >82


MeaningMeasured PWMdifference >2Right Motor current >100mAMid Motor current >100mARight + Mid Motorcurrent > 100mALeft Motor current >mrnfc <Right + Left Motorcurrent > 100mAMid+Left Motor current> 100mARight+Mid+Left Motor

Left odometer are disconnected



I




Test again

Test again


Right Motor power unit is faulty

Mid Motor power unit is faulty

Right+Mid Motor power units arefaultyLeft Motor power units is faulty

Right+Left Motor power units arefaultyMid+Left Motor power units arefaultyRight+Mid+Left Motor power units

•

22


23

331

332

333

334

335

336

337

341

342

343

344

345

346

347

Fault*351

352

353

354

motorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotors

TestedMowingmotorsMowingmotorsMowingmotorsMowingmotors

current > 100mARight Motor current <100mAMid Motor current <100mARight+Mid Motorcurrent < 100mALeft Motor current <100mARight+Left Motorcurrent < 100mAMid+Left Motor current< 100mARight+Mid+Left Motorcurrent < 100mARight Motor current >2AMid Motor current > 2A

Right+Mid Motorcurrent > 2ALeft Motor current > 2A

Right+Left Motorcurrent > 2AMid+Left Motor current>2ARight+Mid+Left Motorcurrent > 2A

MeaningRight Motor current >100mAMid Motor current >100mARight+Mid Motorcurrent > 100mALeft Motor current >100mA

356

357

401

motors( R/qht+Left Motor

current > 100mA

are faultyRight Motor is disconnected

Mid Motor is disconnected

Right+Mid Motor are disconnected

Left Motor is disconnected

Right+Left Motors are disconnected

Mid+Left Motors are disconnected

Right+Mid+Left Motors aredisconnectedRight Motor is overloaded

Mid Motor is overloaded

Right+Mid Motors are overloaded

Left Motor is overloaded

Right+Left Motors are overloaded

Mid+Left Motors are overloaded

Right+Mid+Left Motors areoverloaded

Possible causeRight Motor stopping is faulty

Mid Motor stopping is faulty

Right+Mid Motors stopping is faulty

Left Motor stopping is faulty

MowingmotorsMowingmotorsWire

Mid+Left Motor current> 100mARight+Mid+Left Motorcurrent > 100mAFR sensor <2

R/ght+Lefi Motors stopping is faulty

Mid+Left Motors stopping is faulty

Right+Mid+Left Motors stopping isfaultyFR sensor is disconnected

23


24

<

/•—•

402

403

404

405

406

407

408

409

410

411

412

413

414

415

Fault*421

422

423

424 (_

425

426

427

428

sensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensors

TestedWiresensorsWiresensorsWiresensorsWre (I S

sensorsWiresensorsWiresensorsWiresensorsWire

FL sensor<2

FR+FL sensors<2

RR sensor<2

FR+RR sensors<2

FL+RR sensors<2

FR+FL+RR sensors<2

RL sensor<2

FR+RL sensor <2

FL+RL sensor<2

FR+FL+RL sensors<2

RR+RL sensor<2

FR+RR+RL sensors<2

FL+RR+RL sensors<2

FR+FL+RR+RLsensors<2

MeaningFR sensor is noisy

FL sensor is noisy

FR+FL sensors arenoisyRR sensor )s noisy

FR+RR sensors arenoisyFL+RR sensors arenoisyFR+FL+RR sensorsare noisyRL sensor is noisy

FL sensor is disconnected

FR+FL sensors are disconnected

RR sensor is disconnected

FR+RR sensors are disconnected

FL+RR sensors are disconnected

FR+FL+RR sensors aredisconnectedRL sensor is disconnected

FR+RL sensor are disconnected

FL+RL sensor are disconnected

FR+FL+RL sensors aredisconnectedRR+RL sensor are disconnected

FR+RR+RL sensors aredisconnectedFL+RR+RL sensors aredisconnectedFR+FL+RR+RL sensors aredisconnected

Possible causeFR sensor is noisy

FL sensor is noisy

FR+FL sensors are noisy

RR sensor )s noisy

FR+RR sensors are noisy

FL+RR sensors are noisy

FR+FL+RR sensors are noisy

RL sensor is noisy

24


25

429

420

431

432

433

434

435

450

500

510

523

525

526

527

Fault*529

530

531 /

sensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeper

TestedDirectionKeeperDirectionKeeper

Direction ,

FR+RL sensor arenoisyFL+RL sensor arenoisyFR+FL+RL sensorsare noisyRR+RL sensor arenoisyFR+RR+RL sensorsare noisyFL+RR+RL sensorsare noisyFR+FL+RR+RLsensors are noisyBeat rate problem

Low resolutionreading=0Low resolutionreadings are noisyCoils 1 +2 cannot bezeroedCoils 1+3 cannot bezeroedCoils 2+3 cannot bezeroedCoils 1+2+3 cannot bezeroed

MeaningCoils 1+3 cannot bezeroedCoils 2+3 cannot bezeroed

Co))s 1+2+4 cannot be

FR+RL sensor are noisy

FL+RL sensor are noisy

FR+FL+RL sensors are noisy

RR+RL sensor are noisy

FR+RR+RL sensors are noisy

FL+RR+RL sensors are noisy

FR+FL+RR+RL sensors are noisy

Beat rate problem

Direction keeper is faulty

Direction keeper is noisy

Magnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnected

Possible causeMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnected

Magneto interference or coils

532

533

534

535

KeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeper

zeroedCoils 3+4 cannot bezeroedCoils 1+3+4 cannot bezeroedCoils 2+3+4 cannot bezeroedCoils 1+2+3+4 cannotbe zeroed

disconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnected

25

Friendly North America, Inc. Sen/ice Guide 2003 Updated: 3/26/2003 76For units serial number starting with IRLOO, IRL01, IRL02

26

RL 550/800

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 jTo be used with RoboMower serial number starting with IRL03...

RL550/800 Service Guideo It is highly recommended to watch the service video clips, on the Dealer CD, prior to servicing a

RoboMower.

Table of contents Page

1. Tools, bench and work area recommendations 22. RoboMower layout and main components 3

2.1. Top view and power pack terminals polarity 32.2. Bottom view 42.3. Inside main components 5

3. Opening the RoboMower (See video clip on Dealer CD or Service Video)... 64. Closing the RoboMower (See video clip on Dealer CD or Service Video).... 65. Typical technical problems and their solution

5.1. Mower doesn't respond: Low voltage power pack and other reasons. 75.2. Charging problem: Power supply (regular mower charger) faulty 85.3. Charging problem: Charging fuse is faulty 85.4. Charging problem: Manual controller holder is faulty 85.5. Charging problem: Other charging problems 85.6. Charging problem: External charging problems 95.7. Manual controller problems: Keys do not respond 95.8. Manual controller problems: Keypad is torn 95.9. Manual controller problems: No automatic mode display 95.10. Perimeter switch problems: P.Switch doesn't turn on 95.11. Perimeter switch problems: P.Switch indicates low batteries 105.12. Drive/Gear problems: Mower doesn't drive properly 105.13. Drive/Gear problems: Rear wheels height adjustment handle broken... 115.14. Drive/Gear problems: Rear wheels spin, loosing track 115.15. Wire crossing in automatic mode: Main Board/wire sensors issues 115.16. DK calibration fails repeatedly: Main board/compass issues 125.17. Edge mow is not completed: Performance issues 135.18. 'Move from wire' message: Learn wire sensors is needed 135.19. Mowing problems 145.20. Automatic mowing problems: Wire sensors reading problems 145.21. Frontwheel problem 155.22. Bumper issues: Bumper is disconnected 155.23. Bumper issues: Bumper sounds without hitting an obstacle 155.24. Bumper issues: Bumper is pressed 165.25. Performance issues: RoboMower doesn't advance is scan mode 16

6. Display messages meaning 177. Diagnostics results - fault table and meaning 19

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 2To be used with RoboMower serial number starting with IRL03...

1. Tools recommended1.1. A digital voltmeter. Could be a simple one but digital is highly recommended.1.2. A flat tip screwdriver.1.3. A mowing motor removal tool (TOL0001A).

1.4. A #20 Torx tool. (For drive motor removal only).1.5. Large tweezers1.6. A carpeted workbench with a perimeter wire and perimeter switch attached at its

base.

1.7. An indoor test area. Recommended size no less than 8x8 feet. The wire could belaid on the floor under a carpet or attached to it with tape. For wire diagnostics it isrecommended to have at least a 20x20 feet area. Advanced wire sensordiagnostics could be done on any size of plot.

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003To be used with RoboMower serial number starting with IRL03...

2. RoboMower layout and main components2.1. Top view

Front

Power packLifting handle

Frontbumper

Manual controllerholder (cradle)

Manualcontroller

Right side

Right rear wheel

Power pack(Battery pack)

Power packterminals polarity

Negative (

Positive (+)' 30-amp fuse

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003To be used with RoboMower serial number starting with IRL03.

2.2. Bottom viewNote: Mower sides are determined by its top view.

Front

Front locks - 4Semi curved ones

Right side


Center mowingmotor/blade

Right rear wheel

Drainage holes

Front wheel

Manualcontroller

Left side

Left mowingmotor/blade

Left rear wheel

Rear locks - 6straight ones

Rear

Friendly North America, toe. Service Guide 2003 Updated: 3/26/2003To be used with RoboMower serial number starting with ERL03...

2.3. Inside main components

FrontFront wheel

Front wire sensors

Front wheellock

Right mowingmotor

Left mowingmotor

Right mowingmotor Thermistor

Center mowingmotor

Front bumperWires & tabs

Rubber seal Main board

ConnectorsDrive gears

Right odometer boardLeft odometerboard Right drive motor

ThermistorLeft odometerBoard Rear wheels height

adjustment handle

Mower serial number

Rear bumperWires & tabs

Rear

5


20

Fault*143

200

201

202

210

211

212

220

221

222

230

231

240

241

242

DiagnosedDrivemotors(Forward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors^Backward)Drivemotors(Backward)Drivemotors(Backward)Drivemotors(Backward)

MeaningMeasured PWMdifference >2

Right motorcurrent< 100mA





Right & Leftodometer reading=0

Right motorpwm>95%

Left motor pwm>95%


Right wheelpwm>Left wheelpwmLeft wheelpwm>Right wheelpwmRight pwm<78 or >82

Left pwm<78 or >82



Right motor is disconnected



Right odometer are disconnected

Left odometer are disconnected






Test again

Test again

20

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 gTo be used with RoboMower serial number starting with IRL03...

3. Opening the RoboMower3.1. Remove power pack and put the RoboMower on a carpeted workbench.

Note: A carpet or a soft clean cover is needed in order to prevent scratching.3.2. Take manual controller out of its cradle.3.3. Tilt the cradle up and pull it up until pivots slide out completely.3.4. Remove the black connector board cover by pinching its tabs and pulling it up.3.5. Remove the two mower fuses from connectors board.3.6. Unhook the white two wires connector and leave it there.3.7. Turn mower upside down and remove all three blades. Using a flat screwdriver,

remove all ten black plastic locks. It is recommended to put the four front roundedged locks separately from the others.

3.8. Put the RoboMower back on its wheels.3.9. Hold the middle of the front bumper with one hand and pry the yellow cover open

by pulling it at the front handle area. Remove the yellow top cover and put itaside.

3.10. Put the power pack contacts, mower side, back to their place on the gray wall ofthe battery pack compartment. Red contact should be on the left side whenstanding behind the mower looking towards the front.

4. Closing the RoboMower4.1. Make sure the rubber seals (bumper end seals) at the rear wheels slide area are

positioned properly, mounted on the lower gray part of the mower.4.2. Make sure the fuses are taken out from the connector board.4.3. Make sure all wires are connected, battery contacts positioned properly and

mowing motor cables are not above the main board.4.4. Take the top yellow part and position it above the lower part. Use the square

battery case compartment for aligning the top part with the lower gray part.4.5. Push the yellow part against the battery contacts some 1/3 of an inch forward

and look at the connector board area to make sure the yellow top part isn'tpushed against the connectors board, which should go into its hole in the yellowpart without being touched.

4.6. Once the top yellow part is positioned correctly in a way that will not harm theconnector board, push it down. You may need to guide the two yellow legs at thebattery compartment base area to guide them in the holes at the gray lower part.

4.7. Hit the top part with your open palms a few solid hits to make sure it got into thelower gray part.

4.8. Turn the mower upside down and make sure the rubber seals at rear wheels axlearea are positioned properly and none escaped aside. If a seal has escaped andis pushed outside the plastic parts, reopen the mower and readjust it.

4.9. Lock the black plastic locks into their place. Use the four curved ones at the front.4.10. Put the mower back on its wheels and return the following parts to their original

location: Ground clearance limiter at rear wheels height adjustment handle area,fuses, manual controller and manual controller holder.

4.11 .Make sure these are done: Manual controller cable is bent down and its rubberpiece is stuck into its groove. Yellow charging lines are bent down into the frontgroove. Than close connector board cover. Make sure it locks into its place bytrying to pull it out without pressing its tabs.


4.12. Put the power pack back into the mower and make sure it wakes up.5. Typical technical problems and their solution

5.1. Mower doesn't respond: Low voltage power pack and other reasonsProblem• The RoboMower doesn't respond to power pack insertion or charger plug. Sometimes

it will make "clicking" noise and sometimes the display shows flickering dark squares.• Power pack voltage is below 13 volts. (Below 1-4 VDC, power pack may be beyond

revival).Resolution• Check power pack fuse. Replace it if blown. (30 amp, green automotive fuse).

(FUS0003A).• Find out why power pack voltage is so low: Was charging neglected? Is the charger

ok? Was the power pack left in the mower while not charging? Does it usually display'Ready' at the end of the charging?

• Get to Bat. Maintenance menu through Service/password/Bat. Maintenance andcheck whether charging has been neglected: See what the 'Last voltage' was, howmany times were 'Warning ignored' and how many times 'Poor storage' occurred. Allindicate neglecting the charging.

• Charge the power pack externally using a fast external charger. (MRK0011B).• If you do not have a fast external charger, recharge the power pack with a regular car

battery charger, at 12 VDC overnight, at no more than 3 amps. Then insert the powerpack to the mower, which should now wake up - audio and display wise. Try to chargeregularly at the mower. The right hand power pack connector (when facing you) is thepositive (+) one. A regular car battery charger charges up to 13 VDC.

• If power pack cannot be revived, replace it. (UNT0009A)• Tech tips: power pack voltage levels: 25-27 VDC is fully charged. 22-23 VDC is when

it displays 'Recharge Battery' message. Below 13 VDC the mower will not wake up orrecognize the charger. A good power supply plug voltage outcome is 38-42 VDC.Below 32 VDC - power supply is faulty.

• In rare cases, inserting the power pack lights up the operation light but there is nodisplay on the manual controller. This could indicate a faulty manual controller. Try toswap it with a new one and see if it works. Replace if needed (MSB00114A).

• If mower doesn't respond and power pack and manual controller are fine, check andreplace at this order: Main fuse (FUS0012A), Connectors board (ESBC021C), Mainboard (SPP0021A).

• In case you have replaced the main board the following setting need to be done through'Service' menu:


area).


5.2. Charging problem: Power supply (regular mower charger) faultyProblem• 'Check power' appears on display + beeping sound, 10 seconds from plugging the

power supply plug to the charging socket.• Power supply outcome voltage is below 32 VDC.• Tech tip: A good power supply lets out 38-42 VDC. In rare cases, the reason for the

low power supply voltage could be a very low AC voltage at the wall, due to excessiveuse by other power supplies. In this case, use another wall outlet.

Resolution• Replace the power supply with a good one. (PWS0003A)

5.3. Charging problem: Charging fuse is faultyProblem

• 'Charging failure' appears on display + beeping sound, 10 seconds from pluggingthe power supply plug to the cradle socket.

• Battery pack and power supply voltage is fine.• The Charging fuse, orange, 5 amp is faulty/corroded. Tested with a voltmeter on

resistance scale, it shows 1 or no continuity at all. A good fuse gives 0.2-0.3 ohmsresistance.

ResolutionReplace the fuse and make sure mower is charging ok. (FUS0015A)

5.4. Charging problem: Manual controller holder faultyProblem• 'Check power* appears on display + beeping sound, shortly after plugging the power

supply plug to the cradle charging socket.• Sometimes 'Charging' message appears when inserting the battery pack into the

mower - even without attempting to charge at all.Resolution• Make sure the charging line is connected properly at the connectors board.• Replace the manual controller holder. (MSB0015B)

5.5. Charging problem: Other charging problemsProblem

• 'Charging failure' appears on display + beeping sound, 10 seconds from pluggingthe power supply plug to the cradle socket.

• Power supply outcome voltage is above 32 VDC.• Charging fuse (5 amp) is fine.

ResolutionCheck and replace the following parts until problem is solved:

• Connectors board (ESB0021C).Flat cable wire bundle (WSB0052A).

• Main board (SPP0019A). (Use the brain from the old board).• In case you have replaced the main board the following setting need to be done

through 'Service' menu:



area).

5.6. Charging problem: External charging problemsProblem

• External charger lights are off even though it is connected to AC power and itsoperating switch is on 1.

Resolution• Check the glass fuse in the charger and replace it if needed. (FUS0021 A).

5.7. Manual controller problems: keys do not respondProblem

• 'Keys locked' message on display doesn't allow operation.• One or more keys/buttons do not respond.

Resolution• If keys are locked, press scroll up arrow and press C button to allow access to

menu, driving or operating the mower. If it isn't a Keys locked issue:• Get to 'Safety tests', press green button, scroll up to 'Buttons', green button

again and play with the non responsive button many times till it responds.• If it doesn't respond, replace manual controller. (MSB0114A).

5.8. Manual controller problems: Keypad is tornProblem

• Keypad is torn. This could happen very rarely in RL550/800.

Resolution• Replace manual controller. (MSB0114A).

5.9. Manual controller problems: No automatic mode displayProblem

• Manual controller display remains on 'Manual settings' rather than changing toautomatic mode display when manual controller is in its cradle and flushed with themower yellow top surface.

Resolution• Make sure manual controller is flushed with the surface.• Replace manual controller. (MSB0114A).• Very rarely the magnet itself could be missing or taken out from the top yellow part

of the mower. If replacing the manual controller doesn't fix the problem open themower and make sure the magnet is imbedded at its place. (Located near theoperation light bulb board).

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 JQTo be used with RoboMower serial number starting with IRL03...

5.10. Perimeter switch problems: P.Switch doesn't turn onProblem

• Perimeter switch doesn't respond when green button is pressed.• Batteries inside it are fine/new.

Resolution• Make sure the 'C' batteries inside are good. Test it with new ones.• Replace perimeter switch. (UNT0007B).• If there are watermarks or water inside the perimeter switch, check with customer

how and where was the perimeter switch mounted. It could be mounted and leftoutside, but it must be mounted vertically!

• If it wasn't mounted vertically and got water penetration, it isn't covered bywarranty!

5.11. Perimeter switch problems: P.Switch indicates low batteriesProblem

« Perimeter switch indicates low batteries with good/new batteries.Resolution

• Make sure the C-cell batteries inside are good. Test it with new ones.• Connect a small loop of wire to the perimeter switch green connector and see if it

keeps showing the low battery indication. If it does - replace it. (UNT0007B).• If it behaves ok with this small loop of wire, it means there is a perimeter wire

problem with the customer's installed area, probably a cut or a bad splice in theperimeter wire. The perimeter switch is ok but shows battery low indication bymistake, while intending to show wire cut indication. Fixing the perimeter wire willcure this problem.

5.12. Drive/Gear problems: Mower doesn't drive properlyProblem fa combination of the following)

• One or both rear wheels are not driving properly while manually or automaticallydriven.

» One or both rear wheels are physically stuck - can't rotate them by hand.• One or more rear wheels are rotating loose - as if not connected to the gears.• Unit goes in tight circles rather than a straight line.• 'Drive problem' or 'Drive overload - Cooling, wait' on the display. (Usually a good

indication the main board is faulty if it happens when there are not any tough drivingconditions)

Resolution• Remove the power pack and try to rotate each rear wheels. Try to determine

whether there is a difference in feel or friction between the two or whether one ofthem is stuck or loose.

• Put the power pack in the mower and place an object under the mower, between therear wheels, so they will be able to rotate without touching the ground. The frontwheel needs to remain firmly on the ground.

• Try to drive the mower manually and see the rear wheels behavior, which one isstuck or not moving.

• Inspect the drive motors pinion and make sure each has both little magnets on it.

10

Friendly North America, tic. Service Guide 2003 Updated: 3/26/2003 J JTo be used with RoboMower serial number starting with IRL03...

Get to 'Service' menu, insert password 12321, green button twice and scroll down to'Drive motors'. Green button to activate and another to confirm. This will test thedrive motors and result in a 'Passed' or 'Failed' message. When it fails, it will alsogive an error number, which will look like this: Failed # 201. This is only an exampleand error #201 is for Left motor disconnected. For Faults error list - see chapter 7.The 'Advanced' drive diagnostics is disabled on 2003 units and will not show anynumbers at the MSR or PWM lines. Ignore it - it doesn't mean anything is faulty.Open the mower and inspect drive motors pinion, gears, tabs and wires.Make sure none of the wires is disconnected.Replace drive motor if pinion is melted/damaged. (SPP0008B).Replace drive motor cables if broken or darkened by heat. (WSB0063A).Replace main board if diagnostics indicated no reading from one or both odometersand odometers and their wires prove to be ok. (SPP0019A). (Use the brain fromthe old board).



area).

5.13. Drive/Gear problems: Rear wheels height adjustment handlebroken

Problem• Mower is lower at one side.• One or two rear wheels grind into the yellow top cover above them.• Rear handle noticed broken at the battery pack compartment.

Resolution• Open the mower and replace gear frame. (SPP0015A).• Try and find how it happened - maybe customer is doing something wrong with it,

like sitting on the mower or dropping it etc. If this is the case it isn't covered bywarranty!

5.14. Drive/Gear problems: Rear wheels spin, loosing trackProblem

• Wheels are spinning while mower is stuck.• Rear height (ground clearance) could be set too low for the grass conditions.• Mower can be stuck against an obstacle, a ditch etc, not allowing it to advance but

too low or high for activating the bumper.• Grass could be very spongy, high, dense, wet or on a slope exceeding 15 degrees.

Resolution• Raise rear wheels to highest position (handle at its lowest possible).• Improve/fix installation if needed by adjusting the perimeter wire or creating a

perimeter island around the obstacle. If it is a ditch that traps the mower, fill it up withsand or gravel.

11


5.15. Wire crossing in automatic mode: Main Board/wire sensors issuesProblem

• Mower crosses the wire in Edge or Scan mode.Resolution

• Position the mower inside an active plot (inside the perimeter wire loop, with theperimeter switch turned on, a few feet from the wire).

• Test wire sensors through Service/wire sensors. If it fails look up the failure code atthe Error faults table. (Chapter 7).

• Perform Service/wires test again to see if it passes or give another error number.• Look at the Fault error numbers table for the meaning of the error number.• Replace wire sensors (SPP0018A + perform Learn wire sensors and Edge

calibration).• If wire sensors replacement didn't fix the problem, replace main board. (SPP0019A).

(Use the brain from the old board).» In case you have replaced the main board the following setting need to be done


area).• Test wire sensors reading while mower is open, on an active plot or on the indoor

test area.• Tip: The installed area needs to be larger than 20x20 feet for the wire sensors test to

pass.

5.16. DK calibration fails repeatedly: Main board/compass issuesProblem

• Mower keeps ending DK calibration with a 'Retry elsewhere' or 'Failed = 18'messages on display instead of a healthy 'Done' score.

Resolution• Make sure Country is set on USA. (Through Service menu).• If the display is 'Failed =18' perform a compass test through Diagnostics/Direction

keeper. If this message is displayed again, replace main board. (SPP0019A). (Usethe brain from the old board).

• If it doesn't display 'Failed + 18' message, but keeps ending the calibration with'Retry elsewhere', retry DK calibration, through Service menu, on smoother surfacesat the lawn or even on a sidewalk. This has nothing to do with the perimeter wire andcould be done anywhere.

• Suspect a faulty main board (compass) only after trying to perform DK calibrationmany times in different locations.

• Test the compass through Service/Direction keeper. Perform the test a few times indifferent directions, since it is a sensitive one. Many times it will fail on error #530 butwill pass the test in a different direction. Once it passes the test, it is a goodcompass. (Even if it failed a few times before!).

12

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 jgTo be used with RoboMower serial number starting with 1RL03...

• If it keeps failing, replace main board. (SPP0019A). (Use the brain from the oldboard).



area).5.17. Edge mow is not completed: Performance issuesProblem

• Mower leaves Edge and starts mowing the inside of the plot prior to completing onefull circle around it.

• There isn't an obstacle on edge that makes it leave the wire. (In case there is, it is aninstallation issue that could be fixed by adjusting the wire).

Resolution• Perform 'Learn edge' through 'User options', on the lawn, when manual controller is

inside its cradle.• If it doesn't help, perform another DK calibration.• If this doesn't work, replace main board. (SPP0019A). (Use the brain from the old

board). In case you have replaced the main board the following setting need to bedone through 'Service' menu:


area).

5.18. 'Move from wire' message: Learn wire sensors is neededProblem

• Mower refuses to start working in automatic mode, displaying 'Move from wire' whileisn't close to the wire at all.

• This is common after replacing wire sensors or main board. Could also happen to anew mower out of the box, on its first automatic operation.


perimeter switch turned on, a few feet from the wire).• Get to Service and insert password 12321.• On Service menu, Scroll to 'Learn wire sensors' and perform it. When done it will say

'Was X now Y' meaning 'Learn wire sensors' happened. Press the green buttonagain (Very important!) in order to finish the process.

• Put the manual controller back into the mower and operate it.• If you just replaced a main board on this mower, you need to set Country and do

another DK calibration prior to being able to work in automatic mode. The mower willoffer it automatically on the display if you try to operate it in automatic mode.

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 ^4To be used with RoboMower serial number starting with IRL03...

• If 'Learn wire sensors' didn't help, replace main board, (SPP0019A). (Use the brainfrom the old board), perform another 'Learn wire sensor1 and operate the mower ona test area.

• In case you have replaced the main board the following setting .need to be donethrough 'Service' menu:

o Learn wire sensors inside an active loop of wire.o Set country to USA.o DK calibration (In some occasions, twice).o Edge calibration (Could be done anywhere, even in an unwired

area).

5.19. Mowing problemsProblem

» Mower stops mid work indicating 'Check mow height' or 'Mowing overload Cooling,wait' message on display.

Resolution• Check whether the grass is too high or dense. If it is due to grass conditions, wait

20-30 minutes and operate again. In some occasions the grass should be mowedfirst with a heavier type mower, in order to reduce its height to 3-4 inches.

• Remove power pack and check whether grass has accumulated and clogged theblades/mulching deck area. Try to rotate each blade, (carefully, wearing a glove),and make sure all blades rotate easily and freely. Dull blades should be replaced.

• If 'Check mow height' is displayed without any of the above conditions, test themowing motors through Service/Mowing motors.

• If a mowing motor is found faulty, open the mower and replace it. (MSB0065B).• If replacing it doesn't solve the problem, it could be the mowing motor cables

(WSB0053A) or the main board. (SPP0019A). (Use the brain from the old board).• In case you have replaced the main board the following setting need to be done


area).

5.20. Automatic mowing problems: Wire sensors reading problemsProblem

« Unit stops mid work often, indicating 'Start elsewhere'. Or« Upon initiating automatic mode, unit doesn't operate showing 'No wire signal' on

display. (Perimeter switch is turned on and the mower is inside the perimeter wiredarea).

Resolution• Inside an active perimeter wire, mower positioned in the middle of the plot, test wire

sensors through Service/Wire sensors.

14

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 ] 5To be used with RoboMower serial number starting with IRL03...

• If the test fails, it will give you an error number. Check the error number meaning onthe fault error table and do what it suggests. Test again by pressing C and reinitiating the test.

• Open the mower and replace the wire sensors with harness. (SPP0018A).• Perform Learn wire sensors and Edge calibration if you replaced the wire sensors.« If this didn't help, replace main board. (SPP0019A). (Use the brain from the old

board).• In case you have replaced the main board the following setting need to be done


area).5.21. Front wheel problemProblem

• Unit stops mid work often, indicating 'Start elsewhere'. Or• Upon initiating automatic mode mowing, unit doesn't operate showing 'Front wheel

problem' on display. Or• Unit displays 'Front wheel problem' constantly.

Resolution• Test front wheel through Safety tests/front wheel sensor.• If it indicates 'Lifted' while the front wheel is on the ground, the front wheel board is

faulty.• Open the mower and check the front wheel wire connector at the main board.• Replace front wheel drop-off board. (SPP0005A).• Test the front wheel through 'Safety tests'/Front wheel sensor while still opened; to

make sure problem is solved.• If it didn't solve the problem, replace main board. (SPP0019A). (Use the brain from

the old board).• In case you have replaced the main board the following setting need to be done

through 'Service1 menu:o Learn wire sensors inside an active loop of wire. (See 5.18)o Set country to USA.o DK calibration (In some occasions, twice).o Edge calibration (Could be done anywhere, even in an unwired

area).

5.22. Bumper issues: Bumper is disconnectedProblem

• Unit displays 'Rear or Front bumper disc'.Resolution

• Open the mower and find the disconnected wire, also looking at the soldering pointconnecting the white wire to the inner bumper spring.

• Solder the wire to the spring or replace the bumper.• If you can't solder it, replace the faulty bumper.

15

Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 J gTo be used wilh RoboMower serial number starting with IRL03...

• Use soapy water or silicone-based lubricant at the bumper inserts (black trapezeshape rubber inserts, inserted into the holes in the gray plastic base of the unit).

• Disconnect the bumper tabs. (See video clip on Dealer CD for replacementdemonstration).

• Peel off the bumper side from the gray plastic base and push down on the bumperwhile supporting the mower on the bench with your other hand. The trapeze shaperubber inserts will pop out. No tool is needed for this process. Lubricate the newbumper trapeze shaped inserts prior to installing it back to the mower.Rear bumper (MSB0107A). Front bumper (MSM0106A)

5.23. Bumper issues: Bumper sounds without hitting an obstacleProblem

• Unit sounds the bumper 'Boing' sound without hitting a real obstacle.• Unit stops often with no apparent reason.

Resolution« Hit the top yellow flat part of the mower, between manual controller area and front

handle, with your open hand, to find out if this activates the bumper. (Boing sound).• If it does, the bumper is oversensitive - the active spring contact part is too close to

the metal strip contact located against it.• Touch the bumper all around to find out which one is the sensitive one. A normal

bumper will be pushed in a 1/8 - % of an inch before activated. The sensitive areawill be where merely touching the bumper will activate it.

• Open the mower and replace the oversensitive bumper. (See video clip on DealerCD for replacement demonstration).

5.24. Bumper issues: Bumper is pressedProblem

• Unit displays 'Front or Rear bumper pressed' message.Resolution

• Squeeze the appropriate pressed bumper and try to see if it is just a case of mowerstored with the bumper pressed against an obstacle, which may temporary set therubber in dented way pressing it all the time. (Check with the customer if this is thecase).

• If this doesn't cure it - replace the faulty bumper. Rear bumper (MSB0107A).Front bumper (MSM0106A). (See video clip on Dealer CD for replacementdemonstration).

5.25. Performance issues: RoboMower doesn't advance is scan modeProblem

• Unit keeps going back and forth on the same lines without advancing sideways.Resolution

• Through 'User preferences' menu, choose 'Wide scan' mode. This will increase theangle between mowing lines and should fix the problem.

• If the problem still exists, set 'Enable DK' to 'off through Service menu.• If it doesn't fix it, replace the main board. (SPP0019A). (Use the brain from the old

board).

16


17


1. Learn wire sensors inside an active loop of wire. (See 5.18)2. Set country to USA.3. DK calibration (In some occasions, twice).4. Edge calibration (Could be done anywhere, even in an unwired area).

6. Display messages meaning

Message

Blocked path

CalibrationReq.

Check Power

ChargingfailureConnectcharger

Failed K= 18

Front wheelproblem

Front/RearbumperdisconnectedFront/Rearbumperpressed

Keys locked

'X' Key pressed

Synch failed

StartElsewhere

MowingDisabled

Explanation- Bumper pressed during warm up.- Bumper pressed for 2 sec during manual mowing.

- A D.K calibration is required (only in the first operation)

- The charger is connected but not charging, usually happensupon initiating charging (there is no power from the powersupply)

- The charger is connected but not charging (Probably faultyMain Board).

- Connect charger (displayed when the mower isn't operatedand connected to the charger).

- Appears during the D.K calibration and indicates that the coilson the electronic compass are probably disconnected.

- The front wheel is not touching the ground for too long.

- There is a problem with Drop-off board.

- An internal problem associated with the front bumper hasoccurred.


- Child guard set to 'on' - Press the scroll upper arrow andthen C to enable mowing.

- One of the keys on the manual controller is pressedcontinuously upon reset.

- Wire synchronization failed. (Very rare. Customer will have topress GO if this appears)

- Drive motors have faced over-current for too long.- For some reason the RoboMower had stopped and user

assessment is required.- When activating motors under 'Diagnostics' but 'mowing' is

set 'off

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18

Message

Theft Guard On

Check mowheight

No wire signal

Drive Problem

MowingOverloadCooling, Wait...Drive OverloadCooling, Wait...

Path problem

ReadyKeep charging

RechargeBattery

RetryElsewhere

Set CountryTimeCompleted

Move fromWire

Max distreached

Explanation

- Anti theft set to 'on' - Insert safety password to enablemowing.

- Mowing motors have faced over-current for too long or someobstacle is stuck or wrapped around the blades.

- The RoboMower cannot detect a signal from the PerimeterWire.

- One of the odometers is not reading a signal from the magnetson the drive motor.

- Mowing motors have faced overheating - the mower stops forcooling.

- Drive motors have faced overheating - the mower stops forcooling.- The RoboMower does not complete edge acquisition in 2 minute- Bumper event while the mower is exiting from the Docking Static- Bumper as the mower leaves the edge for scanning.- Bumper as starting the turn for obstacle bypass during edge.- Battery is fully charged, the mower is ready to the next

operation - keep charging the battery.

- The RoboMower battery needs recharging.- The RoboMower battery reaches 19V under load.- There is a problem with the compass readings due to a

distortion in the local magnetic field (during DK Calibration oras pressing the 'GO' button).

- GEO location is not set

- Displayed when the time set for the operation is reached.

.- The RoboMower is too close to the perimeter wire or on thewire itself.- There is a reading problem while pressing the 'GO' button.- The RoboMower will stop after about an hour or 800 meters,

if the customer for some reason did not stop it while learningedge. (Maximum distance reached)

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19

7. Diagnostics fault table and meaning.

Fault*100

101

102

110

111

112

120

121

121

130

131

140

141

142

DiagnosedDrivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)DrivemotorsDrivemotors(Forward)Drivemotors(Forward)

Drivemotors(Forward)Drivemotors(Forward)Drivemotors(Forward)Drivemotors(ForwardJDrivemotors(Forward)

MeaningRight motorcurrent< 100mA





Right & Leftodometer reading=0

Right motorpwm>95%Left motor pwm>95%


Right wheelpwm>Left wheelpwmLeft wheelpwm>Right wheelpwmRight pwm<78 or >82

Left pwm<78 or >82


Possible causeRight motor is disconnected



Right odometer is disconnected

Left odometer is disconnected






Test again

Test again

19


21

Fauit#243

301

302

303

304

305

306

307

331

332

333

334

335

336

337

341

342

343

344

345

346

DiagnosedDrive motors(Backward)

MowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotors

MowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotors

MowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotors

MeaningMeasured PWMdifference >2Right Motor current >100mAMid Motor current >100mARight + Mid Motorcurrent > 1 00mALeft Motor current >100mARight + Left Motorcurrent > 1 00mAMid+Left Motorcurrent > 1 00mARight+Mid+LeftMotor current >100mARight Motor current <100mAMid Motor current <100mARight+Mid Motorcurrent < 1 00mALeft Motor current <100mARight+Left Motorcurrent < 1 00mAMid+Left Motorcurrent < 1 00mARight+Mid+LeftMotor current <100mARight Motor current >2AMid Motor current >2ARight+Mid Motorcurrent > 2ALeft Motor current >2ARight+Left Motorcurrent > 2AMid+Left Motorcurrent > 2A


Right Motor power unit is faulty

Mid Motor power unit is faulty

Right+Mid Motor power units arefaultyLeft Motor power units is faulty

Right+Left Motor power units arefaultyMid+Left Motor power units arefaultyRight+Mid+Left Motor power unitsare faulty

Right Motor is disconnected

Mid Motor is disconnected

Right+Mid Motor are disconnected

Left Motor is disconnected

Right+Left Motors are disconnected

Mid+Left Motors are disconnected

Right+Mid+Left Motors aredisconnected

Right Motor is overloaded

Mid Motor is overloaded

Right+Mid Motors are overloaded

Left Motor is overloaded

Right+Left Motors are overloaded

Mid+Left Motors are overloaded

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22

Fault#347

351

352

353

354

355

356

357

401

402

403

404

405

406

407

408

409

410

411

412

413

414

DiagnosedMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotorsMowingmotors

WiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensorsWiresensors

MeaningRight+Mid+LeftMotor current > 2ARight Motor current >100mAMid Motor current >100mARight+Mid Motorcurrent > 100mALeft Motor current >100mARight+Left Motorcurrent > 1 00mAMid+Left Motorcurrent > 1 00mARight+Mid+LeftMotor current >100mAFR sensor <2

FL sensor<2

FR+FL sensors<2

RR sensor<2

FR+RR sensors<2

FL+RR sensors<2

FR+FL+RRsensors<2RL sensor<2

FR+RL sensor <2

FL+RL sensor<2

FR+FL+RLsensors<2RR+RL sensor<2

FR+RR+RLsensors<2FL+RR+RLsensors<2

Possible causeRight+Mid+Left Motors areoverloadedRight Motor stopping is faulty

Mid Motor stopping is faulty

Right+Mid Motors stopping is faulty

Left Motor stopping is faulty

Right+Left Motors stopping is faulty

Mid+Left Motors stopping is faulty

Right+Mid+Left Motors stopping isfaulty

FR sensor is disconnected

FL sensor is disconnected

FR+FL sensors are disconnected

RR sensor is disconnected

FR+RR sensors are disconnected

FL+RR sensors are disconnected

FR+FL+RR sensors aredisconnectedRL sensor is disconnected

FR+RL sensor are disconnected

FL+RL sensor are disconnected

FR+FL+RL sensors aredisconnectedRR+RL sensor are disconnected

FR+RR+RL sensors aredisconnectedFL+RR+RL sensors aredisconnected

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Fault#527

529

530

531

532

533

534

535

TestedDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeperDirectionKeeper

MeaningCoils 1+2+3 cannotbe zeroedCoils 1+3 cannot bezeroedCoils 2+3 cannot bezeroedCoils 1 +2+4 cannotbe zeroedCoils 3+4 cannot bezeroedCoils 1+3+4 cannotbe zeroedCoils 2+3+4 cannotbe zeroedCoils 1+2+3+4cannot be zeroed

Possible causeMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnectedMagnetic interference or coilsdisconnected

24

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