Robomow Service Guide

Read carefully and thoroughly all relevant sections before servicing Robomow. It is very important to read and follow all warning and safety instructions in this manual and in the Robomow Operating and Safety Manual. All maintenance procedures and troubleshooting must be carried out exactly as given in this manual. All rights reserved. No part of this book may be reproduced or used in any form or by any means graphic, electronic or mechanical, including photocopying, recording, taping or by any electronic information storage and retrieval systems without a prior written consent of F. Robotics Acquisitions Ltd. This book was carefully prepared. However, F. Robotics Acquisitions Ltd. will not bear any responsibility for any errors, mistakes or misunderstandings. F. Robotics Acquisitions Ltd. shall not bear responsibility for any damage resulting from faulty instructions in this manual. F. Robotics Acquisitions Ltd. reserves the right to introduce changes in the product and/or to this manual without any prior notice.

2010. All rights reserved to F. Robotics Acquisitions Ltd.

Table of Content
Chapter 1- Robomow Layout & IPLs (Illustrated Parts List)... 3 - 32

Chapter 2 - Menu Items.33 - 56 Chapter 3 Troubleshooting..57 - 97 Chapter 4 - Repair and Maintenance Procedures..98 Chapter 5 Diagnostics....99 - 128

1. Robomow Layout & Spare Parts

This first section is dedicated to the layout of Robomow, how it is constructed, part numbers and identification of parts. Important: Be sure to review section 1.1 (Orientation). It explains what is referred to as right, left etc. Failure to understand this can result in a mistake or problem in the analysis or repair of the product.

Table of Contents
1.1 Robomow layout and main components ................................................................. 2 1.1.1 Robomow External Views ...................................................................................... 2 1.1.2 Robomow Bottom View .......................................................................................... 4 1.1.3 Robomow Internal Views ........................................................................................ 5 1.1.4 Base Station ............................................................................................................. 8 1.1.5 Perimeter Switch ...................................................................................................... 9 1.2 Illustrated Parts List (IPL) ........................................................................................ 10 1.3 Board Identification ................................................................................................... 21 1.4 Wiring Layout ............................................................................................................. 26 1.5 Screws Identification ................................................................................................. 28 1.6 Spare Parts List ......................................................................................................... 30

1-1

1.1 Robomow layout and main components

1.1.1 Robomow External Views
3

Bumper air-inlet INJ5004A

1

Bumper assembly SPP5005B

4

Bumper door ass. SPP5003A

Operating panel ass. MSB5011A

Figure 1.1.1 Top view

10

Bumper air-inlet INJ5004A

Drive wheel INJ5044A

RM510 sticker STC5001D RM200 sticker STC5002B

Bumper charging nozzle INJ5026A

Charging pins MCH5008B

41

33

&

39

Wheel cup GEN0201A

M5x10 DIN 7985A2 SCR5008A Spring washer M5 DIN 127 ZP RNG0025A

Bumper assembly SPP5005A

64

40

Base Station INJ5041A

37

Base Station sticker STC5008A

1-2

Figure 1.1.2 RM400 & Base Station

Base Station Door SPP5048A

11

Bumper cover ball support - SPP5029A

Bumper assembly SPP5005B

Bumper air-inlet INJ5004A Fuse cover INJ5052A

4 12

Bumper door ass. SPP5003A

20

108

Bumper shaft INJ5031A Screw M3x12 MCH4105A Bumper insert MCH5018A

99

107

Fuse holder INJ5059A Chassis front cover INJ5054B

13

104

Chassis front cover nut INJ5062A Adjustment knob SPP5033A

14

Power Supply door - INJ5059A

100

15

Chassis stud IMCH5014A

Bumper sensor ball ass. MSB5009A

19

18

Mowing motor ass. MSB5003A Danger sticker STC5004A

62

Mowing hood + height adjustment SPP5046B Screw 4x20 WN 1411 SCR5002A

Screw 4x30 WN 1411 SCR5005A

16 17

35

Mowing hood cover SPP5047A

5800RPM sticker STC5003A

1-3

Figure 1.1.3 Cover lifted

1.1.2 Robomow Bottom View

Note: Mower sides are determined by its top view

New Mowing Deck from '09

21

Front Wheel SPP0011A

Mowing hood + height adjustment SPP5046B

22 83

Low cut blade MRK5003A

Chassis SPP5042B

10

Drive wheel INJ5044A

35

Screw 4x20 PT WN 1412 ZP SCR5002A

Figure 1.1.4 Bottom view

1-4

1.1.3 Robomow Internal Views

26 25

27

Drop off Board ESB5008D

Charging contacts MCH5009AA

Suspension INJ5054A

16

Mowing hood cover SPP5047A

24

Siren GEN5002A Winter charger 230VAC - EUR PWS5001A 110VAC - US PWS5002A 230VAC - UK PWS5003A

17

5800 RPM sticker STC5003A

23

18

Mowing motor ass. MSB5003A

46

Mowing height sticker STC5006A

28 33

(2) batteries 12AH12V MRK5001A

Communication board ESB5004B

32

29

Fuse holder cable WSB5005A

Flat cable WSB5012A

34 30

Main to mow cable WSB5005A

5

Drive motor ass. MSB5007A

Operation panel Ass. MSB5011A

Drive motor cable WSB5003B

36

Figure 1.1.5 Internal view (Top)

Main Board SPP5000H (ESB5000H)

31

1-5

18

19

86

Mowing motor ass. MSB5003A

Bumper sensor ball ass. MSB5009A

Mowing cable folder INJ5055A

43

Bumper grommet INJ5050A

35

Screw 4x20 ZP SCR5002A

23

Winter charger
230VAC - EUR PWS5001A 110VAC - US PWS5002A 230VAC - UK PWS5003A

Siren GEN5002A

24

Charging contact rubber seal INJ5057A Drop off to wire sensors cable WSB5017A Suspension INJ5054A Charging contacts MCH5009AA
85 26

59

27

25

43

Drop off Board ESB5008D

Bumper grommet INJ5050A

45

29

Magnet 5x20 GEN0133A

44

Flat cable WSB5012A

Drop off magnet holder INJ5039A Drop off to wire sensors cable WSB5017A
59

24

Siren GEN5002A

61

Charging contact spring MCH5010B

Charging contacts MCH5009A

26

Figures 1.1.6 Internal view (Front)

1-6

55

Batteries cable WSB5004A

30

Drive motor ass. MSB5007A

36

Drive motor cable WSB5003B

29

Flat cable WSB5012A

Operation panel Ass. MSB5011A

Figures 1.1.7 Internal view (Back)

Main board SPP5000H (ESB5000H)

31

28

48

Fuse house holder MCH5004A

(2) batteries 12AH-12V MRK5001A

33

Communication board ESB5004B

91

Com. socket grommet INJ5053A

Fuse holder cable WSB5005A

32

Figures 1.1.8 Internal view (Batteries)

Connection to Main Board

1-7

1.1.4 Base Station

41

Charging pins MCH5008B

39

Spring washer M5 DIN 127 ZP RNG0025A

33

51

M5x10 DIN 7985-A2 SST SCR5008A

40

Metal peg GEN0223B

Base Station INJ5041A

88

Base Station Door SPP5048A 900mA Power Supply PWS0004C - EUR PWS0005C US PWS0006C - UK
50

37

Base Station Door SPP5048A

Screw WN 1412 KA25x8 SCR0027A

109

Base Station Board SPP0028G

Base Station Board to charging pins cable WSB5018A

74

Base Station sticker STC5008A

64

Base Station door SPP5048A

37

1-8

1.1.5 Perimeter Switch

Perimeter Switch
includes power supply and stake (Refer to accessory list)

Stake for Perimeter Switch GEN0175A

36

87

Power Supply for Perimeter Switch SPP5100A - EUR SPP5101A - US SPP5102A - UK

33

Perimeter Switch UNT5007D

Perimeter Switch batteries pack MRK5006A

33

Perimeter Switch sticker STC

56

Perimeter Switch board seal GEN0176A

33 37

Perimeter Switch back cover GEN0156A

1-9

1.2 Illustrated Parts List (IPL)

1

3 16

13

31

61

11

10

Mowing hood + height adjustment SPP5046A

Figures 1.2.1 IPL External View

1 - 10

11 63 13 13

62

16

3 31 19

33

34

14

11

13

41 39

Figures 1.2.2 IPL Internal View

1 - 11

11

11

Figures 1.2.3 Bumper View

1 - 12

16

Adjustment knob SPP5033A

16

Mowing hood cover SPP5047A

Mowing hood + height adjustment SPP5046A

Screw 4x20 ZP SCR5002A

35

Figures 1.2.4 Mow Top View

1 - 13

62

18

Screw 4x20 PT WN 1412 SST SCR5003A

Mowing motor ass. MSB5003A

Figures 1.2.5 Mow Bottom View

64

Circlip 8 DIN6799 RNG5002A

63

10

Drive wheel INJ5044A

Circlip 4 DIN6799 RNG0034A

Wheel cup GEN0201A

Figures 1.2.6 Drive shaft circlip View

1 - 14

67

Gear 4 & cover right assembly SPP5021A

Gear shaft 9mm

MCH5002A
65

31

Wheel cup GEN0201A

64 66

Circlip 8 DIN6799 RNG5002A

Gear 4 & cover left assembly SPP5022A

64

Washer M10x15 BN 739 RNG5003A

Figures 1.2.7 Drive and Gear View

65

Circlip 8 DIN6799 RNG5002A x2 3 or 4

x2

Washer M10x15 BN 739 RNG5003A

79 62

Shaft seal (9mm)

2 or 3

Screw KA40x30 PT WN 1411 ZP

GEN5006A

SCR5004A x1 Drive motor ass. MSB5007A

30

Gear shaft 5mm

x2 Gear wheels (1+2+3) kit SPP5016A Drive wheel INJ5044A x2 Flat washer M5 RNG0026A
68

MCH5003A x4
31 69

10

98

Washer 5diax8diax0.3 MCH4025A

Shaft seal (5mm)

GEN5005A
78

Screw 4x20 ZP SCR5002A

35

x2

1 - 15

Drive Mechanism - Gear Wheels

3
Washer M10x15 Washer M10x15 RNG5003A (2 or 3) RNG5003A (1 or 2) (2 3) Circlip 8 DIN6799 Circlip 8 DIN6799 RNG5002A (x1) RNG5002A (x1)

12
Gear 4 Gear 4 INJ5013A INJ5013A

Washer M10x15 Washer M10x15 RNG5003A (x2) RNG5003A (x2)

Circlip 8 DIN6799 Circlip 8 DIN6799 RNG5002A (x1) RNG5002A (x1)

Washer M10x15 Washer M10x15 RNG5003A (3 or 4) RNG5003A (3 or 4)

Gear 2 Gear 2 INJ5015A INJ5015A Washer M10x15 Washer M10x15 RNG5003A (x2) RNG5003A (x2)

10 3

Gear shaft 9mm Gear shaft 9mm

Shaft seal (9mm) Shaft seal (9mm) GEN5006A (x1) GEN5006A (x1)

MCH5002A MCH5002A

17 12

Washer 22x9 RNG5007A (x1)

2
Shaft seal (5mm) Shaft seal (5mm) GEN5005A (x1) GEN5005A (x1)

Figures 1.2.8 Gear Wheels Assembly

Gear shaft 5mm Gear shaft 5mm

MCH5003A MCH5003A

4
Washer 5diax8diax0.3 Washer 5diax8diax0.3 MCH4025A (x4) MCH4025A (x4) Gear 1 Gear 1 INJ5016A INJ5016A Flat washer M5 Flat washer M5 RNG0026A (x1) RNG0026A (x1) Washer 5diax8diax0.3 Washer 5diax8diax0.3 MCH4025A (x2) MCH4025A (x2)

Flat washer M5 Flat washer M5 RNG0026A (x2) RNG0026A (x2) Washer 5diax8diax0.3 Washer 5diax8diax0.3 MCH4025A (x2) MCH4025A (x2) Gear 3 Gear 3 INJ5014A INJ5014A

11 1 - 16

1 4

Shaft seal (9mm) Shaft seal (9mm) GEN5006A GEN5006A Washer 5diax8dia Washer 5diax8dia MCH4025A MCH4025A

2 5

Shaft seal (5mm) Shaft seal (5mm) GEN5005A GEN5005A Circlip 8 DIN6799 Circlip 8 DIN6799 RNG5002A RNG5002A

Washer M10x15 Washer M10x15 RNG5003A RNG5003A

17 12 6
Flat washer M5 Flat washer M5 RNG0026A RNG0026A

Washer 22x9 RNG5007A (x1)

Gear shaft 9mm Gear shaft 9mm

MCH5002A MCH5002A
Gear shaft 5mm Gear shaft 5mm

MCH5003A MCH5003A

Gear 1 Gear 1 INJ5016A INJ5016A

10

Gear 2 Gear 2 INJ5015A INJ5015A

11

Gear 3 Gear 3 INJ5014A INJ5014A

12

Gear 4 Gear 4 INJ5013A INJ5013A

Figures 1.2.9 Gear wheels parts identification

1 - 17

(Gear wheels are not available as separated spare parts)

Drive Mechanism Timing Belt (P/N SPP5019A)

Picture ID 1 2 6 15 4 9 10 4 15 11 4 3 5 3 12 6 3 5

Description Shaft seal (9mm) Shaft seal (5mm) Washer 22m x 9.34mm x 1mm Flat Washer M5 Washer 5diax8dia Gear 1 Gear 2 Washer 5diax8dia Flat Washer M5 LEFT SIDE ONLY Gear 3 Washer 5diax8dia Washer M10x15 Circlip 8 DIN6799 Washer M10x15 Gear 4 Washer 22m x 9.34mm x 1mm Washer M10x15 Circlip 8 DIN6799

TB Part Number GEN5006A GEN5005A RNG5007A RNG0026A MCH4025A MSB5016A INJ5015B MCH4025A RNG0026A INJ5014A MCH4025A RNG5003A RNG5002A RNG5003A INJ5013A RNG5007A RNG5003A RNG5002A

TB Qty 1 1 5 1 3 1 1 2 1 1 2 2-4 1 2 1 1 1 1

Gear Shaft 9mm - MCH5002A 5mm - MCH5003A 9mm - MCH5002A 5mm - MCH5003A 5mm - MCH5003A 5mm - MCH5003A 9mm - MCH5002A 5mm - MCH5003A 5mm - MCH5003A 5mm - MCH5003A 5mm - MCH5003A 9mm - MCH5002A 9mm - MCH5002A 9mm - MCH5002A 9mm - MCH5002A 9mm - MCH5002A 9mm - MCH5002A 9mm - MCH5002A

1 - 18

1 - 19

1 - 20

1.3 Board Identification

73

Screw WN 1412 KA22x6

71

On/Off button board ESB5005B

SCR5006A

Up/Down button (+buzzer) board ESB5006B

72

Figures 1.3.1 Main Board Top View

73

Screw M2.5x20 SCR0034A

31

Main board SPP5000H (ESB5000H)

Spacer for tact switch boards INJ5061A

93

Figures 1.3.2 Main Board Bottom View

1 - 21

25

77

76

Drop off Board ESB5008D

Tilt housing + flag SPP5038A

Magnet 5x10 GEN4001A

75

Bumper board ESB5003E

59

Drop-off to wire sensors cable WSB5017A

Figures 1.3.3 Bumper and Drop-Off Boards Location

82

Bumper sensor cover INJ5024A

19

Bumper sensor ball assembly MSB5009A

Figures 1.3.4 Bumper sensor ball and cover

1 - 22

75

Bumper board ESB5003E

Drop off Board ESB5008D

25

Figures 1.3.5 Bumper Board Figures 1.3.6 Drop Off Board

77

Tilt housing + flag SPP5038A

Figures 1.3.7 Drop Off Board connection

1 - 23

Connection to Power Supply

Figures 1.3.8 Perimeter Switch Board

Connection to Perimeter Wire

28

Communication board ESB5004B

Figures 1.3.9 Communication Board

1 - 24

30

Drive motor ass. MSB5007A

Drive motor cable WSB5003B

36

Odometer board (not available as spare part)

Figures 1.3.10 Drive motor assembly

Magnet

Sensor

Figures 1.3.10 Drive motor assembly - MSB5007A

1 - 25

1.4 Wiring Layout

WSB5001A

MSB5003A Mowing motor assembly Wire sensor

WSB5012A

ESB5006C Up/Down board ESB5004C Communication board

WSB5012A Right Battery Right Battery

MCH5009A Charging Contacts

WSB5017A

ESB5003E Bumper Board

MSB5007A BAT5001A Drive motor assembly

WSB5017A

ESB5008D Drop off board

Left Battery BAT5001A

WSB5004A

GEN5002A Siren PWS5001/2/3A Winter charger

1 - 26

FUS0002A 15A 32V

SPP5000H

WSB5003B

Main Board (ESB5000H)

ESB5005C On/Off board

1.5 Screws Identification

#
1 2 3 4 5 6 7 8 9 10 11

P/n
MCH4025A MCH5019A RNG0025B RNG0026A RNG0030A RNG0031A RNG5001B RNG5002A RNG5003A SCR0027A SCR5001A

Where?
Drive shaft (5mm) Bumper shafts Charging pins Drive shaft (5mm) Front wheel - large Front wheel small Drive shaft (5mm) Drive shaft (9mm) Drive shaft (9mm) Base Station board Siren to Chassis Main Board to Operating Panel Mowing hood cover Drive motor ass. to Chassis Operating panel to Chassis Communication board Mowing motor assembly to Mowing hood Front cover chassis Gear cover to Chassis Wire sensor to Chassis Tact switch board to Main Board Charging pins screw Drive shaft (9mm)

Qty
2x8 2x2 2 2x3 2 1 1 (2 x 2) + 1 2 x (9-11) 8 2 4 6 2x3 2 1 6 4 2x2 2x1 16 2 2 x (9-11)

Description
Washer 5diax8diax0.3 Screw M3x12 Spring washer DIN127 M5 Flat washer M5 DIN 125 ZP Washer M10 DIN 125 Z P Washer M10x15 BN 739 Circlip 4 DIN6799 d1=4 Circlip 8 DIN6799 BN811 Shim Washer D9xD15xS0.3mm (DIN988) Screw WN 1412 KA25x8 Screw 3x14 PT WN 1412 ZP

12

SCR5002A

Screw 4x20 PT WN 1412 ZP

13

SCR5003A

Screw 4x20 PT WN 1412 SST

14 15 16 17

SCR5005A SCR5006A SCR5008A RNG5007A

Screw KA40x30 PT WN 1411 ZP Screw WN 1412 KA22x6 M5x10 DIN 7985-A2 Washer (22m x 9.34mm x 1mm)

1 - 28

Technical details about the WN 1411 and 1412 screws:

1 - 29