Friendly Robotics Robomow RM510 Service Guide

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 & IPL’s (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. SPP5003A 5 Operating panel ass.2 RM400 & Base Station Base Station Door SPP5048A . MSB5011A Figure 1.1.1 Robomow layout and main components 1.1 Robomow External Views 3 Bumper air-inlet INJ5004A 1 Bumper assembly SPP5005B 4 Bumper door ass.1.1 Top view 10 3 Bumper air-inlet INJ5004A Drive wheel INJ5044A RM510 sticker STC5001D RM200 sticker STC5002B 2 6 Bumper charging nozzle INJ5026A Charging pins MCH5008B 41 9 33 & 39 Wheel cup GEN0201A 1 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. SPP5029A 1 3 Bumper assembly SPP5005B Bumper air-inlet INJ5004A Fuse cover INJ5052A 4 12 Bumper door ass.INJ5059A 100 15 Chassis stud IMCH5014A Bumper sensor ball 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 .3 Cover lifted .11 Bumper cover ball support .1. MSB5009A 19 18 Mowing motor ass. MSB5003A Danger sticker STC5004A 62 3 7 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. 1.4 Bottom view 1-4 .1.2 Robomow Bottom View Note: Mower sides are determined by its top view New Mowing Deck from '09 21 Front Wheel SPP0011A 7 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. MSB5007A Operation panel Ass.EUR PWS5001A 110VAC .1. MSB5011A Drive motor cable WSB5003B 36 Figure 1. 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.1.UK PWS5003A 17 5800 RPM sticker STC5003A 23 18 Mowing motor ass.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 .5 Internal view (Top) Main Board SPP5000H (ESB5000H) 31 1-5 .US PWS5002A 230VAC . MSB5009A Mowing cable folder INJ5055A 43 Bumper grommet INJ5050A 35 Screw 4x20 ZP SCR5002A 23 Winter charger 230VAC .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.EUR PWS5001A 110VAC .1.6 Internal view (Front) 1-6 .18 19 86 Mowing motor ass. MSB5003A Bumper sensor ball ass. 55 Batteries cable WSB5004A 30 Drive motor ass. MSB5007A 36 Drive motor cable WSB5003B 29 Flat cable WSB5012A 5 Operation panel Ass. MSB5011A Figures 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.1.8 Internal view (Batteries) Connection to Main Board 1-7 .1. socket grommet INJ5053A Fuse holder cable WSB5005A 32 Figures 1. 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 .1.4 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 .1.EUR PWS0005C – US PWS0006C . 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 .1.1.5 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 . 1 IPL External View 1 .1.10 .2 Illustrated Parts List (IPL) 1 3 16 13 31 61 11 10 7 Mowing hood + height adjustment SPP5046A Figures 1.2. 2.11 .11 63 13 13 62 16 3 31 19 33 34 9 14 11 13 41 39 Figures 1.2 IPL Internal View 1 . 12 .2.6 3 4 11 11 Figures 1.3 Bumper View 1 . 2.16 Adjustment knob SPP5033A 16 7 Mowing hood cover SPP5047A Mowing hood + height adjustment SPP5046A Screw 4x20 ZP SCR5002A 35 Figures 1.4 Mow Top View 1 .13 . 6 Drive shaft circlip View 1 . MSB5003A Figures 1.2.5 Mow Bottom View 64 Circlip 8 DIN6799 RNG5002A 63 10 Drive wheel INJ5044A Circlip 4 DIN6799 RNG0034A 9 Wheel cup GEN0201A Figures 1.14 .2.62 18 Screw 4x20 PT WN 1412 SST SCR5003A Mowing motor ass. 3 MCH4025A Shaft seal (5mm) GEN5005A 78 Screw 4x20 ZP SCR5002A 35 x2 1 .9 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 1.7 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.15 .2. 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. 16 4 6 .8 Gear Wheels Assembly 8 Gear shaft 5mm Gear shaft 5mm MCH5003A MCH5003A 4 Washer 5diax8diax0.3 Washer 5diax8diax0.3 MCH4025A (x2) MCH4025A (x2) Gear 3 Gear 3 INJ5014A INJ5014A 9 4 11 1 .2.3 Washer 5diax8diax0.3 Washer 5diax8diax0.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 3 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) 3 Gear 2 Gear 2 INJ5015A INJ5015A Washer M10x15 Washer M10x15 RNG5003A (x2) RNG5003A (x2) 10 3 5 5 7 Gear shaft 9mm Gear shaft 9mm Shaft seal (9mm) Shaft seal (9mm) GEN5006A (x1) GEN5006A (x1) MCH5002A MCH5002A 1 17 12 Washer 22x9 RNG5007A (x1) 2 Shaft seal (5mm) Shaft seal (5mm) GEN5005A (x1) GEN5005A (x1) Figures 1.3 MCH4025A (x2) MCH4025A (x2) 6 Flat washer M5 Flat washer M5 RNG0026A (x2) RNG0026A (x2) 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.Drive Mechanism . 9 Gear wheels parts identification 1 .2.1 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 3 Washer M10x15 Washer M10x15 RNG5003A RNG5003A 17 12 6 Flat washer M5 Flat washer M5 RNG0026A RNG0026A Washer 22x9 RNG5007A (x1) 7 Gear shaft 9mm Gear shaft 9mm MCH5002A MCH5002A Gear shaft 5mm Gear shaft 5mm 8 MCH5003A MCH5003A 9 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 1.17 (Gear wheels are not available as separated spare parts) . MCH5002A 5mm .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 9.18 .MCH5003A 9mm .MCH5002A 9mm .MCH5002A 9mm .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 .MCH5002A 9mm .MCH5003A 5mm .MCH5002A 1 .MCH5002A 9mm .MCH5003A 5mm .MCH5002A 5mm .MCH5003A 5mm .MCH5002A 9mm .MCH5003A 5mm .MCH5003A 9mm .MCH5003A 9mm .MCH5002A 9mm .MCH5003A 5mm .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. 19 .1 . 20 .1 . 3.1 Main Board Top View 73 Screw M2.2 Main Board Bottom View 1 .3.21 .1.5x20 SCR0034A 31 Main board SPP5000H (ESB5000H) Spacer for tact switch boards INJ5061A 93 Figures 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. 22 .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 .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. 3.7 Drop Off Board connection 1 .5 Bumper Board Figures 1.3.6 Drop Off Board 77 Tilt housing + flag SPP5038A Figures 1.75 Bumper board ESB5003E Drop off Board ESB5008D 25 Figures 1.3.23 . 8 Perimeter Switch Board Connection to Perimeter Wire 28 Communication board ESB5004B Figures 1.24 .3.Connection to Power Supply Figures 1.3.9 Communication Board 1 . MSB5007A 1 .10 Drive motor assembly Magnet Sensor Figures 1. MSB5007A Drive motor cable WSB5003B 36 Odometer board (not available as spare part) Figures 1.30 Drive motor ass.10 Drive motor assembly .3.3.25 . 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 . . 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.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. 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 5diax8diax0.34mm x 1mm) 1 .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 9.1.28 . 29 .Technical details about the WN 1411 and 1412 screws: 1 .