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 bumper disconnected Front/Rear bumper pressed Keys locked 'X' Key pressed Start Elsewhere Mowing Disabled Theft Guard On Check mow height No wire signal Drive Problem Mowing Overload Cooling, WaitDrive Overload Cooling, WaitPath problem Ready Keep charging Recharge Battery Retry Elsewhere Set Country Time 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 initiating charging (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 to the charger). - 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. - 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 enable mowing. - 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 stuck or 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 drive motor. - 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 - 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 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 distance reached)
RL550 User Interface

User Options Press GO i Press GO again to skip Edge Zone A: MAX Press GO 1 lorn B: MAX Press GO | Zone C: MAX Press GO 1 Edge RoboScanZ MowinQ RoboScanZ
Manual Controller
* ,1
T 1^
Manual User Options
Manual Controller is user's hands ] User Preferences Press GO sound Press GO on Sound mowing on Press GO Mowing language Press GO English Work time Press GO Zone A: MAX Press GO A V Zone A : MAX A Confirm Child guard off Press GO Child guard Safety Tests Press GO front wheel snsr Press GO to test Front Wheel: On the ground Front Wheel: Lifted Bumpers Press GO to test *- ok D-discon. Front: - Rear: Buttons Press GO to test Press any key Service Press GO Password req. Press GO .00000 (0) next digit A V
key
on
on Confirm
off
12321 Confirm Set Country Press GO

USA
Confirm OK calibration Press GO
A V
activate motors Confirm Done score DK problem failed! K-18

XXX XX XXXX
retry elsewhere Edge calibration Press GO Edge calibration xxxdone Learn wire snsrs Press GO wait... Confirm was:x Now:x No:a confirm wire sensors Press GO i 1 1 1 1 JE Wf *
wait... advanced -aaa -ccc direction keeper Press GO
test passed confiiiit +bbb +ddd
mowing motors Press OO activate motors confirm test passed Confirm Force reset Press GO CPU version 61 Class:3 S.W. version: vx.xx (date) Board versions Press QO
petim swtoh g
total time: xxhxxm Bat. Maintenance Press OO

Last bat Volt 25 win ignored 0 Poof storage 0 Reset Press GO
Factory defaults Press QO

Are you sure?
Confirm
Small wheels off Press QO Small Wheels on Confirm Miscellaneous Press QO

BattV: Temp C F
Enable DK on Press GO Enable DK on Confirm Wide scan off Press GO Wide scan off A Confirm V Learn Edge Press GO (Appears only when the Manual Controller in its place)
Learn zone B Press GO to leam Learning Edge Press GO to leam Learning Edge STOP to set
Set default edge Press GO Zone A orig edge Press GO A V
RL800 User Interface

User Options Press 60 Zone A: Press OO again to skip Edge Edge RoboScan2 Mowing RoboScanZ
Manual Controlled in its cradle
MAX
Press GO Zone B: MAX Press GO B Zone C: MAX Press GO i
Manual Controller in user's hands Manual User Options User Preferences Press GO sound Press GO on Sound mowing on Press GO Mowing language Press GO English Work time Press GO Zone A: MAX Press GO A V Zone A: MAX A Confirm V Wide scan off Press GO A on A on *
1
Learn Edge Press GO (Appears only when the Manual Controller in its place)
Wide scan off Confirm
* V
Learn zone B A Press GO to team V Learning Edge Press GO to learn Learning Edge STOP to set
Set default edge Press GO Zone A orig edge Anti theft off Press GO Anti theft off A Confirm V Set lock passwd Press GO QOOO A next digit A
Key 1234 confirm

Child guard off Press GO
i. _ _
_
Safety Tests Press GO
Child guard off Confirm
A v
front wheel snsr Press GO to test Front Wheel: On the ground Front Wheel: Lifted Bumpers Press GO to test *-ok D-discon. Front: - Rear: Buttons Press GO to test Press any key Service Press GO Password req. Press GO 00000 10) next digit A V
PRICING
FriendlyRobotics
Robomower Spare Parts Price List for the 2003 Season (in US Dollars)
Friendly P/N
Part Description
2003 Dealer Price
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97
GEN0163A GEN0171A GEN0175A GEN0182A GEN0201A GEN0202A GEN0207A GEN0208A GEN0210A GEN0211A HSN0003A LMP0001A LMP0004A MSB0065A MSB0065B MSB0072A MSB0077A MSB0078A MSB0079A MSB0090A MSB0091B MSB0099A MSB0105A MSB0105B MSB0106A MSB0107A MSB0114A NIT0009A PRG0005A PRG0007A PWS0003A RNG0002A RNG0005A RNG0030A SCR0024A SCR0025A SNS0004A SPP0003A SPP0004A SPP0004B SPP0005A SPP0007A SPP0008A SPP0008B SPP0009A SPP0011A SPP0012A SPP0013A
Snap lock (curved) Motor shield, round Stake for perimeter switch Water drain seal Wheel cup, black Ground clearance limiter Front wheel detent Front wheel detent spring Charge socket seal Charge plug seal Thermistor heat sink insulator Operating bulb (version "A") Operating bulb (version 'B' & 'C') Mowing Motor w/mounting hub and spline Mowing Motor w/mounting hub and spline Manual controller- US Slider assembly Smooth drive wheel + bearing Gear spline + bearing Contact strip front assembly Contact strip rear assembly Knobby drive wheel + bearing Manual Controller Holder Assy Manual Controller Holder Assy Front bumper assy Rear bumper assy Manual Controller- US Pop rivet, thermistor Flash 3.2i RL800US Flash 3.2e RL550 US 1 1 5VAC power supply - US External zeger ring D12 DIN 471 BLK Washer D18*D12*0.5 DIN 988 Washer M10 DIN 125 Z P Front wheel ScrewWN1413K25*6 Screw for RL motors Double thermistor with harness Front wheel assembly (with board) Spare part gear case Spare part gear case Drop off board w/holder PS front cover w/board Drive motor replacement kit Drive motor replacement kit Gear shaft replacement kit Front wheel w/axle High cut blade (1) (Use accessory part #) Not Available
'.-':.'. .i:- " ---
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0.82 5.48 2.85 6.29 2.30 4.19 4.19 2.09 2.09 2.09 1.08 WSEE^BlOE '"'- *.. Rffji "Vi'^T!!??^! BJ&MPS0Q4A 5.48 ; ;>DuuooD tasfcw *of6*eise 55.96 6.27 17.15 12.50 20.93 20.93 19.95
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1.18 7.84 4.07 8.99 3.29 5.99 5.99 2.99 2.99 2.99 1.65 1 7.84 s,
79.95
8.96 24.50 17.86 29.90 29.90 ^ 28.50
impBMiiB 7.35
41.30 34.30 55.97 0.91 36.74 36.74 24.50 0.44 1.10 0.60 0.60 0.44
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10.50 59.00 49.00 79.95 1.30 52.49 52.49 35.00 0.63 1.57 0.86 0.86 0.63
^^ENWISM^j ! 6 926 118.48 """"""*'" 17.45 24.96 uUsy ttOOOTB 3P0038B I Iiil J ili "59.68 '2 1 85.27] 44.65 63.79 25.19 35.99
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FriendlyRobotics
# 1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
Friendly P/N
Part Description
2003 Dealer Price
2003 Retail
BAT0003A CBL0038A CON0054A CPS0007A DOC0008B DOC0010A DOC0015A DOC0015B DOC0051A DOC0051B ESB0018C ESB0019C ESB0020A ESB0022B ESB0031A ESBC017B ESBC021C ESBC024B ESBC025B FUS0003A FUS0012A FUS0021A FUS0015A GEN0094A GEN0095A GEN0101A GEN0103A GEN0104A GEN0111A GEN01 16A GEN0117A GEN0118A GEN0122A GEN0130A GEN0131A GEN0132A GEN0133A GEN0135A GEN0137A GEN0138A GEN0140A GEN0142A GEN0143A GEN0144A GEN0145A GEN0146A GEN0148A GEN0156A GEN0162A
Battery holder for perim.switch Ext. Charger Power Cable Plot Connector (Use Accessory part #) Wire twist lock RoboRuler Installation Video Owner/user manual 2001-2002 500 Owner/user manual 2003 500/550/800/850 Service Guide (English hard-copy) Service Guide (English hard-copy) Incl. CD Drop-off board Main Board Wire Sensor Board Lamp Board Rear RH Wire Sensor Board Charge socket board Connectors Board Odometer Board R Odometer Board L Fuse AT blade 30A 32V Fuse AT blade 1 A 32V Fuse, External Charger 10A, 125V Fuse mini blade 5A RL cover RL Base Odometer magnet Gear unit frame only Wheel Cup, gray Contact leaf-base Drop off flag Adjusting hub, front wheel Front Wheel Click Spring Gear shaft clamp Contact leaf-battery Power pack case Power pack cover Magnet for Manual Controller Contact base adaptor Operating lamp cover Operating Lamp Seal Sealing cup Connector's cover Manual controller's holder Charge socket housing Pivot for manual controller's tray Main board rubber holder MC navigator keypad PS back cover Snap lock (straight)
5.59 12.47
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8.00 17.81 s
3.13 4.50
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2.19 3.15 .,,,,
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45.00 1 t3SE$PPWJ05A USSPPtk)19A USESPPOQ18A 13.46 10.96 26.54 14.06 14.06 1.53 2.19 3.20 2.19 97.95 105.00 0.93
2.30
* 19.25 15.67 37.95 20.11 20.11 2.19 3.13 4.57 3.13 125.00 150.00 1.33 .,-,.,-V .;. I 3.29
7.84 20.14 3.59 4.31 12.34 21.75 18.18 5.64
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5.48 14.09 2.51 3.01 8.63 15.21 12.72 3.95
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6.19 1.88 1.66 5.64
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3.78 6.30 0.82
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mm
2.19 5.41 9.01 1.18
FriendlyRobotics
Friendly P/N
Part Description
98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133
SPP0014A SPP0015A SPP0016A SPP0018A SPP0019A SPP0020A SPP0021A STC0012A STC0018A STC0022A STC0036A STC0048A STC0049A STC0050A STC0051A STC0052A TOL0001A UNT0007A UNT0007B UNT0016A WSB0025A WSB0025B WSB0035A WSB0040A WSB0041A WSB0042A WSB0043A WSB0044A WSB0045A WSB0046A WSB0048A WSB0049A WSB0052A WSB0053A WSB0055A WSB0063A
Battery contact assembly RL side Gear frame Flash 3.2i with US manual Wire sensors assembly with harness Main Board RL800/RL550 Thermistor assy, heat pads and pop rivets Main Board With Flash, Special RL500 Rear warning sticker Danger sticker Front caution sticker FR power pack charging decal RL550 Decal RL850 Decal RL500 Decal RL800 Decal TheftGuard decal RL800 Mowing motor removal tool Perimeter Switch 5Hr Perimeter Switch 5 Hr External Charger Adaptor Perim. wire to perim. switch cable PS cable, molded Main board to battery cable Wire sensors cable Odometers cable Drop-off cable Bumper cable Lamp board cable Charge socket cable Power pack fuse holder w/wire Power pack cable, negative Power pack cable, series jumper Flat cable Mowing motors cable External battery charge cable Drive motor cable w/ferrite ring
mm
m* Ip2ie 4.19
6.33 USES!*P0018A 8.29 4.52 7.08 2.86 11.23 15.76 0.00 13.73 166.25 23.00 173.33 0.93 0.93 0.96 1.70 3.49 3.49 3.49 3.49 3.73 35.73 13&E13! 53.75 19.55 16.06 22.54 0.00 19.63 237.75 32.89 247.61 1.33 1.33 1.38 2.43 4.98 4.98 4.98 4.98 5.33 51.10
77.50 27.95
yam 13.71
9.05 I 11.85 6.46 10.13 4.09
3.48 3.48 9.19 4.97
13.71
IA
ir:~v3
4.96 4.98 13.14 7.11
19.61
BULLETINS
Robotics
U.S. Service Bulletins
riendlvRobotics
Service Bulletin #RL0301-02
Technical Service Bulletin

Date: 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 version utilizes 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. Included with these two parts is a Ground Clearance Limiter, part # GEN0202A. When using the gear frame version with the riser removed on units with the larger knobby/treaded wheels, it is also necessary to install the limiter (GEN0202A) to allow for proper clearance between the larger knobby/treaded wheels and the cowling. See Figure below. When using the frame where the riser is intact on units with knobby/treaded wheels, no additional procedure is required and the limiter (GEN0202A) is not needed.
Slick/small wheel units require this
Knobby / treaded wheel units require this
Ground clearance limiting riser molded to gear frame. They may be removed if necessary 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 block the 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. assembly includes the following parts: Gear Case Ground Clearance Limiter (GEN0202A) Thermistors kit (SPP0020A) Extra motor shading (GEN0171 A) The
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 the metal pieces may cause to short in the electronics). 2. Remove the right mowing motor shield 3. 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 connector disconnected as a future.
Right mowing motor shield
v?
Connection to the Main Board (only from S/N IRL03 and onwards)
Figure 1
Page 2
FriendlvRobotics
Date: December 25,2002 Product Model: RL500 US & RL800 Europe Serial Range: IRL02340100 and below Part Number SPP0018A Countries Affected: All
Wire Sensors/Cable (SPP0018A) A new wire sensor assembly is introduced for 2003. All four wire sensors and the harness are included 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 only spare part SPP0018A is provided. On these units, the right rear sensor board (Figure 1) must be removed from the support tower and placed in the right rear corner well of the base, as shown in Figure 2. Leave the black and white wires connected to the sensor board. All other sensor parts and wires are removed and discarded. Install part SPP0018A to complete the repair.
Figure 1 Note: Confirm the top side of the the sensor is place as shown in Figure 3.
Figure 2
Figure 3
IvRobotics
Date: December 25, 2002 Product Model: RL500/550/800/850 Serial Range: IRL03000000 and above Part Number GEN0094A Countries Affected: All
Service Bulletin 3RL0301-O4
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 a Robomower with a S/N IRL02340100 and below use the Top Cover as received without modifications.. 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
Figure 1
Figure 2
DOC0056A for SPP0004B and SPP0015A
Robotics

Date: December 25,2002 Product Model: RL500/550/800/850 Serial Range: IRL03000000 and above Part Number GEN0207A / GEN0208A Countries Affected: All
Front Wheel Detent Change A new front wheel detent is introduced for 2003. If the S/N is IRL03000000 and after, use the new Front Wheel detent (GEN0207A) with two Front Wheel detent springs (GEN0208A) as shown in Figure 2 below. If you are servicing a Robomower with a S/N IRL02340100 and below, use part number GEN0118A, front wheel detent spring, as shown in Figure 1 below.
Figure 1
Figure 2
Robotics
Service Bulletin 3RL0301-06

Date: December 25, 2002 Product Model: RL550/800/850 Serial Range: IRL03000000 and later Part Number MSB0065B - Mowing Unit Countries Affected: All
Blade Motor Change (MSB0065B)
A new blade motor, part number (MSB0065B) is introduced for 2003. The wire harness at the motor end is now soldered to the terminals for better rigidity. When replacing the blade motor on all S/N units it will be necessary to remove the cowling first in order to disconnect the motor wires from the main board. Then remove from the blade motor from the base with special tool TOL0001A. See Figure 1. IMPORTANT - It is also necessary to remove the metal motor shield from the original motor and place it on the new motor before installation. See Figure 2. Inventory of the MSB0065A, which does not have soldered leads, may be used on IRL02340100 and below units until depleted and does not require removal of the cowling.
Stepl
Step 2
Step 3
Figure 1
Metal shield must be removed from motor and placed on new
Figure 2
motor before installation.
DOCforMSBOOSSB
IPL's
Robotics
RL500
Illustrated Parts List
57 58 59
RL500 Operating & Safety Manual
60
51
53
:52
69
54 65 56
"55
RL500 US
<M
',
ISPP0014AI
Battery Contacts RLside
1)TOfM3ffBfd.
SPP0005A
Main board to battery cable
1
Optical sensor board cable FUS0012A Fuse 1 Amp Flat cable
iWSB0052A 1 . Fuse 3 Amp |
Manual Controller IMSBOIUAI

Red
Fuse holder & cable WSBO046A
Fuse 30 Amp
. Fuse
, Holder I
Manual CpnWfer Charge board cable JWSB0045AI
Battery
EH
1
Battery jumper cable WSB0049A Grey
Red
Connectors Board Mowing motor cable lWSB0053AlRfldGBen(X3i / wire sensors cable Lamp board
Contact "LeftH
IWSBOMOA]
Bumpers cable JBlue White 1 Gray Purple
LampBrd,
Battery
i '
Black
Negative battery cable WSBO048A
I21 yUi* \ f
lu
tensor Fra< RH
Lm
Front
IK
Em
mm Rear
sensor
sensor fear
RH
m^
short
long medium
Red
Front Bumper LH
: X Number of pins on connector
Front Bumper RH
Bumper
External Charge Socket External charge socket & cable
RL500 US Wiring Parts List
Parts List RL500
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
GEN0146A GEN0207A CPS0007A ESB0020A SPP0021A ESBC021C FUS0012A FUS0015A SPP0004B ESB0031A SPP0020A GEN0182A MSB0106A MSB0090A GEN0095A MSB0091B MSB0107A SPP0011A GEN0162A GEN0171A MSB0065B MRK0002A GEN0140A GEN0162A ESB022B GEN0133A RNG0005A RNG0002A GEN0201A MSB0099A GEN0094A GEN0142A MSB0105B GEN0145A MSB0114A GEN0138A GEN0137A LMP0004A UNT0009A GEN0202A ESBC024B ESBC025B SPP0008B SCR0025A GEN0101A SPP0009A SCR0025A GEN0122A MSB0077A MSB0079A UNT0007B
Main board rubber mount Front wheel detent Wire twist lock Wire sensor board Main board, RL500 special Connector board Fuse, 1A 32V Fuse, mini 5A Gear case assy, complete RR wire sensor board Thermistor assy w/hardware Water drain seal Front bumper Front bumper contact strip Mower base Rear bumper contact strip Rear bumper Front wheel w/axle Snap lock, curved Motor shield Mowing motor assembly Cutting blade, set 3 Sealing cup Snap lock, straight Operating lamp circuit board Magnet, manual controller Washer, shim Retaining ring, wheel Wheel cup, black Knobby wheel w/bearing Mower cowling Connector board cover Manual controller pocket Manual controller pocket pivot Manual controller pocket Operating lamp cover seal Operating lamp lens cover Operating lamp bulb Power pack assy Ground clearance limiter Odometer board, RH Odometer board, LH Drive motor kit Screw, drive motor Odometer magnet, pinion Gear and shaft kit Screw, drive motor Gear shaft clamp Slider , seal Gear spline w/bearing Perimeter switch only j
52 53 54 55 56 57 58 59
60 61 62 63 64 65 66 67 68 69
GEN0175A GEN0156A BAT0003A MRK0024A WSB0025B PWS0003A DOC0008B MRK0024A DOC0015B RNG0030A GEN0117A GEN0116A SPP0005A SPP0011A GEN0131A FUS0003A GEN0132A GEN0130A
Perimeter switch stake Perimeter switch back cover Perimeter switch battery holder Connector, perimeter switch Perimeter switch cable Power supply, charging RoboRuler Wire nut, sealing splice Op/Safety Manual RL550/RL800 Washer, front wheel Front wheel adjusting hub Flag, lift sensor Lift sensor circuit board w/holder Front wheel w/axle Power pack case Fuse, power pack 30A 32V Power pack cover Contact, power pack side NOT SHOWN
STC0012A STC0018A STC0022A STC0036A STC0050A TOL0001A UNT0016A CBL0038A DOC0051B FUS0021A
Warning decal, rear Blade warning decal, side Front lift warning decal Charging decal, power pack RL500 decal Mowing motor removal tool Adaptor, external optional fast charger Power cable, optional fast charger Service manual w/CD Fuse, optional fast charger 10A 125V
Note additional part numbers located on Wiring Parts List
Dealer Manual 2-2003
Robotics
RL550/800
Illustrated Parts List
CD
1
41 11
RL550/800 Operating & Safety Manual
63 10 60
74
\
72 73
64
70
71
54
56
!55
57
69
59
\ 58
22
44
RL550/800 US
SPP0014A I RLside
(tofHJffBrd,
SPP0005A
[MSB0114AI Manual Controller cable
Main board to 0 battery cable 1 Optical sensor board cable IWSB0042AI Fuse 1 Amp Flat cable WSB0052A Fuse 3 Amp |
Red
Fuse holder & cable WSBO046A
i Fuse I Holder I
Manual ConMa
Battery
Red
Charge board
cable IMSB0105BI Battery jumper cable
WSB0049A Grey
.Battery Contact Left{+)
Mowing motor cable iistofLWSB0053A| RedGreen(X3) TherrnL Asseml nbly / /
Negative battery cable
Black
Odometers cable WSB0041A

Yellow
3E
WSB0048A
. Battery Contact GEN0130A
Orange!
m
Assembly W/Hamess Front Bumper LH Front Bumper RH
Odometer board Oofxnetef board LH RH

ESBC0253 ESBC0024B
Bumper
Note:(x] Number of pins on connector
RL550/800 US Wiring Parts List
Parts List RL550/RL800
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
GEN0146A GEN0207A GEN0208A CPS0007A SPP0018A SPP0019A ESBC021C FUS0012A FUS0015A SPP0004B SPP0020A SPP0014A GEN0182A MSB0106A MSB0090A GEN0095A MSB0091B MSB0107A SPP0011A GEN0162A GEN0171A MSB0065B MRK0002A GEN0140A GEN0162A ESB022B GEN0133A RNG0005A RNG0002A GEN0201A MSB0099A GEN0094A GEN0142A MSB0105B GEN0145A MSB0114A GEN0138A GEN0137A LMP0004A UNT0009A GEN0202A ESBC024B ESBC025B HSN0003A NIT0009A SPP0008B SCR0025A GEN0101A SPP0009A SPP0015A GEN0122A
Main board rubber mount Front wheel detent Front wheel detent spring Wire twist lock Wire sensor assembly Main board - RL550/RL800 Connector board Fuse, 1 A 32V Fuse, mini 5A Gear case assy, complete Thermistor assy w/hardware Battery contact, RL side Water drain seal Front bumper Front bumper contact strip Mower base Rear bumper contact strip Rear bumper Front wheel w/axle Snap lock, curved Motor shield Mowing motor assembly Cutting blade, set 3 Sealing cup Snap lock, straight Operating lamp circuit board Magnet, manual controller Washer, shim Retaining ring, wheel Wheel cup, black Knobby wheel w/bearing Mower cowling Connector board cover Manual controller pocket Manual controller pocket pivot Manual controller pocket Operating lamp cover seal Operating lamp lens cover Operating lamp bulb Power pack assy Ground clearance limiter Odometer board, RH Odometer board, LH Thermistor heat sink pad Pop rivet, thermistor Drive motor kit Screw, drive motor Odometer magnet, pinion Gear and shaft kit Gear frame only Gear shaft clamp |
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 |
MSB0077A MSB0079A UNT0007B GEN0175A GEN0156A BAT0003A MRK0024A WSB0025B PWS0003A DOC0008B MRK0024A DOC0015B GEN0211A RNG0030A GEN0117A GEN0116A SPP0005A SPP0011A FUS0003A GEN0132A GEN0130A GEN0131A MSB0105B GEN0210A
Slider , seal Gear spline w/bearing Perimeter switch only Perimeter switch stake Perimeter switch back cover Perimeter switch battery holder Connector, perimeter switch Perimeter switch cable Power supply, charging RoboRuler Wire nut, sealing splice Op/Safety Manual RL550/RL800 Charge plug seal Washer, front wheel Front wheel adjusting hub Flag, lift sensor Lift sensor circuit board w/holder Front wheel w/axle Fuse, power pack 30A 32V Power pack cover Contact, power pack side Power pack case Manual controller pocket Charge socket seal NOT SHOWN
STC0012A STC0018A STC0022A STC0036A STC0048A STC0050A STC0052A TOL0001A UNT0016A CBL0038A DOC0051B FUS0021A
Warning decal, rear Blade warning decal, side Front lift warning decal Charging decal, power pack RL550 decal RL800 decal TheftGuard decal, RL800 Mowing motor removal tool Adaptor, external optional fast charger Power cable, optional fast charger Service manual w/CD Fuse, 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 o It is highly recommended to watch the service video clips, on the Dealer CD, prior to servicing a RoboMower. For servicing an RL550/800, see the previous document in this divider.
Table of contents
Page
2 3 3 4 5 6 6 7 8 8 8 8 9 9 9 10 10 10 10 10 11 12 12 13 13 14 14 15 15 16 17 17 17 18 18 19 19 20 21
1. Tools, bench and work area recommendations 2. RoboMower layout and main components 5.1. Top view and power pack terminals polarity 5.2. Bottom view 5.3. Inside main components 3. Opening the RoboMower 4. Closing the RoboMower 5. Typical technical problems and their solution 5.1. Mower doesn't respond: Low voltage power pack 5.2. Charging problem: Power supply (regular mower charger) faulty ... 5.3. Charging problem: Charging fuse is faulty 5.4. Charging problem: Manual controller holder is faulty 5.5. Charging problem: Other charging problems 5.6. Charging problem: External charging problems 5.7. Manual controller problems: Keys do not respond 5.8. Manual controller problems: Keypad is torn 5.9. Manual controller problems: Magnet sensor faulty 5.10. Manual controller problems: Emits a squealing noise 5.11. Perimeter switch problems: P.Switch doesn't turn on 5.12. Perimeter switch problems: P.Switch indicates low batteries 5.13. Perimeter switch problems: P.Switch wires came out 5.14. Drive/Gear problems: Mower doesn't drive properly 5.15. Drive/Gear problems: Growling noise from rear wheels 5.16. Drive/Gear problems: Rear wheel height adjustment handle broken.. 5.17. Drive/Gear problems: Rear wheels spin, loosing track 5.18. Wire crossing in automatic mode: Main Board issues 5.19. DK calibration fails repeatedly: Main board/compass issues 5.20. Performance issues: Edge mowing is not completed 5.21. 'Wire too close' message: Learn wire sensors is needed 5.22. 'Mowing problem' message 5.23. Automatic mowing problems: Wire sensors contacts corroded 5.24. Front wheel problem: Front wheel contact 5.25. Bumper issues: Bumper is disconnected 5.26. Bumper issues: Bumper sounds without hitting an obstacle 5.27. Bumper issues: Bumper is pressed 5.28. Performance issues: RoboMower doesn't advance is scan mode... 5.29. Mower stops driving but blades run in Scan mode 5.30. Doesn't respond: Underside was exposed to excessive water 6. Display messages meaning 7. Diagnostics fault table and meaning
1. Tools recommended
1.1. 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 tweezers 1.6. 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 be laid on the floor under a carpet or attached to it with tape. For wire diagnostics it is recommended to have at least a 20x20 feet area. Advanced wire sensor diagnostics could be done on any size of plot.
2. RoboMower layout and main components

2.1. Top view
Front
Front bumper Front lifting handle Manual controller holder (cradle)
Manual controller
Left side
Left rear wheel
Right side
Right rear wheel
Operating light
Power pack (Battery pack) Power pack Lifting handle
Power pack terminals polarity
Negative ( Positive (+)' 30 amp fuse
2.2. Bottom view Note: Mower sides are determined by its top view.
Front
Front locks - 4 Semi curved Front wheel
Manual controller
Right side
Right mowing motor/blade Center mowing motor/blade Right rear
Left side
Left mowing
Left rear
Drainage Rear locks - 6 straight ones
Rear
2.3. Inside main components
Front
Front wire Front wheel lock Left mowing motor Right mowing motor/blade Front bumper Wires & tabs
Right
Main board
Right odometer Right drive motor Left rear Rear wheels height adjustment handle
Left odometer board Left odometer board
Rear
3. Opening the RoboMower

3.1. 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 round ones 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 when standing behind the mower looking at its front.
4. Closing the RoboMower

4.1. 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't pushed against the connectors board, which should go into its hole in the yellow part without being touched. 4.6. Once the top yellow part is positioned correctly in a way that will not harm the connector board, push it down. You may need to guide the two yellow legs at the battery 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 the lower gray part. 4.8. Turn the mower upside down and make sure the rubber seals and the rear wheel axle area are positioned properly and none escaped aside. If a rubber seal has escaped and is 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: 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 front groove. Than close connector board cover. Make sure it locks into its place by trying 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 solution

5.1. Mower doesn't respond: Low voltage power pack
Problem 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 'Fully charged' 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, and then insert the power pack to the mower, which should now wake up. Try to charge regularly at the mower. The right hand power pack connector (when facing you) is the positive (+) 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 or recognize 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 no display on the manual controller. This could indicate a faulty manual controller. Try to swap 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 and replace at this order: Main fuse (FUS0012A), Connectors board (ESBC021C), 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 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) faulty

Problem '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 excessive use by other power supplies. In this case, use another wall outlet.
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 faulty

Problem 'Charging problem' appears on display + beeping sound, 10 seconds from plugging 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 ohms resistance. Resolution Replace the fuse and make sure mower is charging ok. (FUS0015A)
5.4. Charging problem: Manual controller holder faulty

Problem '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 problems

Problem 'Charging problem' appears on display + beeping sound, 10 seconds from plugging the power supply plug to the cradle socket. Power supply outcome voltage is above 32 VDC. Charging fuse is fine. Resolution Check 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 problems

Problem External charger lights are off even though it is connected to good AC power outlet and 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 respond

Problem One or more buttons do not respond. Resolution Manual controller was exposed to water or excessive humidity. Some button contacts have corroded. On rare cases could happen to a new mower taken out of the box. Get to Diagnostics, 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 torn

Problem Keypad is torn, usually at the steering pad area. Reso/t;f/on Replace manual controller. The new ones have a thicker, way more durable rubber keypad that will not get torn again. (MSB0114A).
5.9. Manual controller problems: No automatic mode display

Problem Manual controller display remains on 'Manual settings' rather than changing to automatic mode display when manual controller is in its cradle and flushed with the mower 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 noise

Problem Manual controller emits a squealing noise. Resolution Replace it. (MSB0114A).
5.11. Perimeter switch problems: P.Switch doesn't turn on

Problem Perimeter switch doesn't respond when green button is pressed. Batteries inside it are fine/new.
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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 left outside, but it got to be mounted vertically! If it wasn't mounted vertically and got water penetration, it isn't covered by warranty! The customer should purchase a new one.
5.12. Perimeter switch problems: P.Switch indicates low batteries

Problem 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: The perimeter wire could be 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 shows battery low indication by mistake, while intending to show wire cut indication. Fixing the perimeter wire will cure this problem.
5.13. Perimeter switch problems: P.Switch wires came out

Problem Perimeter switch wires came out of the green fast connector. Resolution Replace these wires with new molded ones. (WSB0025B) by opening the perimeter switch and releasing the broken ones from the connectors.
5.14. Drive/Gear problems: Mower doesn't drive properly

Problem (a combination of the following) One or both rear wheels are not driving properly while manually or automatically 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 between the two or whether one of them is stuck or loose.
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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 touching the ground. The front wheel needs to remain solidly on the ground. Try to drive the mower manually and see the rear wheel behavior, which one is stuck or not moving. Get to 'Service key', insert password 12321, press green button twice and scroll down to 'Drive motors'. Green button to activate and another to confirm. This will result in a 'Passed' or 'Failed' message. When it fails, it will also give an error number, which will look like this: Failed # 201. This is only an example and error # 201 is for Left motor disconnected. Faults error list - see chapter 7. Press C and you will be back to 'Drive motors' test. If you press the green button 3 times now, you will do an advanced test, which will show the raw odometers reading on each drive motor. The top line of the display will show the MSR - measured RPM of both drive motors and the bottom display line will show PWM - the current needed to get to this RPM on each drive motor. These raw reading numbers can tell us a lot about the drive motors. Can the mower equalize their speed? The MSR numbers will be identical. Is there a different friction on one drive motor and gears? The PWM will show it and be higher on the side the friction is larger. 00 or no reading at all on any of the advanced diagnostics display usually means 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 wheels

Problem 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
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Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 For un'rts serial number starting with IRLOO, IRL01, IRL02
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wheel spline and squirt generously. The lubricant will penetrate to the gear case and lubricate the gear bushing which makes the noise. In case it doesn't help, open the mower and squirt directly on the plastic gears 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 cable that can connect only to a new version main board, but can work with an old version main board without connecting to it. Thread the wires through the white wire holders towards the front of the mower in a way that will prevent the wires getting close to the gears or drive pinion. Replace the right mowing motor shield with the one that is attached to the Thermistors cable. In the future, in case a main board will be replaced on this mower with a new version one which is compatible with the Thermistors, the Thermistors cable would be connected to it.
5.16. Drive/Gear problems: Rear wheels height adjustment handle broken

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 track

Problem 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 limiter and the latest RL500 software version available, 3.2. (Get the brain on a case 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).
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Improve installation if needed.
5.18. Wire crossing in automatic mode: Wire sensors or main board issues
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 the reading 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 one harness. (SPP0018A). Perform Learn wire sensors inside an active wired area and Edge calibration through Service key 12321 and Diagnostics menu. The rear right wire sensor, which serves as a rear bumper connector as well, should be left in the mower, attached to the rear bumper wires. The best place to put it is at the hollow corner of the gray mower base at the rear right area. If the low wire sensor reading doesn't improve while playing with the contacts or replacing the wire sensors, 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. (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 issues

Problem Mower keeps ending DK calibration with a 'Retry elsewhere' message on display. Very rarely the display could say 'Failed = 18'.
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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. Many times 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 completed

Problem Mower leaves Edge and starts mowing the inside of the plot prior to completing one full circle around it. There isn't an obstacle on edge that makes it leave the wire. (In case there 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 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). If this doesn't help, perform 'Learn edge' through 'User options' when manual controller is in its cradle, which teaches the mower the true length of the edge to be done. (Available now since the new main board comes with RL550 software).
5.21. 'Wire too close' message: 'Learn wire sensors' is needed

Problem Mower refuses to start working in automatic mode, indicating 'Wire too close' while it isn't close to the wire at all. This is common after replacing a wire sensor or a main board. Could also happen to a new mower out of the box, on its first automatic operation.
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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). 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 the green button again (Very important!) in order to finish the process. Put the manual controller back into the mower and operate it automatically. If you just replaced a main board on this mower, you need to set GEO location and do another DK calibration prior to being able to work in automatic 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 message

Problem 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 grass conditions, wait 20 minutes and operate again. In some occasions the grass should be mowed first with a heavier type mower, in order to reduce its height. Remove power pack and check whether grass has clogged the blades 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 a 'Mowing problem' happens without any of the above conditions, test the mowing motors through Service password 12321, Diagnostics/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 faulty. Check the mowing motor wires for discoloration. If they overheated you will 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).
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4. Edge calibration (Could be done anywhere, even in an unwired area).
5.23. Automatic mowing problems: Wire sensors contacts corroded

Problem 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 wire sensors through Diagnostics/Wire sensors/Advanced. If one wire sensor shows a very low reading (000-006), while other wire sensors reading are high, it probably means this wire sensor contact is corroded or a faulty wire sensor. It could also be that one sensor reading is 20-30 while the rest of them are showing a lot higher reading, such as 60-200. In both faults the remedy is replacing the wire sensors plus their harness. Open the mower and play with this contact. If it cures the reading, add some 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 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).
5.24. Front wheel problem: Front wheel contact

Problem 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
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remove the corrosion. Test front wheel sensor again. It should say 'On the ground' when not lifted. In case this doesn't cure the problem, open the mower and replace front wheel 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 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).
5.25. Bumper issues: Bumper is disconnected

Problem 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 the bumper inserts for easy removal and insertion of the new one. No tool is needed for removing and replacing the new one. Lubricate the new bumper 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 obstacle Problem

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 area will be where merely touching the bumper will activate it, indicating regular operation vibrations will activate it. Open the mower and replace the oversensitive bumper. Rear bumper (MSB0107A). Front bumper (MSM0106A).
5.27. Bumper issues: Bumper is pressed

Problem Unit displays 'Front or Rear bumper pressed' message constantly.
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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 temporary cure the rubber in dented way pressing it all the time. (Check with the customer if this 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 mode

Problem Unit keeps going back and forth on the same lines without advancing sideways. 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 between mowing lines and will solve the problem. 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). 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 to Service menu and set 'Enable DK' to off.
5.29. RoboMower stops driving but blade keeps on in Scan mode

Problem 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 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). If the mower has slick wheels, choose 'Small wheel' option in Service menu.
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5.30. Doesn't respond: Underside was exposed to excessive water

Problem Unit doesn't respond at all after being exposed to rain, sprinklers or excessive water while being cleaned. Typical if the mower was positioned upside 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 not get 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 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).
6. Display messages meaning

Message Blocked path Calibration Req. Check Power Charging problem Recharge Bat. Failed K=18 Front wheel problem 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 power supply) - The charger is connected but not charging (Probably faulty Main 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.
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- There is a problem with Drop-off board. Front/Rear bumper - Bumper wire disconnected inside the RoboMower. disconnected Front/Rear - Front or rear bumper is constantly pressed. bumper pressed - Child guard set to 'on' - Press the scroll upper arrow and Keys locked then C to enable mowing. - One of the keys on the manual controller is pressed 'X' Key pressed continuously upon reset. - When activating motors under 'Diagnostics' but 'mowing' is Mowing set 'off Disabled - Mowing motors have faced over-current for too long or some Mowing problem obstacle is stuck or wrapped around the blades. - The RoboMower cannot detect a signal from the Perimeter No wire signal Wire. - One of the odometers is not reading a signal from the magnets Drive Problem on the drive motor. - Drive motors have faced overheating - the mower stops for Motor OVC cooling. -Bumper hits an obstacle in less than 2 feet from mowing initiatioi Path problem - There is a problem with the compass readings (during DK Retry Elsewhere Calibration or as pressing the 'GO' button). Set GEO - GEO location is not set (Set your country) Location - Displayed when the time set on 'Work time' is reached. Time! - The RoboMower is too close to the perimeter wire or on the Wire too close wire itself. Or, a 'Learn wire sensors' needs to be performed.
7. Diagnostics fault table and meaning.

Fault* Diagnosed 100 Drive motors (Forward) 101 Drive motors JForward) 102 Drive motors (Forward) 110 Drive motors (Forward) 111 Drive Meaning Right motor current< 100mA Left motor currents 100mA Right & Left motors current< 100mA Right odometer reading=0 Left odometer Possible cause Right motor is disconnected Left motor is disconnected Right & Left motors are disconnected Right odometer is disconnected Left odometer is disconnected
20
21
112
120
121
121
130
131
140
141
142
motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (Forward)
reading=0 Right & Left odometer reading=0 Right motor pwm>95% Left motor pwm>95% Right & Left motors pwm>95% Right wheel pwm>Left wheel pwm Left wheel pwm>Right wheel pwm Right pwm<78 or >82 Left pwm<78 or >82 Right & Left pwm<78 or>82 Meaning Measured PWM difference >2 Right motor current< 100mA Left motor current< 100mA Right & Left motors current< 100mA Right odometer reading=0 Right & Left odometers are disconnected Right wheel friction is too high Left wheel friction is too high Right & Left wheels friction is too high Right wheel friction>Left wheel friction, or Right motor is slower than Left motor Left wheel friction>Right wheel friction, or Left motor is slower than Right motor Test again Test again Test again
Fault* Tested 143 Drive motors (Forward) 200 Drive motors (Backward) 201 Drive motors (Backward) 202 Drive motors ^Backward) 210 Drive motors (Backward)
Possible cause Test again Right motor is disconnected Left motor is disconnected Right & Left motors are disconnected Right odometer are disconnected
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22
Drive motors (Backward) 212 Drive motors (Backward) 220 Drive motors (Backward) Drive 221 motors JBackwardJ^ 222 Drive motors (Backward) 230 Drive motors (Backward) 231 Drive motors (Backward) 240 Drive motors (Backward) Drive 241 motors (Backward) 242 Drive motors (Backward) Fault* Tested
211 243 301 302 303
Drive motors (Backward)
Left odometer reading=0 Right & Left odometer reading=0 Right motor pwm>95%
Left odometer are disconnected
Right & Left odometers are disconnected Right wheel friction is too high
I
Left motor pwm>95%
Left wheel friction is too high
Right & Left motors pwm>95% Right wheel pwm>Left wheel pwm Left wheel pwm>Right wheel pwm Right pwm<78 or >82
Right & Left wheels friction is too high Right wheel friction>Left wheel friction, or Right motor is slower than Left motor Left wheel friction>Right wheel friction, or Left motor is slower than Right motor Test again
Left pwm<78 or >82 Right & Left pwm<78 or>82
Test again Test again
_^ 304
305
<
s~
306 307
Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing
Meaning Possible cause Measured PWM Test again difference >2 Right Motor current > Right Motor power unit is faulty 100mA Mid Motor current > Mid Motor power unit is faulty 100mA Right + Mid Motor Right+Mid Motor power units are current > 100mA faulty Left Motor current > Left Motor power units is faulty mrnfc < Right + Left Motor Right+Left Motor power units are current > 100mA faulty Mid+Left Motor current Mid+Left Motor power units are > 100mA faulty Right+Mid+Left Motor Right+Mid+Left Motor power units
22
23
331 332 333 334 335

336 337
motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors
Mowing motors
current > 100mA Right Motor current < 100mA Mid Motor current < 100mA Right+Mid Motor current < 100mA Left Motor current < 100mA Right+Left Motor current < 100mA
Mid+Left Motor current < 100mA
are 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
341
342
343
344
345 346 347
Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors
Right+Mid+Left Motor current < 100mA Right Motor current > 2A Mid Motor current > 2A
Right+Mid+Left Motors are disconnected Right Motor is overloaded Mid Motor is overloaded
Right+Mid Motors are overloaded Right+Mid Motor current > 2A Left Motor current > 2A Left Motor is overloaded Right+Left Motor current > 2A Mid+Left Motor current >2A Right+Mid+Left Motor current > 2A Right+Left Motors are overloaded Mid+Left Motors are overloaded Right+Mid+Left Motors are overloaded
Fault* Tested 351 Mowing motors 352 Mowing motors 353 Mowing motors 354 Mowing motors
356
357 401
motors Mowing motors Mowing motors Wire
Meaning Possible cause Right Motor current > Right Motor stopping is faulty 100mA Mid Motor current > Mid Motor stopping is faulty 100mA Right+Mid Motor Right+Mid Motors stopping is faulty current > 100mA Left Motor current > Left Motor stopping is faulty 100mA ( R/qht+Left Motor R/ght+Lefi Motors stopping is faulty current > 100mA Mid+Left Motor current Mid+Left Motors stopping is faulty > 100mA Right+Mid+Left Motor Right+Mid+Left Motors stopping is current > 100mA faulty FR sensor <2 FR sensor is disconnected
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402 403 404 405 406 407 408 409 410 411 412 413 414 415
sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors
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+RL sensors<2 Meaning FR sensor is noisy FL sensor is noisy FR+FL sensors are noisy ( RR sensor )s noisy S FR+RR sensors are noisy FL+RR sensors are noisy FR+FL+RR sensors are noisy RL 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 are disconnected RL sensor is disconnected FR+RL sensor are disconnected FL+RL sensor are disconnected FR+FL+RL sensors are disconnected RR+RL sensor are disconnected FR+RR+RL sensors are disconnected FL+RR+RL sensors are disconnected FR+FL+RR+RL sensors are disconnected Possible cause FR 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
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Fault* Tested Wire sensors 422 Wire sensors 423 Wire sensors < 424 (_I Wre sensors 425 Wire sensors 426 Wire sensors 427 Wire sensors 428 Wire
421
25
429 420 431 432 433 434 435 450 500 510 523 525 526 527
sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Direction Keeper Direction Keeper Direction Keeper Direction Keeper Direction Keeper Direction Keeper
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 Low resolution reading=0 Low resolution readings are noisy Coils 1 +2 cannot be zeroed Coils 1+3 cannot be zeroed Coils 2+3 cannot be zeroed Coils 1+2+3 cannot be zeroed Meaning Coils 1+3 cannot be zeroed Coils 2+3 cannot be zeroed , Co))s 1+2+4 cannot be zeroed Coils 3+4 cannot be zeroed Coils 1+3+4 cannot be zeroed Coils 2+3+4 cannot be zeroed Coils 1+2+3+4 cannot be zeroed
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 disconnected Magnetic interference disconnected Magnetic interference disconnected Magnetic interference disconnected or coils or coils or coils or coils
529
Fault* Tested Direction Keeper 530 Direction Keeper
Possible cause Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magneto interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected
25
531
532 533 534 535
/ Direction
Keeper Direction Keeper Direction Keeper Direction Keeper Direction Keeper
Friendly North America, Inc. Sen/ice Guide 2003 Updated: 3/26/2003 For units serial number starting with IRLOO, IRL01, IRL02
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RL 550/800
Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 To be used with RoboMower serial number starting with IRL03...
RL550/800 Service Guide

o It is highly recommended to watch the service video clips, on the Dealer CD, prior to servicing a RoboMower.
Table of contents
Page
2 3 3 4 5 6 6 7 8 8 8 8 9 9 9 9 9 10 10 11 11 11 12 13 13 14 14 15 15 15 16 16 17 19
1. Tools, bench and work area recommendations 2. RoboMower layout and main components 2.1. Top view and power pack terminals polarity 2.2. Bottom view 2.3. Inside main components 3. Opening the RoboMower (See video clip on Dealer CD or Service Video)... 4. Closing the RoboMower (See video clip on Dealer CD or Service Video).... 5. Typical technical problems and their solution 5.1. Mower doesn't respond: Low voltage power pack and other reasons. 5.2. Charging problem: Power supply (regular mower charger) faulty 5.3. Charging problem: Charging fuse is faulty 5.4. Charging problem: Manual controller holder is faulty 5.5. Charging problem: Other charging problems 5.6. Charging problem: External charging problems 5.7. Manual controller problems: Keys do not respond 5.8. Manual controller problems: Keypad is torn 5.9. Manual controller problems: No automatic mode display 5.10. Perimeter switch problems: P.Switch doesn't turn on 5.11. Perimeter switch problems: P.Switch indicates low batteries 5.12. Drive/Gear problems: Mower doesn't drive properly 5.13. Drive/Gear problems: Rear wheels height adjustment handle broken... 5.14. Drive/Gear problems: Rear wheels spin, loosing track 5.15. Wire crossing in automatic mode: Main Board/wire sensors issues 5.16. DK calibration fails repeatedly: Main board/compass issues 5.17. Edge mow is not completed: Performance issues 5.18. 'Move from wire' message: Learn wire sensors is needed 5.19. Mowing problems 5.20. Automatic mowing problems: Wire sensors reading problems 5.21. Frontwheel problem 5.22. Bumper issues: Bumper is disconnected 5.23. Bumper issues: Bumper sounds without hitting an obstacle 5.24. Bumper issues: Bumper is pressed 5.25. Performance issues: RoboMower doesn't advance is scan mode 6. Display messages meaning 7. Diagnostics results - fault table and meaning
1. Tools recommended
1.1. 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 tweezers 1.6. 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 be laid on the floor under a carpet or attached to it with tape. For wire diagnostics it is recommended to have at least a 20x20 feet area. Advanced wire sensor diagnostics could be done on any size of plot.
2. RoboMower layout and main components

2.1. Top view
Front
Front bumper
Manual controller holder (cradle)
Manual controller
Right side
Right rear wheel
Power pack (Battery pack) Power pack Lifting handle
Power pack terminals polarity
Negative ( Positive (+)' 30-amp fuse
Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 To be used with RoboMower serial number starting with IRL03.
2.2. Bottom view Note: Mower sides are determined by its top view.
Front
Front locks - 4 Semi curved ones Front wheel
Manual controller
Right side
Right mowing motor/blade Center mowing motor/blade Right rear wheel
Left side
Left mowing motor/blade
Left rear wheel
Drainage holes Rear locks - 6 straight ones
Rear
Friendly North America, toe. Service Guide 2003 Updated: 3/26/2003 To be used with RoboMower serial number starting with ERL03...
2.3. Inside main components
Front
Front wheel Front wire sensors Front wheel lock Left mowing motor Center mowing motor Right mowing motor Right mowing motor Thermistor Front bumper Wires & tabs
Rubber seal
Main board
Drive gears Left odometer board Left odometer Board
Connectors Right odometer board Right drive motor Thermistor Rear wheels height adjustment handle
Mower serial number Rear bumper Wires & tabs
Rear
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Fault* Diagnosed 143 Drive motors (Forward) 200 Drive motors (Backward) 201 Drive motors (Backward) 202 Drive motors (Backward) 210 Drive motors (Backward) Drive 211 motors (Backward) 212 Drive motors (Backward) 220 Drive motors (Backward) 221 Drive motors (Backward) 222 Drive motors (Backward) 230 Drive motors (Backward) 231 Drive motors ^Backward) 240 Drive motors (Backward) 241 Drive motors (Backward) 242 Drive motors (Backward)
Meaning Measured PWM difference >2 Right motor current< 100mA Left motor current< 100mA Right & Left motors current< 100mA Right odometer reading=0 Left odometer reading=0 Right & Left odometer reading=0 Right motor pwm>95% Left motor pwm>95% Right & Left motors pwm>95% Right wheel pwm>Left wheel pwm Left wheel pwm>Right wheel pwm Right pwm<78 or >82 Left pwm<78 or >82 Right & Left pwm<78 or>82
Possible cause Test again Right motor is disconnected Left motor is disconnected Right & Left motors are disconnected Right odometer are disconnected Left odometer are disconnected Right & Left odometers are disconnected Right wheel friction is too high Left wheel friction is too high Right & Left wheels friction is too high Right wheel friction>Left wheel friction, or Right motor is slower than Left motor Left wheel friction>Right wheel friction, or Left motor is slower than Right motor Test again Test again Test again
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3. Opening the RoboMower

3.1. 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 round edged 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 it aside. 3.10. Put the power 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 when standing behind the mower looking towards the front.
4. Closing the RoboMower

4.1. 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't pushed against the connectors board, which should go into its hole in the yellow part without being touched. 4.6. Once the top yellow part is positioned correctly in a way that will not harm the connector board, push it down. You may need to guide the two yellow legs at the battery 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 the lower gray part. 4.8. Turn the mower upside down and make sure the rubber seals at rear wheels axle area are positioned properly and none escaped aside. If a seal has escaped and is 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 rubber piece is stuck into its groove. Yellow charging lines are bent down into the front groove. Than close connector board cover. Make sure it locks into its place by trying 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 reasons
Problem 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 and check whether charging has been neglected: See what the 'Last voltage' was, how many times were 'Warning ignored' and how many times 'Poor storage' occurred. All indicate 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 power pack to the mower, which should now wake up - audio and display wise. Try to charge regularly at the mower. The right hand power pack connector (when facing you) is the positive (+) 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 or recognize 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 no display on the manual controller. This could indicate a faulty manual controller. Try to swap 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 and replace at this order: Main fuse (FUS0012A), Connectors board (ESBC021C), 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 5.18) 2. Set country to USA. 3. DK calibration (In some occasions, twice). 4. Edge calibration (Could be done anywhere, even in an unwired area).
5.2. Charging problem: Power supply (regular mower charger) faulty

Problem '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 excessive use 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 faulty

Problem 'Charging failure' appears on display + beeping sound, 10 seconds from plugging the 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 ohms resistance. Resolution Replace the fuse and make sure mower is charging ok. (FUS0015A)
5.4. Charging problem: Manual controller holder faulty

Problem '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 problems

Problem 'Charging failure' appears on display + beeping sound, 10 seconds from plugging the power supply plug to the cradle socket. Power supply outcome voltage is above 32 VDC. Charging fuse (5 amp) is fine. Resolution Check 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:
o o o o
Learn wire sensors inside an active loop of wire. (See 5.18) Set country to USA. DK calibration (In some occasions, twice). Edge calibration (Could be done anywhere, even in an unwired area).
5.6. Charging problem: External charging problems

Problem External charger lights are off even though it is connected to AC power and its operating 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 respond

Problem '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 torn

Problem Keypad is torn. This could happen very rarely in RL550/800. Resolution Replace manual controller. (MSB0114A).
5.9. Manual controller problems: No automatic mode display

Problem Manual controller display remains on 'Manual settings' rather than changing to automatic mode display when manual controller is in its cradle and flushed with the mower 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 the mower and make sure the magnet is imbedded at its place. (Located near the operation light bulb board).
JQ
5.10. Perimeter switch problems: P.Switch doesn't turn on

Problem 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 left outside, but it must be mounted vertically! If it wasn't mounted vertically and got water penetration, it isn't covered by warranty!
5.11. Perimeter switch problems: P.Switch indicates low batteries

Problem 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 the perimeter wire. The perimeter switch is ok but shows battery low indication by mistake, while intending to show wire cut indication. Fixing the perimeter wire will cure this problem.
5.12. Drive/Gear problems: Mower doesn't drive properly

Problem fa combination of the following) One or both rear wheels are not driving properly while manually or automatically 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. '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 driving conditions) 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 of them is stuck or loose. Put the power pack in the mower and place an object under the mower, between the rear wheels, so they will be able to rotate without touching the ground. The front wheel needs to remain firmly on the ground. Try to drive the mower manually and see the rear wheels behavior, which one is stuck or not moving. Inspect the drive motors pinion and make sure each has both little magnets on it.
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Friendly North America, tic. Service Guide 2003 Updated: 3/26/2003 To be used with RoboMower serial number starting with IRL03...
JJ
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 the drive motors and result in a 'Passed' or 'Failed' message. When it fails, it will also give an error number, which will look like this: Failed # 201. This is only an example and 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 any numbers 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 odometers and odometers and their wires prove to be ok. (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: 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).
5.13. Drive/Gear problems: Rear wheels height adjustment handle broken

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 by warranty!
5.14. Drive/Gear problems: Rear wheels spin, loosing track

Problem 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 with sand or gravel.
11
5.15. Wire crossing in automatic mode: Main Board/wire sensors issues

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 Service/wire sensors. If it fails look up the failure code at the 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 through 'Service' 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). 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 issues

Problem 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). (Use the 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 surfaces at 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. Test the compass through Service/Direction keeper. Perform the test a few times in different directions, since it is a sensitive one. Many times 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. (Even if it failed a few times before!).
12
Friendly North America, Inc. Service Guide 2003 Updated: 3/26/2003 To be used with RoboMower serial number starting with 1RL03...
jg
If it keeps failing, 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 'Service' 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).
5.17. Edge mow is not completed: Performance issues Problem

Mower leaves Edge and starts mowing the inside of the plot prior to completing one full circle around it. There isn't an obstacle on edge that makes it leave the wire. (In case there is, it is an installation 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 be done through 'Service' 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).
5.18. 'Move from wire' message: Learn wire sensors is needed

Problem Mower refuses to start working in automatic mode, displaying 'Move from wire' while isn't close to the wire at all. This is common after replacing wire sensors or main board. Could also happen to a new mower out of the box, on its first automatic operation. 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). 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 button again (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 will offer it automatically on the display if you try to operate it in automatic mode.
^4
If 'Learn wire sensors' didn't help, replace main board, (SPP0019A). (Use the brain from the old board), perform another 'Learn wire sensor1 and operate the mower on a test area. 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. 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 problems

Problem 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 mowed first 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 the blades/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 the mowing 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 through 'Service' menu: 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).
5.20. Automatic mowing problems: Wire sensors reading problems

Problem 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 wired area). Resolution Inside an active perimeter wire, mower positioned in the middle of the plot, test wire sensors through Service/Wire sensors.
14
]5
If the test fails, it will give you an error number. Check the error number meaning on the fault error table and do what it suggests. Test again by pressing C and re initiating 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 through 'Service' 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).
5.21. Front wheel problem Problem

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 disconnected

Problem Unit displays 'Rear or Front bumper disc'. Resolution Open the mower and find the disconnected wire, also looking at the soldering point connecting 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 To be used wilh RoboMower serial number starting with IRL03...
Jg
Use soapy water or silicone-based lubricant at the bumper inserts (black trapeze shape 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 replacement demonstration). Peel off the bumper side from the gray plastic base and push down on the bumper while supporting the mower on the bench with your other hand. The trapeze shape rubber inserts will pop out. No tool is needed for this process. Lubricate the new bumper 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 obstacle

Problem 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 area will be where merely touching the bumper will activate it. Open the mower and replace the oversensitive bumper. (See video clip on Dealer CD for replacement demonstration).
5.24. Bumper issues: Bumper is pressed

Problem 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 mower stored with the bumper pressed against an obstacle, which may temporary set the rubber in dented way pressing it all the time. (Check with the customer if this is the case). If this doesn't cure it - replace the faulty bumper. Rear bumper (MSB0107A). Front bumper (MSM0106A). (See video clip on Dealer CD for replacement demonstration).
5.25. Performance issues: RoboMower doesn't advance is scan mode

Problem 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 the angle 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
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 5.18) 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 Calibration Req. Check Power Charging failure Connect charger Failed K= 18 Front wheel problem Front/Rear bumper disconnected Front/Rear bumper pressed Keys locked 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 power supply) - The charger is connected but not charging (Probably faulty Main Board). - Connect charger (displayed when the mower isn't operated and connected to the charger). - 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. - 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 enable mowing. - One of the keys on the manual controller is pressed 'X' Key pressed continuously upon reset. - Wire synchronization failed. (Very rare. Customer will have to Synch failed press GO if this appears) - Drive motors have faced over-current for too long. Start - For some reason the RoboMower had stopped and user Elsewhere assessment is required. Mowing - When activating motors under 'Diagnostics' but 'mowing' is Disabled set 'off
17
18
Explanation - Anti theft set to 'on' - Insert safety password to enable Theft Guard On mowing. Check mow - Mowing motors have faced over-current for too long or some obstacle is stuck or wrapped around the blades. height - The RoboMower cannot detect a signal from the Perimeter No wire signal Wire. - One of the odometers is not reading a signal from the magnets Drive Problem on the drive motor. Mowing - Mowing motors have faced overheating - the mower stops for Overload cooling. Cooling, Wait... Drive Overload - Drive motors have faced overheating - the mower stops for Cooling, Wait... cooling. - The RoboMower does not complete edge acquisition in 2 minute - Bumper event while the mower is exiting from the Docking Static Path problem - 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 Ready operation - keep charging the battery. Keep charging Message Recharge Battery Retry Elsewhere Set Country Time Completed Move from Wire Max dist reached - 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 distance reached)
18
19
7. Diagnostics fault table and meaning.

Fault* Diagnosed 100 Drive motors (Forward) 101 Drive motors (Forward) Drive 102 motors (Forward) 110 Drive motors (Forward) 111 Drive motors (Forward) 112 Drive motors (Forward) 120 Drive motors 121 Drive motors (Forward) 121 Drive motors (Forward)
130
Meaning Right motor current< 100mA Left motor current< 100mA Right & Left motors current< 100mA Right odometer reading=0 Left odometer reading=0 Right & Left odometer reading=0 Right motor pwm>95% Left motor pwm>95%
Possible cause Right motor is disconnected
Left motor is disconnected
Right & Left motors are disconnected Right odometer is disconnected
Left odometer is disconnected
Right & Left odometers are disconnected Right wheel friction is too high Left wheel friction is too high
Right & Left motors pwm>95%
Right & Left wheels friction is too high
131
140
141
142
Drive motors (Forward) Drive motors (Forward) Drive motors (Forward) Drive motors (ForwardJ Drive motors (Forward)
Right wheel pwm>Left wheel pwm Left wheel pwm>Right wheel pwm Right pwm<78 or >82
Right wheel friction>Left wheel friction, or Right motor is slower than Left motor Left wheel friction>Right wheel friction, or Left motor is slower than Right motor Test again
Left pwm<78 or >82 Right & Left pwm<78 or>82
Test again Test again
19
21
Fauit# Diagnosed Drive motors 243

(Backward)
301 302 303 304

305 306 307
Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors Mowing motors
331 332 333 334 335 336 337
341 342 343 344 345 346
Meaning Measured PWM difference >2 Right Motor current > 100mA Mid Motor current > 100mA Right + Mid Motor current > 1 00mA Left Motor current > 100mA Right + Left Motor current > 1 00mA Mid+Left Motor current > 1 00mA Right+Mid+Left Motor current > 100mA Right Motor current < 100mA Mid Motor current < 100mA Right+Mid Motor current < 1 00mA Left Motor current < 100mA Right+Left Motor current < 1 00mA Mid+Left Motor current < 1 00mA Right+Mid+Left Motor current < 100mA Right Motor current > 2A Mid Motor current > 2A Right+Mid Motor current > 2A Left Motor current > 2A Right+Left Motor current > 2A Mid+Left Motor current > 2A
Possible cause Test again Right Motor power unit is faulty Mid Motor power unit is faulty Right+Mid Motor power units are faulty Left Motor power units is faulty Right+Left Motor power units are faulty Mid+Left Motor power units are faulty Right+Mid+Left Motor power units are 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 are disconnected 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
21
22
Fault# Diagnosed 347 Mowing motors 351 Mowing motors 352 Mowing motors 353 Mowing motors 354 Mowing motors 355 Mowing motors 356 Mowing motors 357 Mowing motors
401 402 403 404 405 406 407 408 409 410 411 412 413 414
Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors Wire sensors
Meaning Right+Mid+Left Motor current > 2A Right Motor current > 100mA Mid Motor current > 100mA Right+Mid Motor current > 100mA Left Motor current > 100mA Right+Left Motor current > 1 00mA Mid+Left Motor current > 1 00mA Right+Mid+Left Motor current > 100mA FR sensor <2 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
Possible cause Right+Mid+Left Motors are overloaded Right 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 is faulty 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 are disconnected RL sensor is disconnected FR+RL sensor are disconnected FL+RL sensor are disconnected FR+FL+RL sensors are disconnected RR+RL sensor are disconnected FR+RR+RL sensors are disconnected FL+RR+RL sensors are disconnected
22
24
Fault# Tested Direction 527 Keeper 529 Direction Keeper 530 Direction Keeper 531 Direction Keeper Direction 532 Keeper 533 Direction Keeper 534 Direction Keeper 535 Direction Keeper
Meaning Coils 1+2+3 cannot be zeroed Coils 1+3 cannot be zeroed Coils 2+3 cannot be zeroed Coils 1 +2+4 cannot be zeroed Coils 3+4 cannot be zeroed Coils 1+3+4 cannot be zeroed Coils 2+3+4 cannot be zeroed Coils 1+2+3+4 cannot be zeroed
Possible cause Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected Magnetic interference or coils disconnected
24

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the Next Level

The AFFORDABLE Automatic Lawn Mower!

RL550 User Interface

12321 Confirm Set Country Press GO

Confirm OK calibration Press GO

activate motors Confirm Done score DK problem failed! K-18

wait... advanced -aaa -ccc direction keeper Press GO

test passed confiiiit +bbb +ddd

total time: xxhxxm Bat. Maintenance Press OO

Factory defaults Press QO

Small wheels off Press QO Small Wheels on Confirm Miscellaneous Press QO

Set default edge Press GO Zone A orig edge Press GO A V

RL800 User Interface

Press GO Zone B: MAX Press GO B Zone C: MAX Press GO i

Wide scan off Confirm

Key 1234 confirm

Child guard off Confirm

2003 Dealer Price

'.-':.'. .i:- " ---

2003 Dealer Price

2.19 3.15 .,,,,

4.50 USE OC MM*

5.48 14.09 2.51 3.01 8.63 15.21 12.72 3.95

4.33 1.32 1.16 3.95 HE' USE**-IBQ1Q5B JBQ105B

2.19 5.41 9.01 1.18

9.05 I 11.85 6.46 10.13 4.09

3.48 3.48 9.19 4.97

4.96 4.98 13.14 7.11

U.S. Service Bulletins

Service Bulletin #RL0301-02

Technical Service Bulletin

Serial Range: All

Slick/small wheel units require this

Knobby / treaded wheel units require this

Gear Case replacement

Service Bulletin #RL0301-03

Technical Service Bulletin

Service Bulletin 3RL0301-O4

Technical Service Bulletin

DOC0056A for SPP0004B and SPP0015A

Service Bulletin #RL0301-05

Technical Service Bulletin

Service Bulletin 3RL0301-06

Technical Service Bulletin

Blade Motor Change (MSB0065B)

Metal shield must be removed from motor and placed on new

motor before installation.

Illustrated Parts List

RL500 Operating & Safety Manual

Battery Contacts RLside

Main board to battery cable

Manual Controller IMSBOIUAI

Manual CpnWfer Charge board cable JWSB0045AI

Negative battery cable WSBO048A

External Charge Socket External charge socket & cable

RL500 US Wiring Parts List

Parts List RL500

Note additional part numbers located on Wiring Parts List

Dealer Manual 2-2003

Illustrated Parts List

Fuse holder & cable WSBO046A

.Battery Contact Left{+)