AL-KO Robolinho 500 User manual

Service Manual
ROBOLINHO 500 / 700
®
Art. Nr.: 119833, 119834, 127446, 127447

Foreword
This technical manual is a supplement to the operating instructions.
It contains information about the Robolinho robotic mower.
The manual is solely intended for authorized service personnel.
All information, illustrations, guidelines and descriptions provided in
this document correspond to the latest data at the time of publication.
AL-KO reserves the right to make changes at any time without notice and
without incurring any obligation. Components of this document may not be
reproduced without the prior written consent of AL-KO.
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

1General product information
General product information for every repair
Upper part
Lower part
Electronics
Connectivity mainboard
1.1
1.2
1.3
1.4
1.5
Page 4
Page 5 / 6
Page 7
Page 19
Page 20
22 Disassembly / Assembly
Design cover / Tool-less
Design cover / With tool
Charging contacts
Drive wheels
Front wheels / Wheels suspension
USB connection
Battery
Blade disc
Mower deck
Blade replacement
STOP button / magnet holder
Functional cover
Cover deviation sensor
Chassis upper part
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.9.1
2.9.2
2.9.3
2.9.4
2.9.5
Page 8
Page 8
Page 9
Page 10
Page 11
Page 12
Page 13
Page 14
Page 14
Page 15
Page 16
Page 17
Page 17
Page 18
Disassembly / Assembly of components
Motherboard
Wireless SmartHome (not on all models)
Display
Cover deviation sensor
Wiring harness for charging contacts
Blade motor
USB socket
Loop sensors
Wheel motors
Cutting height adjustment
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.9.1
Page 21
Page 22
Page 23
Page 24
Page 25
Page 26
Page 27
Page 28
Page 29 / 30
Page 31
3
Maintenance
Replace cutting knife4.1 Page 32
4
Disassembly / Assembly of base station
Base station elements
Disassembly / Assembly
Charging contacts base station
5.1
5.2
5.3
Page 33
Page 34
Page 35
5
Transportation / Shipment
Packaging6.1 Page 36
6
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1General product information
- Repair work may only be carried out by authorized AL-KO service partners.
- Safety devices should not be bypassed, manipulated or removed.
- Always place the device on a soft and clean surface (risk of scratching).
- Place the device at an ergonomic working height.
- The device should rst be roughly cleaned for any repair works:
- Use a wet cloth without detergents (unless otherwise stated).
- Do not use a high-pressure cleaner or even running water.
- Always wear cut-resistant gloves during repair work of the device´s underside or work near the knives.
- All repair work must be carried out on a weather-protected, clean work surface to prevent moisture and dirt
from entering the product.
- Always wear ESD gloves during repair work on the electronics.
- Always disconnect the mainboard from the power supply before carrying out repairs to the electronics
(chapter 3.1)
- Repair works have to be carried out in accordance with the service instructions and always use original
spare parts.
- The Robolinho has to be switched off during repair works. Unintended switch-on or unauthorized usage
may lead to serious injuries.
- Improper modications and / or the usage of non-original parts may lead to signicant damage being
caused to the product, injuries or personal damage.
- All screws of the robotic mower must be mounted with the correct tightening torques, as specied.
- Oil, grease and dirt can cause problems with electrical contacts, ensure that all electrical
contacts are kept clean abd dry.,
- Touch circuit boards only at the edge. Never touch delicate electrical components with the ngers,
for example connectors or components on a circuit board.
- Always ground yourself before working on electrical components to avoid damage of
electronic components by electrostatic discharge.
- Disconnect supply lines by pulling the connector – Never pull on the cable itself
- If possible, test exchange components before installation
- During installation: Make sure, that none of the cables or components are pinched.
- A leaking housing could lead to damage or even complete failure.
- Always use new sealing elements.
- All repairs must be carried out according to the service instructions.
- Only use original spare parts for repairs.
1.1 General product information for every repair
4
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5
1General product information
1 - “Hidden“ front carrying handle (underneath the cover)
2 - Cover (fold away)
3 - STOP button
4 - Charging contacts for base station
5 - Drive wheels
1.2 Upper part
1
3
4
5
2
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

1General product information
1.2
6
1 - “Hidden“ backside carrying handle (underneath the cover)
2 - Display
3 - STOP button
4 - Rotary knob for stepless cutting height adjustment
Upper part
1
2
3
4
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7
General product information
1 - “Hidden“ carrying handles “front“ and “back“
2 - Cap for USB connector
3 - Front wheels
4 - Battery compartment
5 - Mower deck / Mower deck cover
6 - Blade disc & knives Attention: Risk of injury!
7 - Drive wheels
1.3 Lower part
11
3
2
4
5
6
7
1
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2Disassembly / Assembly of components
2.1
8
Design cover / Tool-less
Open the lid.
Pull up and lever at the same time.
Unclip cover with slight pressure.
Carefully loosen the clips with a long screwdriver.
2.2 Design cover / With tool
9,5 mm
1 Min
1 Min
info
For mounting the design cover,
rst clip them at the front.
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2Disassembly / Assembly of components
2.3
9
Charging contacts
Remove design cover.
Carefully separate cable lugs with needle-nose pliers.
Remove charging contact element.
Installation note:
Pay close attention to all wiring during assembly.
Release 2x screws at the charging contacts.
Charging contact element.
Red
+
Blue
-
T20 / 1,2 Nm
info
6 Min
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.4
10
Drive wheels
Use a small screwdriver to lever out the hubcap.
Loosen the screw.
Screw is provided with a coating against loosening.
It can be used multiple times.
Unclip the hubcap.
Remove the wheel.
Disassembly / Assembly of components
13 mm / 5 Nm
info
3 Min
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.5
11
Front wheels / Wheels suspension
Turn the device over. Fix screw head and loosen the nut.
Remove the wheel.
Remove axle.
Front wheel.
Loosen 2x screws. Suspension.
Disassembly / Assembly of components
10 mm / 3,5 Nm
6 Min
T20 / 1,5 Nm
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2 Nm
2
2.6
12
USB connection
Turn the device over.
Cover including sealing ring. When installing,
please use some grease.
Open the cap by using a coin.
When screwing in, be sure to screw the
screw cap straight. Hand-tight.
USB connection.
Disassembly / Assembly of components
info
info
3 Min
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.7
13
Battery
Turn the device, set the cutting height to minimum and
loosen the screws in order as numbered above.
Mount and assemble in order (blue numbers).
Attention! Risk of injury!
Rubber gasket must be clean!
Clean the battery compartment cover and lift it
sideways with a small at-head screwdriver.
Push the plug to the battery pack on the right
and left side and pull it off.
Rated voltage: 18V / charging voltage: 21V.
1
23
4
Disassembly / Assembly of components
T20 / 1,5 Nm
info
info
6 Min
32
41
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

Turn the device over. Loosen 3x nuts with a wrench.
Attention risk of injury!
Remove the blade disc. Attention risk of injury!
Blade disc.
Loosen 3x screws and remove mower deck. Mower deck.
2
2.8
14
Blade disc
2.9 Mower deck
Disassembly / Assembly of components
7 mm / 1,5 Nm
3 Min
4 Min
T20 / 1,5 Nm
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.9.1
15
Blade Replacement
Turn the device over. Loosen 3x nuts with a wrench. Attention risk of injury!
Use a washer. Cutting blade.
Remove blade disc. Release knives with wrench.
Disassembly / Assembly of components
info
7 mm / 2 Nm
6 Min
7 mm / 1,5 Nm
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.9.2
16
STOP button / Magnet holder
Loosen 4x screws Remove the STOP button.
Loosen the screw and remove it from the magnet holder. Remove magnet holder.
Detailed picture of the magnet holder. Installation hint: Fix the magnet holder during calibration.
Disassembly / Assembly of components
T20 / 1,5 Nm
T20 / 1,5 Nm
info
4 Min
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.9.3
17
Functional cover
2.9.4 Cover deviation sensor
Loosen 3x screws Carefully lift the cover upwards.
Positions of the deviation domes.
Pull deviation dome upwards.
Loosen 3x screws to remove single deviation dome.
Only necessary if broken!
Deviation dome.
Disassembly / Assembly of components
info
T20 / 1,5 Nm
M5 / 1,5 Nm
1 Min
1 Min
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

2
2.9.5
18
Chassis upper part
Remove design cover (2.1) and functional cover
(2.9.3) then loosen 12x screws.
STOP button / Do not lose the spring.
Carefully remove the top of the chassis.
Chassis upper part can be hooked on the back.
Detail view of chassis hooks.
Disassembly / Assembly of components
T20 / 1,2 Nm info
12 Min
info
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany

19
1General product information
1.4 Electronics
1 - Loop sensors
2 - USB connector
3 - Blade motor
4 - 2x wheel motors
2
10
11
4
12
5 - Mainboard
6 - Wireless Smart Homeboard(optional)
7 - Deviation sensor board
8 - Cutting height adjustment
9 - Display
10 - Charging contacts
11 - STOP button
12 - Battery
13 - Sealing gasket
13
3
1
4
5
6
78
9
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20
1General product information
1.5
1 - Charging contacts
2 - Power supply for mainboard
3 - Blade motor
4 - Drive motor - left
5 - Drive motor - right
6 - USB
7 - Loop sensor
8 - Deviation sensor board
9 - SmartHome board (optional)
10 - Not used
11 - Keyboard slide
12 - Display
13 - STOP button
2
1
3
8
9
11
12
6
4
5
Connectivity mainboard
7
10
13
All rights reserved. Reproduction, including excerpts © 2018 AL-KO Geräte GmbH, Ichenhauserstr. 14, 89359 Koetz, Germany