GreenWorks PRO Optimow 25 Manual de usuario

Greenworks PRO Optimow

25/25H & 50/50H

Greenworks Commercial Optimow

33/33H & 66/66H

SERVICE MANUAL

GREENWORKSTOOLS.COM GREENWORKSCOMMERCIAL.COM

2021-03-18

GREENWORKSTOOLS.COM GREENWORKSCOMMERCIAL.COM

22021-03-18

The materials, technical data, and figures in this manual are provided for guidance only and are not

binding. The manufacturer reserves the right to make any changes to the technical characteristics

and all features of operation, materials, technical data, or figures without prior warning.

The following pages contain important safety and

operating instructions

Carefully read and review all safety instructions,

warnings and cautions contained in this manual.

Failure to read and follow these instructions,

warnings and cautionary statements may result

in severe injury or death to persons and pets or

damage to personal property.

GREENWORKSTOOLS.COM GREENWORKSCOMMERCIAL.COM 3

Contents

1. Service checklist................................................................................. 4

2. Advanced troubleshooting.................................................................. 5

2.1. Fault codes................................................................................ 5

2.2. Symptoms............................................................................... 10

2.3. Interpreting LED indicators ..................................................... 12

2.4. Finding a break in the boundary loop ...................................... 13

3. Fasteners.......................................................................................... 14

4. Repairing the mower........................................................................ 15

4.1.1 Replacable components - Mower and charging station

– Regular cut .................................................................................. 15

4.1.2 Replacable components - Mower and charging station

– High cut ....................................................................................... 15

4.2. Main board connections.......................................................... 17

4.3. Disassembling the body.......................................................... 17

4.4. Replacing the body rear assy .................................................. 17

4.5. Replacing the cutting blades ................................................... 17

4.6. Replacing the blade disc ......................................................... 18

4.7. Replacing the suspension assy ............................................... 18

4.8. Replacing the inner Start/Stop button assy............................. 18

4.9. Replacing the front wheel assy............................................... 19

4.10. Disassembling the chassis.................................................... 19

4.11. Replacing the communication board..................................... 20

4.12. Replacing the collision sensor assy....................................... 20

4.13. Replacing the main board...................................................... 21

4.14. Replacing the lift sensor assy ............................................... 21

4.15. Replacing the loop sensor assy............................................. 22

4.16. Replacing the cutting motor assy.......................................... 22

4.17. Replacing the wheel motor assy........................................... 23

4.18.1. Replacing the charging connector assy – Regular cut........ 23

4.18.2. Replacing the charging connector assy – High cut............. 24

4.19. Replacing the battery ............................................................ 24

4.20. Assembling the chassis ........................................................ 25

4.21. Assembling the body ............................................................ 25

5. Repairing the charging station .......................................................... 26

5.1. Disassembling the charging station ........................................ 26

5.2. Replacing the charging station board ...................................... 26

5.3. Replacing the charging nozzle................................................. 26

5.4. Replacing the charging station plate ....................................... 27

5.5. Assembling the charging station............................................. 27

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GREENWORKSTOOLS.COM GREENWORKSCOMMERCIAL.COM

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1. Service checklist

Table 1 contains a checklist of actions to be taken during a yearly mower service.

Table 1. Yearly service checklist

Action Explanation

Remove the body. Clean chassis and body. See the Operator Manual.

Inspect the suspension bellows. Check that all four suspension bellows are clean and have normal

movement (compare with each other. If any suspension bellows are

damaged, replace them (see section 4.7).

Check/replace the blades and blade screws. See the Operator Manual.

Check that the blade disk can rotate freely. The 3 screws that hold the blade disk may need to be removed to

check that nothing is wrapped around the motor shaft.

Clean the charging station. Clean the exterior of the charging station using a soft brush.

Check and polish the charging plates on the mower and in the

charging station.

Disconnect the charger. Polish contact surfaces on both mower and

charging station charging plates with a fine grade emery cloth.

Perform function test of the mower and charging station. Start the mower outside charging station and check that it starts

cutting.

Charge the battery full. Place the mower with Stop-button pressed in charging station for 1

hour.

Note: Always fully charge the battery before winter storage.

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2021-03-18

2. Advanced troubleshooting

Troubleshooting is performed as explained in Table 2 with one or more

possible causes of the problem, followed by one or more corrective

actions, based on fault codes, symptoms, and LED indicators.

Note: Before performing further troubleshooting and component

replacement, ensure that the latest software is installed in the mower.

2.1. FAULT CODES

Table 2 lists all the fault codes that can occur in the mower with the

software that was applicable at the time of printing of this manual.

Table 2. Fault codes and corrective actions

Code Message Cause Action

1 Collision sensor defect. Collision sensor defect. Unexpected

signal from a collision sensor.

1. Take off the robot's upper cover, control that the

marked line are visible for the 2 magnets and make

sure that the upper cover are attached in a correct way.

2. Check the polarity of the magnet.

3. Replace collissions sensor.

2Mower stuck or collision sensor

defect.

Mower stuck or collision sensor defect.

10 s moving pattern has not solved the

problem.

1. Take off the robot's upper cover, control that the

marked line are visible for the 2 magnets and make

sure that the upper cover are attached in a correct way.

2. Check the polarity of the magnet.

3. Replace collissions sensor.

3 Front collision sensor defect or

mower stuck when starting.

Front collision sensor defect or jammed

mower when starting mower.

1. Take off the robot's upper cover, control that the

marked line are visible for the 2 magnets and make

sure that the upper cover are attached in a correct way.

2. Check the polarity of the magnet.

3. Replace collissions sensor.

4 Rear collision sensor defect or

mower stuck when starting.

Rear collision sensor defect or jammed

mower when starting mower.

1. Take off the robot's upper cover, control that the

marked line are visible for the 2 magnets and make

sure that the upper cover are attached in a correct way.

2. Check the polarity of the magnet.

3. Replace collissions sensor.

6 Lift sensor defect. Lift sensor defect. Unexpected signal

from a lift sensor.

1. Remove mower from possible charging sources

and restart.

2. Replace lift sensors.

3. Replace mainboard.

7 Mower lifted or lift sensor

defect.

Mower lifted or lift sensor defect.

10 s moving pattern has not solved the

problem.

1. Take off the robot's upper cover and make sure

it's attached in a correct way.

2. Control the suspensions for any damage.

3. Replace lift sensor.

8 Front lift sensor defect or

mower lifted when starting.

Front lift sensor defect or mower lifted

when starting mower.

1. Press Stop then Start, and check if it solves the

problem.

2. Take off the robot's upper cover and make sure

it's attached in a correct way.

3. Control the suspensions for any damage.

4. Replace lift sensor.

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Code Message Cause Action

9Rear lift sensor defect or

mower lifted when starting.

Rear lift sensor defect or mower lifted

when starting mower.

1. Press Stop then Start, and check if it solves the

problem.

2. Take off the robot's upper cover and make sure

it's attached in a correct way.

3. Control the suspensions for any damage.

4. Replace lift sensor.

10 Stop button defect. Stop button defect. Unexpected signal

from stop button.

1. Control the attachment of stop button magnet.

2. If problem still remains change the

communication board.

3. If problem still remains change main board.

11 Safety key defect. Disabling device defect. Unexpected

signal from disabling device.

1. Control the attachment of disabling device

magnet.

2. If problem still remains change main board.

12 Tilt sensor defect. Tilt sensor defect. Unexpected data

from tilt sensor.

1. Reset gryroscope in A3S.

2. If problem still remains change mainboard.

13 Too high inclination. Mower tilted too much to continue. 1. Secure that there is no slope on lawn greater

than 35%.

2. Reset gryoscope in A3S.

3. If problem still remains change mainboard.

14 Mower is upside down. Mower upside down. 1. Reset gryroscope in A3S.

2. If problem still remains change mainboard.

15 Power Supply Unit failure. Too high current or voltage from PSU. Replace the power supply.

16 No boundary signal detected

when starting.

No boundary signal detected when

Start-button pressed.

1. If LED on charging station is flashing blue, control

the boundary wire for any damage or loose connector.

2. If LED on charging station is steady green, set a

new loop code.

3. Full reset of mower and CS.

4. Verify installation of loop sensors.

5. Replace loop sensors.

17 Wrong loop signal code. Mower can’t find expected loop code.

Mismatch between mower and CS

installation code.

Set a new loop code.

18 Guide 1 not found. Guide 1 was previously detected but is

now missing.

1. Control guide 1 for any damage or loose connector.

2. Full reset of mower and CS.

19 Guide 2 not found. Guide 2 was previously detected but is

now missing.

1. Control guide 2 for any damage or loose connector.

2. Full reset of mower and CS.

20 Front right loop sensor defect. No loop signal on this sensor, but other

loop sensors ok.

1. Replace the loop sensor.

2. If the problem still remains, change mainboard.

21 Front left loop sensor defect. No loop signal on this sensor, but other

loop sensors ok.

1. Replace the loop sensor.

2. If the problem still remains, change mainboard.

22 Rear loop sensor defect. No loop signal on this sensor, but other

loop sensors ok.

Replace the main board.

23 Communication problem with

Charging station.

Mower has problem with

communication with CS.

Verify that charging connectors are clean.

24 No communication with

communication module.

No communication with GPRS/LTE-

modem.

1. Replace the communication board.

2. If problem still remains change mainboard.

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Code Message Cause Action

25 No communication with GNSS-

module.

No communication with GNSS-module. 1. Replace the communication board.

2. If problem still remains change mainboard.

26 Weak GNSS signal. Weak GNSS signal for most of the time. 1. If this is a recurring error change communication

board.

2. If problem still remains it is probably because of a

lot of trees or buildings close to the installation.

27 SIM card problem. SIM card not ok. If this is a recurring error change the

communication board.

28 Communication problem with

cutting MCU.

Communication problem with Cutting

MCU.

1. Full reset of mower.

2. Replace mainboard.

29 PCBA Production data missing. Data not set or NVRAM fault (checksum

fault) in PCBA Production data area.

Mower main state = Power-up state.

Replace mainboard.

30 Mower Production data

missing.

PCBA data OK, but Device type missing

or NVRAM fault (checksum fault) in

Mower Production data area.

Mower main state = Power-up state.

Replace mainboard.

31 Mower reset to factory

settings.

NVRAM fault (checksum fault) in

Configuration data area. Data set to

factory setting.

No action needed.

32 Right wheel motor defective. Error reported by motor driver. 1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

33 Right wheel motor overloaded. High average motor current. 1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

34 Right wheel motor blocked. Wheel cannot rotate and motor current

high.

1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

35 Right wheel motor drive

system defect.

Wheel cannot rotate and motor current

low.

1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

36 Left wheel motor defective. Error reported by motor driver. 1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

37 Left wheel motor overloaded. High average motor current. 1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

38 Left wheel motor blocked. Wheel cannot rotate and motor current

high.

1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

39 Left wheel motor drive system

defect.

Wheel cannot rotate and motor current

low.

1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

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Code Message Cause Action

40 Cutting motor defective. Error reported by motor driver. 1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

41 Cutting motor overloaded. High average motor current. 1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

42 Cutting motor blocked. The motor cannot rotate and motor

current high.

1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

43 Cutting motor drive system

defect.

The motor cannot rotate and motor

current low.

1. Make sure motor is not blocked.

2. If problem still remains replace the motor.

3. If problem still remains change main board.

44 Outside working area. All loop sensors outside working area.

Problem not solved with moving pattern.

1.Make sure the installation is OK acording to the

installation manual.

2. Change loop code.

45 The battery is not compatible

with this mower.

Battery type invalid. Replace battery to an original battery.

46 Battery communication problem. No response from battery. 1. Make a battery reset.

2. Replace battery.

47 Battery empty. Mower switched to power off because

of battery voltage too low for operating.

1. Make sure the installation is OK

acording to the installation manual.

2. Make sure nothing is blocking the charging station.

3. Make sure that charging plates on robot and

charging station has no damage and are free from

dirt and oxide.

48 Battery temperature too high. Temperature too high for charging. 1. Place the mower in a cool place for at least 1 hour.

2. If problem still remains change battery.

49 Battery temperature too low. Temperature too low for charging. Bring in robot and charging station for winter storage.

50 Battery over-voltage. Over-voltage on battery. 1. Make a battery reset.

2. Replace battery.

51 Battery over-current. Over-current on battery. 1. Make a battery reset.

2. Replace battery.

52 No drive. Slipping. No collision or boundary event

for long time.

1. Make sure the robot has traction and cannot get

stuck on lawn.

2. Make sure that wheel motors work correctly.

3. If problem still remains change main board.

53 Trapped Mower cannot run any longer distance

or stuck. Problem not solved with

moving pattern.

Take away any possible obstacles.

54 Charging station blocked. After several attempts, the mower can

still not reach the charging connector

on CS.

1. Make sure the installation is OK acording to the

installation manual.

2. Make sure nothing is blocking the charging station.

3. Make sure that charging plates on robot and

charging station has no damage and are free from

dirt and oxide.

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Code Message Cause Action

55 Stuck in Charging station. Mower has tried to leave CS, but can

still detect charging power.

1. Make sure the charging station is installed in an

even level.

2. Make sure rear wheels and charging station base

are clean and has traction.

3. Make sure that charging plates on robot and

charging station has no damage and are free from

dirt and oxide.

4. Make sure that wheel motors work correctly.

5. If problem still remains change main board.

56 Not used.

57 Not used.

58 Geofence alarm. Alarm started because of mower

outside geofence area.

Acknowledge alarm with PIN. Note: Mower have

to be returned to geofence area for the function to

be resetted.

59 No loop signal. Boundary signal lost while running. 1. If LED on charging station is flashing blue, control

the boundary wire for any damage or loose connector.

2. If LED on charging station is steady green, set a

new loop code.

3. Fully reset the mower and CS.

60 Lost connection to Charging

station.

Mower is pulled out from CS. Loop

signal still detected.

Press STOP then START on the robot.

61 No power in Charging station. Mower in CS. Lost CS Power. No loop

signal.

1. Check that it is power in the wall socket.

2. Make sure the powersupply is pluged in and

there is no damaged on power cable.

3. If problem still remains replace the power supply.

4. If problem still remains change the charging

station board.

62 Loop signal installation conflict. Interference with loop signal from other

installation. Change loop code.

63 Mower software updated. Indicates that a new Main Application

SW is installed.

Log data 1: Byte 0 = Minor version, Byte

1 = Major version.

Log data 2 = Build no.

64 STOP followed by START

required on mower.

Maybe mower started on disabling

device with Start button pressed. Press

on Stop + Start on mower needed.

Press STOP--> START on robot.

65 Front loop sensor defect. No loop signal on this sensor, but other

loop sensors ok.

1. Replace the loop sensor.

2. If problem still remains change main board.

66 Cutting motor brake defect. Cutting motor cannot be stop fast

enough.

Repair by service personnel needed.

1. Reset the fault indication from A3S.

2. If problem still remains change main board.

3. If problem still remains replace cutting motor.

67 Too low charging current. Charging current very low.

May be bad connection to CS or faulty

PSU.

1. Make sure that charging plates on robot and

charging station has no damage and are free from

dirt and oxide.

2.If problem still remains replace power supply.

3.If problem still remains replace main board.

68 Charging system defect in

mower.

Charging system on mower Main board

defect.

1. Complete a power cycle on mower.

2. Change mainboard.

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10 2021-03-18

2.2. SYMPTOMS

Table 3 lists the most commonly occurring symptoms grouped by the

following situations where they occur most often (mowing, docking,

and charging).

Table 3: Symptoms and corrective actions

Symptom Cause Action

Mowing

Uneven mowing results The mower works too few hours per day. Increase the working hours in the app.

Working area too large. Try to limit the working area or extend the working

time in the app.

Blunt blades. Replace all the blades and screws so that the

rotating parts are balanced (see the Operator

Manual).

Long grass in relation to the set cutting height. Increase the cutting height and then gradually

lower it (see the Operator Manual).

Incorrect lawn coverage settings. Check the lawn coverage settings and optimize them

for the installation (see the Operator Manual).

Does not follow the guide wire to the areas

specified.

Check the guide signal (see section 2.4), as well

as the settings for following the guide wire (see

section 2.4).

Accumulation of grass by the blade disc or

around the motor shaft.

Check that the blade disc rotates freely and easily.

If not, the blade disc may need to be removed

and grass and foreign objects removed (see the

Operator Manual).

The mower operates at the

wrong time.

The mower clock needs to be set. Set the clock in the app.

The start and stop times for mowing are incorrect. Adjust the start and stop time setting for mowing

in the app.

The mower vibrates. Damaged blade on blade disc. Inspect the blades and screws and replace them if

necessary (see section 4.5).

The mower mows for shorter

periods than usual between charges.

Grass or a foreign object is blocking the blade

disc or wheels.

Remove and clean the blade disc (see section 4.6).

Both the mowing and charging

times are shorter than usual.

Impaired battery capacity. Replace the battery (see section 4.18).

Docking

The mower detects charging

station plate, but cannot dock.

The mower can not dock. Clean the charging station (see the Operator

Manual).

Check the mechanical components like wheels

so that it is not stuck due to grass.

Follow the yearly service.

Make sure the cable lugs and connection for the

contact strips are intact and properly connected.

Ensure the correct cable is connected to the right

charging strip (see section 5.2).

Charging

Both the mowing and charging

times are shorter than usual

Impaired battery capacity. Replace the battery (see section 4.19).

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