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Robin America R1700i Service Manual

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SERVICE
MANUAL
Model
R1700i
GENERATOR
PUB-GS1950
Rev. 09/04

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Summary of Contents for Robin America R1700i

  • Page 1 SERVICE MANUAL Model R1700i GENERATOR PUB-GS1950 Rev. 09/04...

  • Page 3: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS ........... . . 1 2.

  • Page 4: Specifications

    1. SPECIFICATIONS MODEL R1700i Inverter Type Frequency Alternating electric current (AC) 1.65 Maximum output Rated output 1.35 Rated voltage 13.5 Rated amperage Rated power factor Direct Current (DC) Output Voltage Power Current Model EH09-2D Type Forced air-cooled, 4-cycle, OHV Gasoline Engine Displacement mL(cc) 85.8...

  • Page 5: General Description

    2. GENERAL DESCRIPTION 2-1) EXTERNAL VIEW R1700i RECOIL STARTER (HANDLE) CONTROL PANEL AIR CLEANER FUEL DRAIN SCREW SIDE PANEL (L) CARRYING HANDLE TANK CAP COVER SPARK PLUG OIL GAUGE (OIL FILLER) EXHAUST OUTLET SIDE PANEL (R) OIL DRAIN PLUG – 2 –...

  • Page 6: Control Panel

    2-2) CONTROL PANEL R1700i OIL SENSOR LAMP OVERLOAD LAMP AUTO POWER SAVE LAMP PILOT LAMP AUTO POWER SAVE SWITCH AC RECEPTACLES DC TERMINALS ENGINE SWITCH DC CIRCUIT BREAKER GROUND TERMINAL (1) ENGINE SWITCH STOP ENGINE SWITCH The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished.
  • Page 7 (2) PILOT LAMP and OVERLOAD LAMP Output lamp OVER Green light ..Indicates that the generator is generating. LOAD PILOT Unlit ... The generator is not generating. LAMP Overload Lamp Red light .
  • Page 8 (5) AC RECEPTACLES AC electric power is available through this receptacle. Use a ground type, three-leg plug. (6) DC TERMINALS DC TERMINAL DC electric power for battery charge is available. - Red is positive (+) terminal. - Black is negative (-) terminal. DC 12V 8.3A (7) DC CIRCUIT BREAKER DC circuit breakers shut off electric current when the current...

  • Page 9: Location Of Serial Number And Specification Number

    2-3) LOCATION OF SERIAL NUMBER (SER No.) PRODUCTION NUMBER (PROD No.) The serial number and production number are located on right side cover of the generator operation panel. R1700i Serial number and Production number ( Label ) NOTE : Please specify these numbers when inquiring about the generator or ordering spare parts. 2-4) GENERATOR ASSEMBLY ROTOR REAR COVER...

  • Page 10: Range Of Applications

    3. RANGE OF APPLICATIONS Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it. The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance.
  • Page 11 (4) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated. In such a case, power consumption is to be worked out according to the numerical formula mentioned below.
  • Page 12 NOTES : Wiring between generator and electrical appliances 1. Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load (electrical appliance). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out.

  • Page 13: Measuring And Checking Procedures

    4. MEASURING AND CHECKING PROCEDURES 4-1) INSTRUMENTS (1) VOLTMETER AC voltmeter is necessary. The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows : 0 to 150 V : Type with an output voltage of 110 or 120 V 0 to 300 V : Type with an output voltage of 220, 230 or 240 V...
  • Page 14 (4) CIRCUIT TESTER For measuring resistance, etc. NOTE : The ordinary circuit tester may cause erroneous readings due to their measuring method. Use a high-grade, precise circuit tester to check the generator components. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select the one with testing voltage range of 500V.
  • Page 15 (7) "Dr.Robin" GENERATOR TESTER The "Dr.Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators. The "Dr.Robin" has the following features : 1) Functions of voltmeter, frequency meter, megger tester, capacitance meter and circuit tester are combined in one unit.

  • Page 16: Ac Output Measuring

    4-2) AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a load. Adjust the load and rpm, and check that the voltage range is as specified in the following table at the rated amperage and rated rpm.
  • Page 17 (2) ALTERNATOR Check the insulation resistance between the three (Red,Blue and White) wires of the stator and the generator body as shown in the figure right. If there is a wire which has insulation resistance less than 1 M , replace the stator. Insulation failure cause electrical leak which may result in electrocution.

  • Page 18: Checking Functional Members

    4-4) CHECKING FUNCTIONAL MEMBERS 1 STATOR Measure the winding wire resistance. Check the resistance of the wires that comes out from the stator using a tester, referring to the following table. NOTE: When measuring according the numerical value shown in the chart, tolerance should be considered because the inaccuracy of the tester.
  • Page 19 (3) DIODE RECTIFIER The internal circuit of the diode rectifier is shown in the figure below. Check the continuity between each terminal using a circuit tester. If the continuity is as charted below, the diode rectifier is normal. Yellow Gray Orange Diode rectifier Yellow / Blue...
  • Page 20 (4) RECEPTACLE, AC PLUG Check burn marks in the areas where electric current flows, such as wire and plastic parts of AC receptacle. (5) OIL SENSOR Confirm that there is a sufficient amount of oil.Measure continuity between the wires of oil sensor and the crankcase using a circuit tester.

  • Page 21: Assembly And Disassembly

    5. ASSEMBLY AND DISASSEMBLY 5-1) PRECAUTIONS (1) Be sure to memorize the location of each part when disassembling the generator so that the generator can be correctly reassembled. Tag the disassembled parts with the necessary information to facilitate easier and smoother reassembling.

  • Page 22: Disassembly Procedures

    5-3) DISASSEMBLY PROCEDURES Please disassemble in the order of the procedure below. 5-3-1 Remove the side panels (Left, Right) Remove the side panels. 16.5mm Bolt 2 pcs. Tools : Screw driver Side Panel 5-3-2 Remove the rear cover Remove the rear cover by unscrewing the four screws. 20mm Screw and Washer 4pcs.
  • Page 23 5-3-4 Remove the recoil starter handle Remove the recoil starter guide connected to the case body (left). Push the guide and the starter hundle through the hole which the case body (left) guide was attached. M4 x 10mm Tapping screw 1pce.
  • Page 24 5-3-7 Remove rear frame Front Remove the rear frame. frame Rear frame 5-3-8 Remove fuel cock bracket Fuel pump Remove the fuel cock bracket. M6 x 12mm Flange bolt 1pce. M6 Nut 1pce. Tools : 10mm Box wrench NOTE 1: Be sure to close the fuel cock before removing the fuel pipe.
  • Page 25 5-3-10 Remove the control panel (2) Remove the control panel by pulling off the three couplers. Remove the choke wire bracket from the front frame. Couplers 5-3-11 Remove the inverter unit Choke wire Disconnect the two couplers and remove the inverter bracket unit.
  • Page 26 5-3-13 Remove the air cleaner and carburetor Air Cleaner Unhook the catch on the right side of the air cleaner. Then remove the air cleaner cover and elements. Loosen the two nuts and bolt to remove the base plate of Carburetor the air cleaner.
  • Page 27 5-3-16 Remove the Stator / Rear cover Remove the Stator / Rear cover. Rear cover M6 x 25mm Flange bolt : 3pcs. Tools : 10mm Box wrench NOTE 1: The stator is attached to the rear cover, both can be removed together. They are attached with a strong magnetic force, so pull out straight.
  • Page 28 5-3-18 Remove Blower housing Remove the blower housing. Blower M8 x 55mm Flange bolt : 1pce. Housing M8 x 90mm Flange bolt : 3pcs. Tools : 12mm Box wrench NOTE : The pipe knock is attached to two places. 5-3-19 Remove the flywheel Remove the flywheel.
  • Page 29 5-3-21 Remove the muffler Remove the muffler. M8 x 80mm Flange bolt : 1pce. M6 Flange nut : 2pcs. Tools : 10mm Box wrench 12mm Box wrench Muffler 5-3-22 Remove the ignition coil Remove the ignition coil. M6 x 14mm Flange bolt : 1pce. M8 Flange nut : 1pce.

  • Page 30: Reassemble Procedures

    5-4) REASSEMBLY PROCEDURES 5-4-1 Cylinder baffle Install the cylinder baffle. (Tighten together) Cylinder baffle M8 x 16mm Flange bolt : 3pcs. Tightening torque : 11.0-13.0 N m 110-130 kgf cm (8.1-9.6 ft lbs) M6 x 12mm Flange bolt : 1pce. Tightening torque : 7.0-9.0 70-90 kgf cm...
  • Page 31 5-4-4 Recoil starter Attach the recoil starter to the crankcase. M6 x 18mm Flange bolt : 3pcs. Tightening torque : 7.0-9.0 70-90 kgf cm (5.2-6.6 ft lbs) Recoil starter 5-4-5 Flywheel Install the flywheel. M8 x 25 Bolt and washer : 1pce. 8.5D x 28D x 3.2T Washer : 1pce.
  • Page 32 5-4-7 Pulsar coil and grommet Recoil guide Pulsar coil Tighten the bolt in place, making adjustments according Grommet Flywheel to 5-4-6. M6 x 8mm Flange bolt : 2pcs. Tightening torque : 3.0-5.0 30-50 kgf cm (2.2-3.7 ft lbs) Place the pulsar coil wires along the groove of the grommet and recoil guide to make it easier to assemble Pulsar coil harness the blower housing.
  • Page 33 5-4-9 Rotor Rotor Install the rotor. M6 x 20mm Flange bolt : 3pcs. Tightening torque : 10.0-12.0 N m 100-120 kgf cm (7.4-8.9 ft lbs) <CAUTION> The stator and the rotor are pulling each other by a strong magnetic force. Please use care when assembling the stator close to the rotor.
  • Page 34 5-4-11 Base Inverter Install the base inverter into the engine main body. M8 x 20 Bolt and washer : 4pcs. Tightening torque : 18.0-20.0 N m 180-200 kgf cm (13.3-14.8 ft lbs) M6 Flange nut : 4pcs. Tightening torque : 9.0-11.0 Base inverter kgf cm 90-110...
  • Page 35 5-4-15 Fuel pipe Fuel pipe Connect the fuel pipes from the fuel pump to the (Carburetor side) crankcase and carburetor and fasten with a hose clamp. NOTE: Assemble with care. Avoid mis-connection of fuel pipes. Fuel pipe (Crank case side) 5-4-16 Inverter unit Attach the inverter unit into the front frame.
  • Page 36 5-4-18 Fuel tank Fuel tank Attach the fuel tank and the fuel cock. After the fuel tank is installed, connect the fuel line between fuel cock and fuel pump. 5-4-19 Fuel cock bracket Fuel cock Install the fuel cock bracket into the base. bracket (Install the rubber pipe with the hose clamp while the fuel cock is closed.)
  • Page 37 5-4-21 Case body, control panel Case body Attach the case body (left and right). Install the bottom part of the case body and the mount together. M6 x 18mm Flange bolt : 4pcs. Tightening torque : 3.0-4.0 30-40 kgf cm (2.2-2.9 ft lbs) NOTE: Install the bottom part of the case body Mount...
  • Page 38 5-4-23 Choke wire and rolling wire Choke wire Install the choke wire into the choke shaft of the carburetor. NOTE: Use the engine switch to confirm that the choke can be fully closed, and fully opened. Install the rolling wire into the wire plate and fuel cock behind the control panel.

  • Page 39: Recoil Starter

    5-5) RECOIL STARTER Tools used : Long-nose pliers, retaining-ring pliers, protective goggles Caution : Please wear protective goggles before starting disassembly 1) Disassembly procedures (1) Unhook the spring. -1 Hold the starter handle, and pull out the starter rope. -2 Pull out all of the rope, and align the rope guide and the knot of the rope inside the reel.
  • Page 40 (2) Remove the small parts. -1 Hold the case, and remove the retaining-ring C with the ring pliers. -2 Beginning at the top, remove the retaining-ring, friction plate, and ratchet. Retaining-ring pliers Retaining-ring C (3) Remove the reel. Retaining-ring C Friction plate -1 Move the reel to left and right at a 1/4 turns several times until it moves smoothly, gently...
  • Page 41 Caution: Please wear protective goggles before starting assembly. 2) Assembly procedure (1) Assemble the reel into the case. Ratchet -1 Install the ratchet, and fasten it with retaining ring E. -2 Install the spiral spring in the reel. Reel -3 Apply grease to the case. -4 Properly orient the inner end of the spring installed Retaining-ring E in the reel.
  • Page 42 (4) Inserting the rope. (this should be done by two people) -1 Thread the rope through the reel where the rope hole on the reel and rope guide are aligned. About 20cm -2 Thread the rope end through the rope guide and the rope hole of the reel, and pull 20cm out from the reel.
  • Page 43 -2 Wind the rope clockwise seven times with the rope hanging from the reel. Gently wind the rope onto the reel while removing any kinks in the rope from the knob side. Rope Assembly is completed. Cut of the reel Wind up for seven times clockwise...
  • Page 44 4) When . . . (1)The spring pops out (a)Hook the end hook of the spring to the notched part of the reel, and attach the spring, applying pressure with your fingers so that it isn’t released from the groove. (Please wear gloves) Spiral spring Reel (b)Hook the inside hook of the spring to the claw of...

  • Page 45: Troubleshooting

    6.TROUBLESHOOTING No output power or Lower output Turned on When engine is running, Remove any electric load check if Overload Lamp is activated equipment that is connected Once stop the engine, and reset the overload warning Turned off When engine is running, Confirm the engine revolutions check if the Pilot Lamp is turned on Voltage...
  • Page 46 Improper revolutions (Electronic throttle) Starts but Go to the "Engine does not start (Start failure)" stops suddenly Engine revolution Confirm connection of does not increase electronic throttle part Hunting Does Pull the recoil lightly with the carburetor throttle fully opened Change the not run stepping motor...
  • Page 47 Engine does not start (Start failure) None Check the gasoline Add gasoline in the tank warning lamp is on Oil warning lamp turns on Check the Add oil (up to the when the recoil is pulled oil volume rated volume) Fuel cock is in Confirm of the oil SW Open...

  • Page 48: Wiring Diagram

    7. WIRING DIAGRAM R1700i (50Hz-230V) CONTROL PANEL LED INDICATOR ENGINE Step motor AC receptacle (230V) Ignition coil INV&E/G C/U Auto power save switch REV Sensor Float switch DC curcuit breaker Main coil Engine switch Brn/W DC coil GENERATOR Wiring color cord : Black LBlu : Light blue...
  • Page 49 R1700i (50Hz-240V) CONTROL PANEL LED INDICATOR ENGINE Step motor AC receptacle (240V) Ignition coil INV&E/G C/U Auto power save switch REV Sensor Float switch DC curcuit breaker Main coil Engine switch Brn/W DC coil GENERATOR Wiring color cord : Black LBlu : Light blue : Green...
  • Page 50 R1700i (60Hz-120V) CONTROL PANEL LED INDICATOR ENGINE Step motor AC receptacle (120V） Ignition coil INV&E/G C/U Auto power save switch REV Sensor Float switch DC curcuit breaker Main coil Engine switch Brn/W DC coil GENERATOR Wiring color cord : Black LBlu : Light blue : Green...
  • Page 52 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2004 Robin America, Inc. PRINTED IN THE USA...

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