SERVICE MANUAL Model R1700i GENERATOR PUB-GS1950 Rev.
CONTENTS Section Title Page 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2-2 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. SPECIFICATIONS R1700i MODEL Inverter Type Frequency Hz 50 50 60 Alternator Alternating electric current (AC) Maximum output kVA 1.65 Rated output kVA 1.35 Rated voltage V Rated amperage A 230 240 120 13.5 Rated power factor 1.0 Direct Current (DC) Output W 100 Voltage V 12 Power Current A 8.3 Model EH09-2D Type Forced air-cooled, 4-cycle, OHV Gasoline Engine Displacement mL(cc) 85.8 Engine Fuel Fuel tank capacity Automotive Unleaded Gasoline L 3.
2.
2-2) CONTROL PANEL R1700i OIL SENSOR LAMP OVERLOAD LAMP AUTO POWER SAVE LAMP AUTO POWER SAVE SWITCH PILOT LAMP AC RECEPTACLES DC TERMINALS ENGINE SWITCH DC CIRCUIT BREAKER GROUND TERMINAL (1) ENGINE SWITCH The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished. STOP ENGINE SWITCH RUN CHOKE (CHOKE) " " To start the engine, turn the knob to the position. (Choke valve is closed.
(2) PILOT LAMP and OVERLOAD LAMP ① Output lamp Green light . . . . . Indicates that the generator is generating. Unlit . . . . . . . . . . . The generator is not generating. ② Overload Lamp Red light . . . . . . . Indicates when an overload occurs, or output is abnormal, generating will stop when the red lamp is displayed. (The electronics breaker is activated) NOTE : When the overload lamp is lit, please consult the Troubleshooting section and disconnect any electrical devices.
(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 exceeds its limit. Check for excessive current consumption. After making sure everything is in order, push the button to the " ON " position.
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.
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. The electrical appliances generally have a label showing their rated voltage, frequency, and power consumption (input wattage). The power consumption of an electrical appliance is the power necessary for using it.
(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. (Output of electrical appliance) = (Power consumption) (Efficiency) Efficiencies of some electrical appliances are as follows : Single-phase motor . . . . . .0.6 to 0.
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. The table below shows cables and their allowable currents for your reference. 2.
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 0 to 150 V, 0 to 330 V : Dual voltage type For AC For DC For AC For DC (2) AMMETER AC ammeter is necessary.
(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. (6) TACHOMETER Use the contactless type tacho meter for checking engine speed.
(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. 2) Fast and easy readout by digital indicator. 3) Built-in automatic battery checker indicates the time to change batteries.
4-2) AC OUTPUT MEASURING SWITCH LOAD A ~ V ~ F 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.
(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 MΩ, replace the stator. Insulation failure cause electrical leak which may result in electrocution. (3) CONTROL PANEL Before checking, disconnect the inverter unit from the control panel.
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. If an accurate value is needed, measure by electric resistance using an Ohm-meter. While doing this, use caution to avoid contact resistance.
(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.
(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. Oil Sensor Ω Below the lower level : ON (continuity) 0Ω Above the lower level : OFF(non-continuity) ∞ Use 4-stroke automotive detergent oil of API service class SE or higher Grade (SG, SH or SJ is recommended).
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. (2) For greater convenience, divide the parts into several groups and store them in boxes. (3) To prevent bolts and nuts from being misplaced or installed incorrectly, place them temporarily back at their original position.
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. M6 x 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. M6 x 20mm Screw and Washer : 4pcs. Tools : Screw driver Rear cover 5-3-3 Remove rolling wire, choke wire Choke wire Loosen the screw that holds the choke wire. And remove it from the swivel.
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. Recoil starter hundle Tools : Screw driver Guide Overflow pipe 5-3-5 Remove the control panel (1) Case body Remove the control panel from the case body. Control Panel M4 x 14mm Screw : 4pcs. M5 x 8mm Screw : 4pcs.
5-3-7 Remove rear frame Front frame Remove the rear 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. (Engine switch in the off position) NOTE 2: A little fuel comes out from the fuel pump when unplug the pipe.
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 bracket Disconnect the two couplers and remove the inverter unit. (one coupler from the alternator body, and one from the engine throttle / ignition system.) Inverter Unit M6 x 20mm Flange bolt : 4pcs.
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 the air cleaner. Carburetor Then remove the carburetor. M6 x 18mm Flange bolt : 1pce. M6 Flange nut : 2pcs. Base plate Tools :10mm Box wrench 5-3-14 Remove the front frame Front frame Remove the front frame. 5-3-15 Remove the base inverter Remove the base inverter.
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. Rear cover The stator and the rotor are pulling each other by a strong magnetic force. Please use caution when removing the stator in order to prevent from getting injury on fingers.
5-3-18 Remove Blower housing Remove the blower housing. Blower Housing M8 x 55mm Flange bolt : 1pce. 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. Flywheel M8 x 20 Bolt and washer : 1pce. NOTE: Use a Flywheel puller (Available on market) for the taper. Tools : 12mm Box wrench Flywheel puller (Available on market) 5-3-20 Remove recoil starter Remove the recoil starter. M6 x 20mm AY Bolt : 3pcs.
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. Ignition coil Tools : 10mm Box wrench 12mm Box wrench 5-3-23 Remove the cylinder baffle Remove the cylinder baffle. Cylinder baffle M8 x 16mm Flange bolt : 3pcs. M6 x 12mm Flange bolt : 1pce.
5-4) REASSEMBLY PROCEDURES 5-4-1 Cylinder baffle Install the cylinder baffle. (Tighten together) M8 x 16mm Flange bolt : 3pcs. Cylinder baffle Tightening torque : 11.0-13.0 N・m 110-130 kgf・cm ft・lbs) (8.1-9.6 M6 x 12mm Flange bolt : 1pce. Tightening torque : 7.0-9.0 70-90 (5.2-6.6 N・m kgf・cm ft・lbs) 5-4-2 Ignition coil Install the ignition coil into the ignition coil bracket and attach it to the engine. Ignition coil tightening torque Tightening torque : 3.0-5.0 30-50 (2.2-3.
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 (5.2-6.6 N・m kgf・cm 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. Tightening torque : 19.0-21.0 N・m 190-210 kgf・cm (14.0-15.5 ft・lbs) NOTE : Wipe off any oil from the tapered shaft and hole before assembling.
5-4-7 Pulsar coil and grommet Recoil guide Tighten the bolt in place, making adjustments according to 5-4-6. M6 x 8mm Flange bolt : 2pcs. Tightening torque : 3.0-5.0 30-50 (2.2-3.7 Flywheel Pulsar coil Grommet N・m kgf・cm ft・lbs) Place the pulsar coil wires along the groove of the grommet and recoil guide to make it easier to assemble the blower housing. Pulsar coil harness Caution : Do not forget to put the 2 pieces of pipe knock.
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) 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. Carelessness may cause injury such as smashing a finger. Rotor NOTE : Avoid damaging the magnet of the rotor. 5-4-10 Rear cover, stator Rear cover Install the rear cover of the generator and stator into the rotor.
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 90-110 (6.6-8.1 N・m kgf・cm ft・lbs) Base inverter NOTE: Avoid cutting your hand by the sharp edge of the base. Front frame 5-4-12 Front frame Install the front frame (L) and (R) onto the base inverter.
5-4-15 Fuel pipe Fuel pipe (Carburetor side) Connect the fuel pipes from the fuel pump to the 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. A grounding wire shall be tightened together to the upper right side of the inverter unit. M6 x 20mm Flange bolt : 4pcs. Inverter unit Tightening torque : 3.0-4.0 N・m kgf・cm 30-40 (2.2-2.
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 bracket Install the fuel cock bracket into the base. (Install the rubber pipe with the hose clamp while the fuel cock is closed.) M6 x 12mm Flange bolt : 1pce. M6 Nut : 1pce. Mounting angle Tightening torque : 3.0-4.0 N・m kgf・cm 30-40 (2.2-2.
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 N・m kgf・cm 30-40 (2.2-2.9 ft・lbs) NOTE: Install the bottom part of the case body correctly. Mount Attach the upper part of the case body. M6 x 25 Screw and Washer : 2pcs. Case body Control panel Tightening torque : 3.0-4.0 N・m kgf・cm 30-40 (2.2-2.
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. Rolling wire 5-4-24 Rear cover Attach the rear cover to the case body. M6 x 30 Screw and Washer : 4pcs. Tightening torque : 3.0-4.0 N・m kgf・cm 30-40 (2.2-2.
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. Starter rope -3 Be sure to hold the reel with both thumbs so your fingers do not become be entangled.
(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 -1 Move the reel to left and right at a 1/4 turns Friction plate several times until it moves smoothly, gently Friction spring holding it down. Ratchet guide -2 Slowly lift the reel, removing it from the case.
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.
(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. -3 Tight the end of the rope. Ab ou t1 0m m (5) Keep pressure on the spring -1 Feed the rope .
-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 ※These are the disassembly and assembly procedures, please be sure to review the following item checklist to insure that the parts securely installed. 3) Checking items after assembly (1) Try to pull the starter handle for 2 to 3 times.
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) (b)Hook the inside hook of the spring to the claw of the starter case while turning. ※ Please refer to assembly procedures.
6.
Improper revolutions (Electronic throttle) Starts but stops suddenly Yes Go to the "Engine does not start (Start failure)" No ・Engine revolution does not increase ・Hunting Yes Confirm connection of electronic throttle part OK ・Pull the recoil lightly with the carburetor throttle fully opened Does not run Full throttle direction ：Towards the opposite direction against the air cleaner in front.
Engine does not start (Start failure) None Check the gasoline in the tank Yes warning lamp is on Oil warning lamp turns on when the recoil is pulled Fuel cock is in the ON position Add gasoline NO Open the cock Check the oil volume Add oil (up to the rated volume) Confirm of the oil SW E/g Resistance value≒0Ω Change Oil SW Yes Gasoline leaks when the carburetor drain is loosened NO Yes Check for gasoline corrosion GND Clean, change the filter Corrosion Change gasoline Tester Change the
7.
R1700i (50Hz-240V) CONTROL PANEL Y R Pur Blu Grn Brn ENGINE Org LED INDICATOR Step motor R Grn Blu Pur Gry AC receptacle (240V) W Ignition coil SPARK PLUG Blu W Blk INV&E/G C/U Auto power save switch Brn Blk REV Sensor Y Grn/Y R Blk Y W R Blu Float switch Blk DC curcuit breaker Main coil Gry Org Blk Engine switch Brn/W DC coil GENERATOR Wiring color cord Blk : Black Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W : Green
R1700i (60Hz-120V) CONTROL PANEL Y R Pur Blu Grn Brn ENGINE Org LED INDICATOR Step motor R Grn Blu Pur Gry AC receptacle (120V） W Ignition coil SPARK PLUG Blu W Blk INV&E/G C/U Auto power save switch Brn Blk REV Sensor Y Grn/Y R Blk Y Blk W R Blu Float switch Blk DC curcuit breaker Main coil Gry Org Blk Engine switch Brn/W DC coil GENERATOR Wiring color cord Blk : Black Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W :
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.
