Robin America R1700i, Service Manual

Page 1: ...SERVICE MANUAL R1700i Model PUB GS1950 Rev 09 04 GENERATOR ...

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Page 3: ...HECKING FUNCTIONAL MEMBERS 15 5 ASSEMBLY AND DISASSEMBLY 18 5 1 PRECAUTIONS 18 5 2 SPECIAL TOOLS 18 5 3 DISASSEMBLY PROCEDURES 19 5 4 REASSEMBLE PROCEDURES 27 5 5 RECOIL STARTER 36 6 TROUBLESHOOTING 42 7 WIRING DIAGRAM 45 The specifications and information included in this manual were in effect at the time of printing FUJI HEAVY INDUSTRIES LTD reserve the right to change the specifications and to ...

Page 4: ... Oil Sensor Yes Frequency Switch Yes Auto Power Save Switch Yes Output Lamp Yes Overload Lamp Yes Oil Warning Lamp Yes Over current protector Recoil starter 490 x 295 x 445 3 5 NGK BMR4A Ignition System Digital ignition Rated continuous operation Approx 3 5 0 36 Fuel Automotive Unleaded Gasoline 100 Alternating electric current AC output Electronics Breaker Direct Current DC output Circuit Breaker...

Page 5: ...IPTION 2 1 EXTERNAL VIEW SPARK PLUG CAP RECOIL STARTER HANDLE TANK CAP COVER AIR CLEANER SIDE PANEL R SIDE PANEL L OIL DRAIN PLUG CARRYING HANDLE CONTROL PANEL EXHAUST OUTLET FUEL DRAIN SCREW OIL GAUGE OIL FILLER R1700i ...

Page 6: ...H The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished CHOKE To start the engine turn the knob to the position Choke valve is closed RUN Keep the knob in this position after the engine starts The engine can be started with the knob at this position when the engine is warm STOP To stop the engine return the knob to the positi...

Page 7: ...ine stops due to oil shortage it can not be started anymore even by pulling the start knob just the alarm lamp flickers In such a case replenish engine oil up to the mouth of the oil filling port 4 AUTO POWER SAVE SWITCH When the switch is in the position the engine speed will be automatically decreased when an electrical device is not in use Also when the switch from the electrical device is on t...

Page 8: ...R 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 Fully dischanged battery of large capacity may cause over current in DC output circuit 5 AC RECEPTACLES AC electric power is available through this receptacle Use a ground type three leg plug ...

Page 9: ...TION 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 NOTE Please specify these numbers when inquiring about the generator or ordering spare parts Serial number and Production number Label R1700i ...

Page 10: ...ample A rated 250 W electric drill requires a 400 W generator to start it NOTE 1 If a power factor correction capacitor is not applied to the fluorescent lamp the more power shall be required to drive the lamps NOTE 2 Nominal wattage of the fluorscent lamp generally indicates the output wattage of the lamp Therefore if the fluorescent lamp has no special indication as to the power consumption effi...

Page 11: ...tor should be multipled by 1 2 to 3 and 570W as explained in the ltem 3 The power consumption of electrical appliances is shown below for reference use this as a measuring guide when choosing electrical appliances and which generator to use Power Consumption W 300 to 1000 450 800 to 1400 100 1200 1200 800 to 1200 400 100 to 260 1100 500 600 600 40 to 400 Electrical appliances Rice Cooker Coffee Ma...

Page 12: ...asing the input voltage to the load electrical product As a result the load can be damaged The table below shows voltage drops per 30 meters of cable Voltage drops per 30 meters of cable 30A 25A 20A 15A 10A 5A A mm2 8 9V 4 5V 12 1 25 8 6V 5 7V 2 8V 17 2 0 6 2V 4 7V 3 1V 1 6V 23 3 5 6 0V 5 0V 4 0V 3 0V 2 0V 1 0V 35 5 5 Allowable Current Cross sectional Ω 100m 1 486 0 952 0 517 0 332 Cable Resistanc...

Page 13: ...oltage 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 2 AMMETER AC ammeter is necessary An AC ammeter with a range that can be changed according to the current rating of a given generator is most desirable About 10 A 20 A 100 A 3 FREQUENCY METER Frequency range To cover 45 to 65Hz NOTE Be careful of the frequency meter s input vol...

Page 14: ...age range of 500V 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 6 TACHOMETER Use the contactless type tacho meter for checking engine speed ...

Page 15: ...carrying SPECIFICATIONS MODEL Dr Robin Part Number 388 47565 08 Measuring Range 0 to 500 V AC 25 to 70 Hz 0 1 to 1 999 Ω 10 to 100 μF 3MΩ Circuit Protector Fuse Power Source 2 x 6F44P 006P Dry Cell Battery Accessories Test leads with needle probes 1 set Test leads with jack plugs 1 set Dimensions L x W x H 285 mm x 200 mm x 110 mm Weight 1 6 kg Voltage Frequency Resistance Condenser Capacity Insul...

Page 16: ...eceptacle using a wire to discharge the electricity remained in the circuit 1 Connect the megger tester across either one of the two output terminals of the AC receptacle and ground terminal to measure the insulation resistance Measure it with the AC breaker on An insulation resistance of 1 MΩor more is normal Original insulation resistance at the time of shipment from the factory is 10 MΩor more ...

Page 17: ...re cause electrical leak which may result in electrocution 3 CONTROL PANEL Before checking disconnect the inverter unit from the control panel Measure the rechargeable parts where the electric current flows and insulation resistance between the live parts and the ground terminal Measure with the AC breaker on If there is a spot where insulation resistance less than 1 MΩ replace the part Insulation...

Page 18: ...Red a b c d 2P connector for AC output Stator wire terminal 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 accurat...

Page 19: ... Yellow Checking table for analogue circuit tester Analogue Circuit Tester 0Ω No continuity Yellow Blue Apply red needle of the circuit tester 0Ω 0Ω Orange No continuity No continuity 0Ω No continuity No continuity No continuity No continuity Gray Yellow Yellow Blue Orange Gray Apply red needle of the circuit tester 0Ω Yellow Checking table for digital circuit tester Digital Circuit Tester 0Ω No c...

Page 20: ...ster Below the lower level ON continuity 0Ω Ω 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 Oil capacity 0 4 liters Oil Sensor 4 RECEPTACLE AC PLUG Check burn marks in the areas where electric current flows such as wire and plastic parts of AC receptacle ...

Page 21: ...s with oil nor water 5 Remove battery before disassembly 6 Use proper tools correctly for each specific job 7 Please be sure to glue the sponge inside the cover Please replace the sponge if it is deformed peeled or damaged with a new one The generator performance may be negatively affected by the lack of a sponge or deformed peeled or damaged sponge 8 Tie the electric wires and fuel pipe with wire...

Page 22: ...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 Loosen the screw that holds the choke wire And remove it from the swivel Unwind the rolling wire by hand or pliers and pull up Tools Screw driver pliers Rolling wire Choke wire ...

Page 23: ...ew 4pcs M5 x 8mm Screw 4pcs Tools Screw driver NOTE At this point the couplers of electrical wires are connected to the control panel Instead of removing the control panel forcibly remove it after disassembling the case body and fuel tank 5 3 6 Remove the case body Left Right Remove the case body Left Right Remove the plastic pipe from the case body Overflow pipe Upper part of the case body M6 x 2...

Page 24: ...uel 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 Fuel cock bracket Fuel pump Unplug the pipe 5 3 9 Remove the fuel tank Remove the fuel tank with the fuel cock still connected Fuel tank Front frame Rear frame 5 3 7 Remove rear frame Remove the rear frame 21 ...

Page 25: ...emove the inverter unit Disconnect the two couplers and remove the inverter unit one coupler from the alternator body and one from the engine throttle ignition system M6 x 20mm Flange bolt 4pcs Tools 10mm Box wrench 5 3 12 Remove the fuel pipes Remove the fuel pipe from the fuel pump to carburetor and the fuel pipe on crank case side Tools Pliers Fuel pipe Carburetor side Fuel pipe Crank case side...

Page 26: ...carburetor 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 Then remove the carburetor M6 x 18mm Flange bolt 1pce M6 Flange nut 2pcs Tools 10mm Box wrench 5 3 14 Remove the front frame Remove the front frame Base plate Carburetor Air Cleaner Front frame ...

Page 27: ...traight Rear cover Stator Rear cover 5 3 17 Remove the rotor Remove the rotor M6 x 20mm Flange bolt 3pcs Tools 10mm Box wrench NOTE There is a strong magnetic field around the rotor Use atmost care to avoid foreign substances such as small iron particles stick to the rotor Rotor CAUTION The stator and the rotor are pulling each other by a strong magnetic force Please use caution when removing the ...

Page 28: ...flywheel Remove the 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 Flywheel 5 3 20 Remove recoil starter Remove the recoil starter M6 x 20mm AY Bolt 3pcs Tools 10mm Box wrench Recoil starter NOTE For the maintenance of recoil starter please refer to item 5 5 Disassembly and assembly of the...

Page 29: ...6mm Flange bolt 3pcs M6 x 12mm Flange bolt 1pce Tools 10mm Box wrench 12mm Box wrench Cylinder baffle 5 3 22 Remove the ignition coil Remove the ignition coil M6 x 14mm Flange bolt 1pce M8 Flange nut 1pce Tools 10mm Box wrench 12mm Box wrench By performing the above steps only a bare engine remains Please refer to EH09 Service manual for further disassembly and service procedures of the engine Ign...

Page 30: ...oil tightening torque Tightening torque 7 0 9 0 N m 70 90 kgf cm 5 2 6 6 ft lbs Tightening torque 7 0 9 0 N m 70 90 kgf cm 5 2 6 6 ft lbs Tightening torque 7 0 9 0 N m 70 90 kgf cm 5 2 6 6 ft lbs Muffler 5 4 3 Muffler Install the muffler M8 x 80mm Flange bolt 1pce M6 Flange nut 2pcs Tightening torque 11 0 13 0 N m 110 130 kgf cm 8 1 9 6 ft lbs Tightening torque 11 0 13 0 N m 110 130 kgf cm 8 1 9 6...

Page 31: ...ywheel M8 x 25 Bolt and washer 1pce 8 5D x 28D x 3 2T Washer 1pce NOTE Wipe off any oil from the tapered shaft and hole before assembling Tightening torque 19 0 21 0 N m 190 210 kgf cm 14 0 15 5 ft lbs Flywheel Pulsar coil 5 4 6 Air gap adjustment of flywheel and pulsar coil Adjust the air gap between flywheel and pulsar coil to 0 5mm with a feeler gauge Attach the pulsar coil to the engine Air ga...

Page 32: ...o the blower housing securely Flywheel Recoil guide Grommet Pulsar coil Pulsar coil harness Tightening torque 3 0 5 0 N m 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 the blower housing 5 4 7 Pulsar coil and grommet Tighten the bolt in place making adjustments according to 5 4 6 M6 x 8mm Flange bolt 2pcs Caut...

Page 33: ...oid damaging the magnet of the rotor Rear cover Stator Rear cover 5 4 10 Rear cover stator Install the rear cover of the generator and stator into the rotor Install the rear cover to the blower housing M6 x 25mm Flange bolt 3pcs Tightening torque 10 0 11 0 N m 100 110 kgf cm 7 4 8 1 ft lbs NOTE The rotor and the stator are pulling each other by a very strong magnetic force Make sure the rotor does...

Page 34: ... M6 x 18mm Flange bolt 1pce Air cleaner base plate Carburetor Air cleaner NOTE Please do not forget to install the gasket 5 4 11 Base Inverter Install the base inverter into the engine main body M8 x 20 Bolt and washer 4pcs M6 Flange nut 4pcs Tightening torque 9 0 11 0 N m 90 110 kgf cm 6 6 8 1 ft lbs Tightening torque 18 0 20 0 N m 180 200 kgf cm 13 3 14 8 ft lbs NOTE Avoid cutting your hand by t...

Page 35: ... pipes from the fuel pump to the crankcase and carburetor and fasten with a hose clamp Fuel pipe Carburetor side Fuel pipe Crank case side NOTE Assemble with care Avoid mis connection of fuel pipes Inverter unit NOTE When fastening make sure there are no mis wiring of harness or forgotten wiring Couplers 5 4 17 Installing coupler Connect the harness of the control panel and inverter unit Be sure t...

Page 36: ...se clamp while the fuel cock is closed M6 x 12mm Flange bolt 1pce M6 Nut 1pce Fuel cock bracket Base surface Mounting angle Fuel tank 5 4 18 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 Front frame Rear frame 5 4 20 Rear frame Attach the rear frame L and R to the base inverter ...

Page 37: ...M6 x 18mm Flange bolt 4pcs 5 4 22 Recoil starter and guide Install the guide of the starter hundle Install the guide and starter hundle after they are pushed through the mounting hole from inside of the case body M4 x 10mm Tapping screw 1pcs Insert the overflow pipe through the hole in the bottom of the case body Attach the upper part of the case body M6 x 25 Screw and Washer 2pcs Install the cont...

Page 38: ...ide panel left and right to the case body M6 x 16 5mm Bolt 2pcs Side Panel This is the end of assembly procedures 5 4 23 Choke wire and rolling wire Install the choke wire into the choke shaft of the carburetor Install the rolling wire into the wire plate and fuel cock behind the control panel Rolling wire Choke wire NOTE Use the engine switch to confirm that the choke can be fully closed and full...

Page 39: ...s 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 3 Be sure to hold the reel with both thumbs so your fingers do not become be entangled 4 Pull the knot of the rope out from the reel loosen the knot then pull it up from the starter handle side this should be done by two people 5...

Page 40: ...inning at the top remove the retaining ring friction plate and ratchet Disassembly is completed 3 Remove the reel 1 Move the reel to left and right at a 1 4 turns several times until it moves smoothly gently holding it down 2 Slowly lift the reel removing it from the case 3 Repeat 3 1 and 3 2 if the spring assembled in the reel sticks out Friction plate Case Reel Spiral spring Retaining ring C Rat...

Page 41: ...spring Retaining ring C Friction plate Caution Please wear protective goggles before starting assembly 2 Assembly procedure 1 Assemble the reel into the case 1 Install the ratchet and fasten it with retaining ring E 2 Install the spiral spring in the reel 3 Apply grease to the case 4 Properly orient the inner end of the spring installed in the reel 5 Hold the reel so that the shaft and hook part c...

Page 42: ...nd the rope hole of the reel and pull 20cm out from the reel 3 Tight the end of the rope 5 Keep pressure on the spring 1 Feed the rope the length of one rotation of the reel from the attached hole of the reel and pull it out from teh hole of the case On the reel side let the rope that was pulled out hang over the notch of the reel About 20cm About 10m m Rope Cut of the reel Pull off hole Fixed hol...

Page 43: ...g reel rotation b When the starter rope does not return smoothly or the starter handle is hangs down loosely please add grease or mobile oil in the rotating and friction parts If it still does not work rewind 1 2 times In that case confirm that the spring is not under pressure by following the previous procedure c Please re assemble from the beginning if there was the sound when the spring was rem...

Page 44: ...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 Reel Spiral spring 2 Oil refill At the end of the season or when disassembling add grease preferably one that is heat resistant if possible or mobile oil to rotation parts friction parts and the spring ...

Page 45: ...Change the generator Resistance value of the generating main body for reference AC230V 240V Red Blue 4 2 Blue White 4 2 White Red 4 2 AC120V 1 2 1 2 1 2 Unit Ω Surrounding temperature 20 Red white White blue Red blue Turned on Voltage exceeds rated range Within the rating Low High Remove any electric load equipment that is connected Once stop the engine and reset the overload warning Confirm the e...

Page 46: ...hrottle part OK Runs Pull the recoil lightly with the carburetor throttle fully opened Full throttle direction Towards the opposite direction against the air cleaner in front Dirty or bad spark plug Poor return of the choke Air cleaner blockage Muffler blockage Bad carburetor water leak in blockage etc Lack of gasoline Gasoline corrosion Blockage from the tank to the carburetor Change the stepping...

Page 47: ...soline corrosion OK Corrosion Remove the spark plug and check the electrode Wet Dry Attach the plug to the plug cap and check for sparks by grounding the electrode Sparks No spark Adjustment Check the valve clearance of the compressed pressure compression NG Resistance value 0Ω Engine does not start Start failure E g GND Tester Change gasoline Blockage of the fuel tube carburetor such as noise etc...

Page 48: ... Pur R Y R W Brn W Brown White Brn W Grn Green Grn W Green White Org Orange Org DC curcuit breaker Engine switch R W Brn Auto power save switch Gry Gray Gry R Red W White Y Yellow Grn Y Green Yellow Blk Grn Y W Blk White Black Pur Purple Step motor Grn LED INDICATOR Blu Pur Gry Y Y Ignition coil REV Sensor Float switch Blu W Blk Blk R Blk SPARK PLUG AC receptacle 230V R1700i 50Hz 230V ...

Page 49: ... R W Brn W Brown White Brn W Grn Green Grn W Green White Org Orange Org DC curcuit breaker Engine switch R W Brn AC receptacle 240V Auto power save switch Gry Gray Gry R Red W White Y Yellow Grn Y Green Yellow Grn Y W Blk White Black Pur Purple Step motor Grn LED INDICATOR Blu Pur Gry Y Y Ignition coil REV Sensor Float switch Blu W Blk Blk R Blk SPARK PLUG Blk R1700i 50Hz 240V ...

Page 50: ... W Brn W Brown White Brn W Grn Green Grn W Green White Org Orange Org DC curcuit breaker Engine switch R W Brn Auto power save switch Gry Gray Gry R Red W White Y Yellow Grn Y Green Yellow Grn Y W Blk White Black Pur Purple Step motor Grn LED INDICATOR Blk Blu Pur Gry Y Y Ignition coil REV Sensor Float switch Blu W Blk Blk R Blk SPARK PLUG AC receptacle 120V Blk R1700i 60Hz 120V ...

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Page 52: ...PRINTED IN THE USA Copyright 2004 Robin America Inc 940 Lively Blvd Wood Dale IL 60191 Phone 630 350 8200 Fax 630 350 8212 e mail sales robinamerica com www robinamerica com ...