Subaru Robin Power Products R1700i manual

SERVICE MANU AL R1700i Model PUB-GS1950 Rev . 09/04 GENERA TOR[...]

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CONTENTS Section Title Page 1. SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

– 1 – 1. SPECIFICA TIONS MODEL T ype Starting system Hz W L mm mL(cc) L kg Model T ype Frequency kV A Rated output Alternating electric current (AC) kV A Maximum output Output Fuel tank capacity hours (at Rated output) Oil pan capacity Alternating electric current output Direct Current Output Spark plug Dry weight kg Specifications are subject [...]

– 2 – 2. GENERAL DESCRIPTION 2-1) EXTERNAL VIEW SP ARK PLUG CAP RECOIL ST ARTER (HANDLE) T ANK CAP COVER AIR CLEANER SIDE P ANEL (R) SIDE P ANEL (L) OIL DRAIN PLUG CARR YING HANDLE CONTROL P ANEL EXHAUST OUTLET FUEL DRAIN SCREW OIL GAUGE (OIL FILLER) R1700i[...]

– 3 – 2-2) CONTROL P ANEL DC TERMINALS GROUND TERMINAL AC RECEPT ACLES DC CIRCUIT BREAKER ENGINE SWITCH OVERLOAD LAMP PILOT LAMP OIL SENSOR LAMP AUTO POWER SA VE SWITCH AUTO POWER SA VE LAMP R1700i ENGINE SWITCH RUN STOP CHOKE (1) ENGINE SWITCH The engine switch is designed for easy operation with the interlocking mechanism between the fuel coc[...]

– 4 – PILOT LAMP OVER LOAD (2) PILOT LAMP and OVERLOAD LAMP ① ① Output lamp Green light . . . . . Indicates that the generator is generating. Unlit . . . . . . . . . . . The generator is not generating. ② ② Overload Lamp Red light . . . . . . . Indicates when an overload occurs, or output is abnormal, generating will stop when the red l[...]

– 5 – ( - ) DC TERMINAL (+) DC 12V 8.3A BUTTON KNOB IN (ON) OUT (OFF) (6) DC TERMINALS DC electric power for battery charge is available. - Red is positive (+) terminal. - Black is negative ( - ) terminal. (7) DC CIRCUIT BREAKER DC circuit breakers shut off electric current when the current exceeds its limit. Check for excessive current consump[...]

– 6 – 2-4) GENERA TOR ASSEMBL Y REAR COVER 3P CONNECTOR 4P CONNECTOR ROTOR STATOR DIODE RECTIFIER 2-3) LOCA 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 genera[...]

– 7 – 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 consump[...]

– 8 – (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. Efficiencies of some electrical appliances are as follows : Sin[...]

– 9 – 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[...]

– 10 – 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[...]

– 11 – (5) MEAGER TESTER Used for measuring generator insulation resistance. Select the one with testing voltage 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 component[...]

– 12 – (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[...]

– 13 – 4-3) MEASURING INSULA TION RESIST ANCE 4-2) AC OUTPUT MEASURING SWITCH LOAD TO AC RECEPTACLE F A ~ V ~ 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 an[...]

– 14 – (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 Ω , replace the stator. Insulation failure cause electrical leak which may result in electrocution. (3) CONTROL PA[...]

– 15 – Red Red White White 0.57 k Ω 0.57 k Ω ーーー ーーー 2P Connector for AC output a a b c b 2.5 M Ω ∼ ーーー 5 M Ω∼ 2.5 M Ω ∼ 10 M Ω∼ 10 M Ω∼ c 4 M Ω∼ 10 M Ω∼ ーーー ーーー ーーー Stator wire Terminal Apply red needle of the circuit tester d 4 M Ω∼ 10 M Ω∼ d 2.5 M Ω ∼ 10 M Ω∼ 10 M Ω∼ A[...]

– 16 – (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. Diode rectifier Circuit Tester Yellow Yellow / Blue Gray Orange Yellow Yellow / Blue Orange Gray Apply black[...]

– 17 – (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. Below the lower level : ON (continuity) 0 Ω Ω Above the lower level : OFF (non-continuity) ∞ ∞ Use 4-stroke automotive detergent oil of API service class SE or higher Grade (SG[...]

– 18 – 5. ASSEMBL Y AND DISASSEMBL Y 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 [...]

– 19 – 5-3) DISASSEMBL Y 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[...]

– 20 – Recoil starter hundle Guide Overflow pipe 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. Tools : Screw driver Case body Control Panel Mount Case b[...]

5-3-8 Remove fuel cock bracket 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. Fuel cock bracket Fuel pump Unplug the pi[...]

– 22 – 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 Inverter Unit Choke wire bracket 5-3-11 Remove the inverter unit Disconnect the two couplers and remove the inverter unit. (one coupler from the alternator body, and one from the eng[...]

5-3-15 Remove the base inverter Remove the base inverter. M6 nut : 4 pcs, also M8 x 16 Bolt and washer : 4pcs. Tools : 12mm Box wrench Base inverter – 23 – 5-3-13 Remove the air cleaner and 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[...]

– 24 – 5-3-16 Remove the Stator / Rear cover Remove the Stator / 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 Stator Rear cover 5-3-17 Remove the rotor Remove the r[...]

– 25 – 5-3-18 Remove Blower housing Remove the 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. Blower Housing 5-3-19 Remove the flywheel Remove the flywheel. M8 x 20 Bolt and washer : 1pce. NOTE: Use a Flywheel puller (Available on market) for t[...]

– 26 – 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 5-3-23 Remove the cylinder baffle Remove the cylinder baffle. M8 x 16mm Flange bolt : 3pcs. M6 x 12mm Flange bolt : 1pce. Tools : 10mm Box wrench 12mm Box wrench Cylinder baffle 5-3-22 Remove t[...]

– 27 – Cylinder baffle Ignition coil 5-4) REASSEMBL Y PROCEDURES T ightening torque : 3.0 - 5.0 N ・ m 30 - 50 kgf ・ cm (2.2 - 3.7 ft ・ lbs) 5-4-2 Ignition coil Install the ignition coil into the ignition coil bracket and attach it to the engine. 5-4-1 Cylinder baffle Install the cylinder baffle. (Tighten together) M8 x 16mm Flange bolt : [...]

– 28 – Flywheel Recoil starter 5-4-4 Recoil starter Attach the recoil starter to the crankcase. M6 x 18mm Flange bolt : 3pcs. T ightening torque : 7.0 - 9.0 N ・ m 70 - 90 kgf ・ cm (5.2 - 6.6 ft ・ lbs) 5-4-5 Flywheel Install the flywheel. M8 x 25 Bolt and washer : 1pce. 8.5D x 28D x 3.2T Washer : 1pce. NOTE : Wipe off any oil from the tape[...]

– 29 – Blower housing 5-4-8 Blower housing Install the blower housing M8 x 55mm Flange bolt : 1pce. M8 x 90mm Flange bolt : 3pcs. T ightening torque : 18.0 - 20.0 N ・ m 180 - 200 kgf ・ cm (13.3 - 14.8 ft ・ lbs) NOTE: Insert the grommet (pulsar coil harness) and recoil guide into the blower housing securely. Flywheel Recoil guide Grommet P[...]

– 30 – Rotor Rotor 5-4-9 Rotor Install the rotor. M6 x 20mm Flange bolt : 3pcs. T ightening 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. Carelessness may cause inj[...]

– 31 – T ightening torque : 7.0 - 9.0 N ・ m 70 - 90 kgf ・ cm (5.2 - 6.6 ft ・ lbs) 5-4-13 Air cleaner bottom plate and carburetor Install the insulator,gaskets, carburetor, baffle stay, and air cleaner base plate into the cylinder head. M6 Flange nut : 2pcs. 5-4-14 Air cleaner Install the element and air cleaner cover onto the air cleaner [...]

– 32 – T ightening torque : 3.0 - 4.0 N ・ m 30 - 40 kgf ・ cm (2.2 - 2.9 ft ・ lbs) 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. 5-4-15 Fuel pipe Connect the fuel pipes from the fuel pump to the cra[...]

– 33 – T ightening torque : 3.0 - 4.0 N ・ m 30 - 40 kgf ・ cm (2.2 - 2.9 ft ・ lbs) 5-4-19 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. Fuel cock bracket Base surface Mounting angle Fuel tank 5-4-18 Fue[...]

– 34 – Recoil starter hundle Guide Overflow pipe Case body Control panel Mount Case body T ightening torque : 3.0 - 4.0 N ・ m 30 - 40 kgf ・ cm (2.2 - 2.9 ft ・ lbs) T ightening torque : 3.0 - 4.0 N ・ m 30 - 40 kgf ・ cm (2.2 - 2.9 ft ・ lbs) T ightening torque : 2.0-3.0 N ・ m 20-30 kgf ・ cm (1.5 - 2.2 ft ・ lbs) 5-4-21 Case body ,[...]

– 35 – T ightening torque : 3.0 - 4.0 N ・ m 30 - 40 kgf ・ cm (2.2 - 2.9 ft ・ lbs) 5-4-24 Rear cover Attach the rear cover to the case body. M6 x 30 Screw and Washer : 4pcs. Rear cover 5-4-25 Side panels (left and right) Attach the side panel (left and right) to the case body. M6 x 16.5mm Bolt : 2pcs. Side Panel This is the end of assembly[...]

– 36 – 5-5) RECOIL ST ARTER T ools used : Long-nose pliers, retaining-ring pliers, protective goggles Caution : Please wear protective goggles before starting disassembly Caution : The pull of the spring is maximized while the rope is fully pulled out. Please do not release it suddenly , or relax your grip. 1) Disassembly procedures (1) Unhook [...]

– 37 – Caution : The reel is disassembled with the spring still assembled, so place it on a flat table without dropping, or shaking. Retaining-ring C Retaining-ring pliers (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 ra[...]

– 38 – (2) Install the small parts. -1 Install the ratchet guide and return spring into the reel. Return spring Ratchet guide (3) Installing friction plate, retaining ring C -1 Install by putting the friction spring end into the spring part of the ratchet guide. Align the cut of the friction plate to the cut of the recoil starter main body, and[...]

– 39 – (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. -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. (5) Keep pressure on the spring -1 Feed the[...]

– 40 – 3) Checking items after assembly (1) Try to pull the starter handle for 2 to 3 times. (a)When the starter handle is difficult to pull, please make sure the parts, etc., are installed in the right direction. (b)When the ratchet does not operate, please re-check if there are any missing parts such as the spring. (2) Pull the starter handle[...]

– 41 – 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 asse[...]

– 42 – 6.TROUBLESHOOTING No output power or Lower output When engine is running, check if Overload Lamp is activated When engine is running, check if the Pilot Lamp is turned on Tu r n ed off Tu r n ed off Red White Blue Change INV C/U Measured resistance value Generator (Refer to the figure below) Measured resistance value between Abnormal Cha[...]

– 43 – Improper revolutions (Electronic throttle) Starts but stops suddenly Go to the "Engine does not start (Start failure)" No Ye s Ye s Does not run ・ Engine revolution does not increase ・ Hunting Confirm connection of electronic throttle part OK Runs ・ Pull the recoil lightly with the carburetor throttle fully opened Full th[...]

– 44 – Check the gasoline in the tank Add gasoline Check the oil volume Confirm of the oil SW Change Oil SW Add oil (up to the rated volume) Open the cock Clean, change the filter Ye s None Oil warning lamp turns on when the recoil is pulled warning lamp is on Fuel cock is in the ON position Ye s NO NO Gasoline leaks when the carburetor drain i[...]

– 45 – 7. WIRING DIAGRAM CONTROL P ANEL ENGINE GENERA TOR INV&E/G C/U Blk : Black Blk DC coil Main coil Wi ring color cord Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Blu Brn Org Grn Blu 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[...]

– 46 – CONTROL P ANEL ENGINE GENERA TOR INV&E/G C/U Blk : Black Blk DC coil Main coil Wi ring color cord Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Blu Brn Org Grn Blu 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 AC receptacle (240V) Auto po[...]

– 47 – CONTROL P ANEL ENGINE GENERA TOR INV&E/G C/U Blk : Black Blk DC coil Main coil Wi ring color cord Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Blu Brn Org Grn Blu 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 :[...]

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