Instruction/ maintenance manual of the product R1100 Subaru
Go to page of 57
SERVICE MANU AL R1100 GENERA TORS Models PUB-GS2363 Rev . 04/07.
.
CONTENTS Section T itle Page 1. SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1 SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– 1 – 1. SPECIFICA TIONS MODEL T ype Starting system Hz W L mm mL(cc) L kg Model T ype Frequency VA Rated output Alternating electric current (AC) VA Maximum output Output Fuel tank capacity hours.
– 2 – 1-2) PERFOMANCE CURVES OUTPUT CURRENT (A) 1000 4.0 0 01 . 0 2 . 03 . 0 800 OUTPUT POWER (VA) 600 OUTPUT VOLTAGE (V) 400 246 238 200 230 FREQUENCY (Hz) 53 52 51 50 50Hz - 230V 4.
– 3 – OUTPUT CURRENT (A) 62 63 OUTPUT POWER (VA) FREQUENCY (Hz) OUTPUT VOLTAGE (V) 1000 600 800 60 61 0 200 400 02 . 0 4.0 6.0 8.0 120 124 128 132 60Hz - 120V.
– 4 – 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 .
– 5 – 2-2) CONTROL P ANEL DC TERMINALS GROUND TERMINAL AC RECEPT ACLES DC CIRCUIT BREAKER AC CIRCUIT BREAKER ENGINE SWITCH PILOT LAMP OIL SENSOR LAMP ENGINE SWITCH RUN STOP CHOKE (1) ENGINE SWITCH The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished.
– 6 – OUT PUT (2) OUTPUT LAMP Green light . . . . . . . . Indicates that the generator is generating. Unlit . . . . . . . . . . . . . The generator is not generating. (3) OIL SENSOR LAMP When the level of the engine oil falls below the prescribed value, the alarm lamp lights up and the engine stops automatically.
– 7 – ( - ) DC TERMINAL (+) DC 12V 8.3A BUTTON KNOB IN (ON) OUT (OFF) BUTTON KNOB IN (ON) OUT (OFF) (5) DC TERMINALS DC electric power for battery charge is available. - Red is positive (+) terminal. - Black is negative ( - ) terminal. (6) DC CIRCUIT BREAKER DC circuit breakers shut off electric current when the current exceeds its limit.
– 8 – 2-4) AL TERNA TOR Brush holder Diode AVR unit Rear cover Ball bearing Through bolt Rotor shaft Stator CP Fan Flywheel Rotor CP 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.
– 9 – 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.
– 10 – (5) 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.
– 11 – 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).
– 12 – 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.
– 13 – (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.
– 14 – (7) "Dr.Robin" GENERATOR TESTER The "Dr.Robin" generator tester is exclusively designed for fast, easy diagnosis and repair of Robin generators.
– 15 – 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.
– 16 – (2) ALTERNATOR Measure insulation resistance between each terminal (Black or White) of 6-P connector from the stator and the stator core. 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.
– 17 – (2) ROTOR ASSEMBLY 1) Field coil Measure resistance between the slip rings. Slip ring Rotor 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.
– 18 – （ 3 ） BRUSH The brushes must be smooth where they contact the slip rings. If not, polish smooth the brushes with sandpaper. A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage.
– 19 – − No continuity No continuity − − − − − Apply red needle of the circuit tester Apply black needle of the circuit tester 1 1 2 2 3 3 a b b 4 4 Orange a Orange Orange/Green Orange/Green (6) A.
– 20 – (8) RECEPTACLE, AC PLUG Check burn marks in the areas where electric current flows, such as wire and plastic parts of AC receptacle. 1 2 3 12 3 − 1 Checking table for analogue circuit tes.
– 21 – (9) 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.
– 22 – 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.
– 23 – 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.
– 24 – 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.
– 25 – 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.
– 26 – 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.
– 27 – 5-3-12 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 base plate of the air cleaner. Then remove the carburetor.
– 28 – 5-3-15 Remove the Base Remove the Base. M6 nut : 4 pcs, also M8 x 16 Bolt and washer : 4pcs. Tools : 12mm Box wrench Base 5-3-16 Remove the Brush holder Remove the Brush holder.
– 29 – 5-3-18 Remove the rotor and Flywheel Remove the rotor and Flywheel. M8 x 195mm Rotor bolt : 1pce. Tools : 12mm Box wrench NOTE 1: Flywheel can be removed with Rotor at the same time. NOTE 2: Counterclockwise threads are applied onto the Rotor (through) bolt.
– 30 – 5-3-20 Remove recoil starter Remove the recoil starter. M6 x 20mm AY Bolt : 3pcs. Tools : 10mm Box wrench Recoil starter 5-3-21 Remove the muffler Remove the muffler.
– 31 – 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 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.
– 32 – Cylinder baffle Ignition coil 5-4) REASSEMBL Y PROCEDURES 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 : 3pcs.
– 33 – Flywheel Rotor Rotor Bolt 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 Rotor and Flywheel Install the Rotor and Flywheel.
– 34 – 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 (Ignition coil harness) and recoil guide into the blower housing securely.
– 35 – T ightening torque : 3.0 - 5.0 N ・ m 30 - 50 kgf ・ cm (2.2 - 3.7 ft ・ lbs) Stator Rear cover Rear cover Stator bolt (M5 : 2pcs.) 5-4-9 Rear cover , stator Install the rear cover of the generator and stator into the blower housing. 5-4-10 Rear cover , stator Install the Brush holder.
– 36 – 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.
– 37 – T ightening torque : 3.0 - 4.0 N ・ m 30 - 40 kgf ・ cm (2.2 - 2.9 ft ・ lbs) 5-4-16 Grounding wire Fasten the ground wire. 5-4-15 Fuel pipe Connect the fuel pipes from the fuel pump to the crankcase and carburetor and fasten with a hose clamp.
– 38 – 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.
– 39 – 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.
– 40 – 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.
– 41 – 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.
– 42 – 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.
– 43 – (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.
– 44 – (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.
– 45 – 3) Checking items after assembly (1) Try to pull the starter handle for 2 to 3 times. -1 When the starter handle is difficult to pull, please make sure the parts, etc., are installed in the right direction. -2 When the ratchet does not operate, please re-check if there are any missing parts such as the spring.
– 46 – 4) When . . . (1)The spring pops out -1 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) -2 Hook the inside hook of the spring to the claw of the starter case while turning.
– 47 – 6.TROUBLESHOOTING Check if brush is weared. Check if the total length of brush is 5mm or over. Check if rotor coil is normal. Check if AVR is normal. Check if wiring is break or improper connection. Refer to "Engine dose not start (Start failure )" Check and replace brush.
– 48 – No DC current Check if diode rectifier is normal. Check if DC circuit breaker is normal. Check if wiring is break or improper connection. OK OK OK Check if DC coil of stator is normal. NG NG NG NG Replace Replace Replace Replace when wiring is break or damage.
– 49 – 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 Ye s N.
– 50 – 7. WIRING DIAGRAM Org Org/Grn GENERA TOR CONTROL P ANEL DC coil + - AC receptacle DC output terminal DC circuit breaker AC circuit breaker LAMP "OIL" LAMP "RUN" INDICATO.
– 51 – GENERA TOR CONTROL P ANEL DC coil + - AC receptacle DC output terminal DC circuit breaker AC circuit breaker LAMP "OIL" LAMP "RUN" INDICATOR UN Grn/Y Grn/Y Grn/Y W W R O.
– 52 – GENERA TOR CONTROL P ANEL DC coil + - AC receptacle DC output terminal DC circuit breaker AC circuit breaker LAMP "OIL" LAMP "RUN" INDICATOR UN Grn/Y Grn/Y Grn/Y W W R O.
.
PRINTED IN THE USA © Copyright 2007 Robin America, Inc. 940 Lively Blvd. • W ood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.
An important point after buying a device Subaru R1100 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Subaru R1100 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Subaru R1100 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Subaru R1100 you will learn all the available features of the product, as well as information on its operation. The information that you get Subaru R1100 will certainly help you make a decision on the purchase.
If you already are a holder of Subaru R1100, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Subaru R1100.
However, one of the most important roles played by the user manual is to help in solving problems with Subaru R1100. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Subaru R1100 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
