Subaru R1100 manual

SERVICE MANU AL R1100 GENERA TORS Models PUB-GS2363 Rev . 04/07[...]

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CONTENTS Section T itle Page 1. SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1 SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2 PERFOMANCE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . [...]

– 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 (at Rated output) Oil pan capacity Alternating electric current output Direct Current Output Spark plug Dry weight kg Specifications are subject to c[...]

– 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 4.0 OUTPUT CURRENT (A) 1000 01 . 0 2 . 03 . 0 0 800 OUTPUT POWER (VA) 600 OUTPUT VOLTAGE (V) 400 256 248 200 240 FREQUENCY (Hz) 53 52 51 50 50Hz - 240V[...]

– 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 EXHAUST OUTLET FUEL DRAIN SCREW OIL GAUGE (OIL FILLER)[...]

– 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. (CHOKE) To start the [...]

– 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. When the engine stops due to oi[...]

– 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. Check[...]

– 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. NOTE : Please specify these numb[...]

– 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. The electrical appliances generally have a label showing their rated voltage, frequency, and power consump[...]

– 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. Efficiencies of some electrical appliances are as follows : Si[...]

– 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). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorat[...]

– 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 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[...]

– 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. Use a high-grade, precise circuit tester to check the generator component[...]

– 14 – (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[...]

– 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. 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[...]

– 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. (3) CONTROL PANEL With AC breaker t[...]

– 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. NOTE: When measuring according the numerical value s[...]

– 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. A brush shorter than 5 mm must be replaced because decreased contact pressure between the brush and slip ring [...]

– 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.V.R (AUTOMATIC VOLTAGE REGULATOR) 1) Features This AVR operates to control the field current in order to maintain the output voltage for [...]

– 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 tester Analogue circuit tester No continuity 2 No continuity 3 No continuity − No continuity Continuity Continuity − Checking table for degital circu[...]

– 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. 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[...]

– 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. (2) For greater convenience, divide the parts into [...]

– 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. M6 x 20mm Screw and Washer : 4pcs. Tools : Screw[...]

– 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. M4 x 10mm Tapping screw : 1pce. Tools : Screw driver Case body Control Panel Mount Case b[...]

– 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. Fuel cock bracket Fuel pump Un[...]

– 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. Disconnect AVR coupler and Diode coupler. Couplers Couplers (Diode) Couplers (A VR) 5-3-11 Remove the fuel pipes Remove the fuel pipe from the fuel pump to carburetor and the fuel pipe on cra[...]

– 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. M6 x 18mm Flange bolt : 1pce. M6 Flange nut : 2pcs. Tools :10mm Box wrench 5-3-13 Groundi[...]

– 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. M5 x 14mm Screw : 1pce. Tools : Screw driver 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. Take care when removing. Rotor Rotor Bolt 5-3-17 Remove the Stator / Rear cover [...]

– 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. M8 x 80mm Flange bolt : 1pce. M6 Flange nut : 2pcs. Tools : 10mm Box wrench 12mm Box wrench Muffler NOTE: For the maintenance of recoil starter, please refer to item "[...]

– 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. M6 x 12mm Flange bolt : 1pce. T ightening torque : 7.0 - 9.0 N ・ m 70 - 9[...]

– 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. M8 x 195mm Rotor bolt : 1pce. NOTE 1: Wipe off any oil from the t[...]

– 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. Ignition coil harness Recoil [...]

– 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. M5 x 14mm Screw : 1pce. Install the rear cover to[...]

– 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. 5-4-14 Air cleaner Install the element and air cleaner cover onto the air cleaner [...]

– 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. Fuel pipe (Carburetor side) Fuel pipe (Crank case side) NOTE: Assemble with care. Avoid mis[...]

– 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. M6 Nut : 1pce. Fuel cock bracket Base surface Mounting angle Fuel tank 5-4-18 Fue[...]

– 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 : 2.0-3.0 N ・ m 20-30 kgf ・ cm (1.5 - 2.2 ft ・ lbs) 5-4-21 Case body ,[...]

– 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. M6 x 16.5mm Bolt : 2pcs. Side Panel This is the end of assembly[...]

– 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. Please do not release it suddenly , or relax your grip. 1) Disassembly procedures (1) Unhook [...]

– 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. -2 Beginning at the top, remove the retaining-ring, friction plate, and ra[...]

– 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. Align the cut of the friction plate to the cut of the recoil starter main body, and[...]

– 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. -3 Tight the end of the rope. (5) Keep pressure on the spring -1 Feed the[...]

– 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. (2) Pull the starter handle[...]

– 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. ※ Please refer to asse[...]

– 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. Replace Replace when wiring is break or damage. Connect[...]

– 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. Connect properly.[...]

– 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 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 carburet[...]

– 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" INDICATOR UN Grn/Y Grn/Y Grn/Y W W R Org R W W Brn Earth (ground) terminal Main coil ENGINE AVR Diode Rectifier Field coil Brush (+) Brush (-) Exciter coil Ig[...]

– 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 Org R W W Brn Earth (ground) terminal Main coil ENGINE Diode Rectifier Field coil Brush (+) Brush (-) Exciter coil Ignition coil Spark plug Oil sensor [...]

– 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 Org R W W Brn Earth (ground) terminal Main coil ENGINE Diode Rectifier Field coil Brush (+) Brush (-) Exciter coil Ignition coil Spark plug Oil sensor [...]

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