Subaru R1100 Service Manual
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Subaru R1100 Service Manual

Subaru R1100 Service Manual

Subaru generators service manual
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SERVICE
MANUAL
Models
R1100
GENERATORS
PUB-GS2363
Rev. 04/07

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  • Page 1 SERVICE MANUAL Models R1100 GENERATORS PUB-GS2363 Rev. 04/07...

  • Page 3: Table Of Contents

    Section Title 1. SPECIFICATIONS ........... . . 1 1-1 SPECIFICATIONS .

  • Page 4: Specifications

    Oil Warning Lamp Dimension Length x Width x High Dry weight kg Specifications are subject to change without notice. R1100 2-Pole, Revolving Field type Self Exciting, Single Phase AVR type EH09-2D Forced air-cooled, 4-cycle, OHV Gasoline Engine 85.8 Automotive Unleaded Gasoline...

  • Page 5: Perfomance Curves

    1-2) PERFOMANCE CURVES 50Hz - 230V 50Hz - 240V OUTPUT CURRENT (A) OUTPUT CURRENT (A) – 2 – 1000 1000...
  • Page 6 60Hz - 120V OUTPUT CURRENT (A) – 3 – 1000...

  • Page 7: General Description

    2. GENERAL DESCRIPTION 2-1) EXTERNAL VIEW RECOIL STARTER (HANDLE) AIR CLEANER FUEL DRAIN SCREW SPARK PLUG OIL GAUGE (OIL FILLER) SIDE PANEL (L) CARRYING HANDLE SIDE PANEL (R) – 4 – CONTROL PANEL TANK CAP COVER EXHAUST OUTLET OIL DRAIN PLUG...

  • Page 8: Engine Switch

    2-2) CONTROL PANEL PILOT LAMP ENGINE SWITCH (1) ENGINE SWITCH The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished. To start the engine, turn the knob to the position. (Choke valve is closed.) (CHOKE) Keep the knob in this position after the engine starts.
  • Page 9 (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.

  • Page 10: Dc Circuit Breaker

    (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 for excessive current consumption.

  • Page 11: Location Of Serial Number And Specification Number

    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. Serial number and Production number ( Label ) NOTE : Please specify these numbers when inquiring about the generator or ordering spare parts. 2-4) ALTERNATOR Diode Rotor CP...

  • Page 12: Range Of Applications

    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.
  • Page 13 (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.
  • Page 14 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.

  • Page 15: Measuring And Checking Procedures

    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...
  • Page 16 (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.
  • Page 17 (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.

  • Page 18: Ac Output Measuring

    4-2) AC OUTPUT MEASURING 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.

  • Page 19: Control Panel

    (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 MΩ, replace the stator. Insulation failure cause electrical leak which may result in electrocution.

  • Page 20: Checking Functional Members

    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.
  • Page 21 （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 lowers generator efficiency and output voltage.

  • Page 22: Automatic Voltage Regulator)

    (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 the AC current, which generated by the magnetic flux by the field coil. 2) A.V.R. trouble may be identified by simply looking at the A.V.R., or by the inter-lead resistance with a tester, or actually mounting it in the generator and operating it.

  • Page 23: Diode Rectifier

    (7) 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. Checking table for analogue circuit tester Analogue circuit tester Apply red needle...

  • Page 24: Oil Sensor

    (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. Oil Sensor Below the lower level : ON (continuity) 0Ω Ω Above the lower level : OFF(non-continuity) ∞...

  • Page 25: Assembly And Disassembly

    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.

  • Page 26: Disassembly Procedures

    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 5-3-2 Remove the rear cover Remove the rear cover by unscrewing the four screws. M6 x 20mm Screw and Washer : 4pcs.
  • Page 27 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 5-3-5 Remove the control panel (1) Remove the control panel from the case body.
  • Page 28 5-3-7 Remove rear frame Remove the rear frame. 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.
  • Page 29 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. 5-3-11 Remove the fuel pipes Remove the fuel pipe from the fuel pump to carburetor and the fuel pipe on crank case side.
  • Page 30 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.
  • Page 31 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 5-3-16 Remove the Brush holder Remove the Brush holder. M5 x 14mm Screw : 1pce. Tools : Screw driver Brush holder –...
  • Page 32 5-3-17 Remove the Stator / Rear cover Remove the Stator / Rear cover. M6 x 25mm Flange bolt : 3pcs. Tools : 10mm Box wrench NOTE : The stator is attached to the rear cover, both can be removed together. 5-3-18 Remove the rotor and Flywheel Remove the rotor and Flywheel.
  • Page 33 5-3-20 Remove recoil starter Remove the recoil starter. M6 x 20mm AY Bolt : 3pcs. Tools : 10mm Box wrench NOTE: For the maintenance of recoil starter, please refer to item "5-5) Disassembly and assembly of the recoil starter". 5-3-21 Remove the muffler Remove the muffler.
  • Page 34 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 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.

  • Page 35: Reassemble Procedures

    5-4) REASSEMBLY PROCEDURES 5-4-1 Cylinder baffle Install the cylinder baffle. (Tighten together) M8 x 16mm Flange bolt : 3pcs. Tightening torque : 11.0-13.0 N 110-130 (8.1-9.6 M6 x 12mm Flange bolt : 1pce. Tightening torque : 7.0-9.0 70-90 (5.2-6.6 5-4-2 Ignition coil Install the ignition coil into the ignition coil bracket and attach it to the engine.

  • Page 36: Recoil Starter

    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 5-4-5 Rotor and Flywheel Install the Rotor and Flywheel. M8 x 195mm Rotor bolt : 1pce. Tightening torque : 19.0-21.0 N 190-210 (14.0-15.5 ft NOTE 1: Wipe off any oil from the tapered shaft and hole...

  • Page 37: Blower Housing

    5-4-7 Ignition coil and harness Tighten the bolt in place, making adjustments according to 5-4-6. M6 x 4mm Flange bolt : 2pcs. Tightening torque : 3.0-5.0 30-50 (2.2-3.7 Place the Ignition coil harness along the groove of the grommet and recoil guide to make it easier to assemble the blower housing.
  • Page 38 5-4-9 Rear cover, stator Install the rear cover of the generator and stator into the blower housing. Install the rear cover to the blower housing. M6 x 25mm Flange bolt : 3pcs. Tightening torque : 10.0-11.0 N 100-110 (7.4-8.1 NOTE: Make sure of the direction of rear cover during installation.

  • Page 39: Front Frame

    5-4-11 Base Install the Base into the engine main body. M8 x 20 Bolt and washer : 4pcs. Tightening torque : 18.0-20.0 N 180-200 (13.3-14.8 ft M6 Flange nut : 4pcs. Tightening torque : 9.0-11.0 90-110 (6.6-8.1 NOTE: Avoid cutting your hand by the sharp edge of the base.
  • Page 40 5-4-15 Fuel pipe 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. 5-4-16 Grounding wire Fasten the ground wire. Tightening torque : 3.0-4.0 30-40 (2.2-2.9 ft 5-4-17 Installing coupler...

  • Page 41: Rear Frame

    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. 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.
  • Page 42 5-4-21 Case body, control panel 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 30-40 (2.2-2.9 ft NOTE: Install the bottom part of the case body correctly.
  • Page 43 5-4-23 Choke wire and rolling wire Set adjusting screw onto Choke wire bracket and fix nut. Fit choke wire with screw at choke lever swivel. NOTE: Make sure the carburetor chock is closed when turning the engine switch into CHOKE position. Also make sure the choke is fully opened when turning the engine switch into RUN position.

  • Page 44: Disassembly Procedures

    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.
  • Page 45 (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. (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.

  • Page 46: Assembly Procedure

    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.
  • Page 47 (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.
  • Page 48 -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. Assembly is completed. ※These are the disassembly and assembly procedures, please be sure to review the following item checklist to insure that the parts securely installed.
  • Page 49 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.

  • Page 50: Troubleshooting

    6.TROUBLESHOOTING Check if engine speed is normal. 50Hz : 3,000rpm 60Hz : 3,600rpm Check if brush is weared. Check if the total length of brush is 5mm or over. Check if stator coil is normal. Main coil Exciter coil Check if rotor coil is normal. Check if AVR is normal.
  • Page 51 No DC current Check if DC coil of stator is normal. Check if diode rectifier is normal. Check if DC circuit breaker is normal. Check if wiring is break or improper connection. Replace Replace Replace Replace when wiring is break or damage. Connect properly.
  • Page 52 Engine does not start (Start failure) None Check the gasoline in the tank warning lamp is on Oil warning lamp turns on when the recoil is pulled Fuel cock is in the ON position the cock Clean, Gasoline leaks when the change carburetor drain is loosened the filter...

  • Page 53: Wiring Diagram

    7. WIRING DIAGRAM 50Hz-230V GENERATOR Diode Rectifier Exciter coil ENGINE Oil sensor control unit Ignition coil Wiring color cord : Black LBlu Blk/W : Black/White : Blue Brn/W : Brown/White DC output DC circuit terminal breaker Grn/Y AC circuit breaker Engine switch : Light blue : Green...
  • Page 54 50Hz-240V GENERATOR Diode Rectifier Exciter coil ENGINE Oil sensor control unit Ignition coil Wiring color cord : Black LBlu : Light blue Blk/W : Black/White : Brown : Blue Brn/W : Brown/White DC output DC circuit terminal breaker Grn/Y AC circuit breaker AC receptacle Engine switch...
  • Page 55 60Hz-120V GENERATOR Diode Rectifier Exciter coil ENGINE Oil sensor control unit Ignition coil Wiring color cord : Black LBlu : Light blue Blk/W : Black/White : Brown : Blue Brn/W : Brown/White DC output DC circuit terminal breaker Grn/Y AC circuit breaker AC receptacle Engine switch...
  • Page 57 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2007 Robin America, Inc. PRINTED IN THE USA...

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