Subaru R1100 User Manual

SERVICE MANUAL

Models

R1100 GENERATORS

PUB-GS2363 Rev. 04/07

CONTENTS

Section Title Page

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 PERFOMANCE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2-1 EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2-2 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-3 LOCATION OF SERIAL NUMBER AND SPECIFICATION NUMBER . . . . . . . . . . . 8

2-4 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3. RANGE OF APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4. MEASURING AND CHECKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4-1 INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4-2 AC OUTPUT MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4-3 MEASURING INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4-4 CHECKING FUNCTIONAL MEMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5. ASSEMBLY AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5-1 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5-3 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5-4 REASSEMBLE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

5-5 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

7. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

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 make

modifications in the course of technical progress, at anytime without notice.

No parts of this manual may be reproduced without written permission.

– 1 –

1. SPECIFICATIONS

1-1) SPECIFICATIONS

MODEL

Type

Frequency

Alternating electric current (AC)

Rated voltage

Rated power factor

Direct Current (DC)

Output

Model

Type

Displacement

Fuel

Fuel tank capacity

VAMaximum output

VARated output

ARated current

VVoltage

APower Current

mL(cc)

R1100

2-Pole, Revolving Field type Self Exciting, Single Phase AVR type

850 1100850

700

240230

3.0

Forced air-cooled, 4-cycle, OHV Gasoline Engine

Automotive Unleaded Gasoline

2.9

1.0

100

8.3

EH09-2D

85.8

3.5

6050

900700

120

7.5

Rated continuous operation [Approx.]

Engine Alternator

Oil pan capacity

Ignition System Solid-state flywheel magneto

Spark plug

Starting system

Alternating electric current output

Direct Current Output

Over current protector

Alternating electric current (AC) output

Direct Current (DC) output

Equipment

Oil Sensor

Output Lamp

Oil Warning Lamp

Dimension

Length x Width x High

Dry weight kg

Specifications are subject to change without notice.

hours(at Rated output)

3.8

0.4

NGK BMR4A

Recoil starter

Te rminal

Current breaker

STD

480 x 295 x 445

25.5

3.7

Receptacle (20A x 2)Receptacle (15A x 2)Receptacle (15A x 2)

– 2 –

1-2) PERFOMANCE CURVES

50Hz - 230V

50Hz - 240V

FREQUENCY (Hz)

246

238 200

230

OUTPUT VOLTAGE (V)

1000

800

600

400

OUTPUT POWER (VA)

01.02.03.0

OUTPUT CURRENT (A)

FREQUENCY (Hz)

256

248 200

240

OUTPUT VOLTAGE (V)

4.0

1000

800

600

400

OUTPUT POWER (VA)

01.02.03.0

OUTPUT CURRENT (A)

4.0

– 3 –

60Hz - 120V

FREQUENCY (Hz)OUTPUT VOLTAGE (V)

1000

800

600

132

128

124

120

02.04.0 6.0 8.0

OUTPUT CURRENT (A)

400

OUTPUT POWER (VA)

200

– 4 –

2. GENERAL DESCRIPTION

2-1) EXTERNAL VIEW

RECOIL STARTER (HANDLE)

AIR CLEANER

FUEL DRAIN SCREW

CONTROL PANEL

SIDE PANEL (L)

SPARK PLUG CAP

OIL GAUGE (OIL FILLER)

CARRYING HANDLE

TANK CAP COVER

EXHAUST OUTLET

SIDE PANEL (R)

OIL DRAIN PLUG

– 5 –

2-2) CONTROL PANEL

(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 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 position. (The fuel cock is closed as well.)

ENGINE SWITCH

PILOT LAMP

OIL SENSOR LAMP

AC RECEPTACLES

AC CIRCUIT BREAKER

DC TERMINALS

DC CIRCUIT BREAKER

GROUND TERMINAL

STOP

ENGINE SWITCH

RUN

CHOKE

– 6 –

(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 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) AC RECEPTACLES

AC electric power is available through this receptacle.

Use a ground type, three-leg plug.

OUT PUT

– 7 –

(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. 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.

(7) AC CIRCUIT BREAKER

AC circuit breaker will cut off electric current when the current

exceeds its limit or a malfunction occurs in the connected

appliances.

Check for excessive current consumption or defects in the

appliances. After making sure everything is in order, push the

circuit breaker button.

(-) DC TERMINAL (+)

DC 12V 8.3A

BUTTON

KNOB

IN (ON) OUT (OFF)

BUTTON

KNOB

IN (ON) OUT (OFF)

– 8 –

2-4) ALTERNATOR

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.

NOTE : Please specify these numbers when inquiring about the generator or ordering spare parts.

Serial number and Production number

(

Label

)

Diode

Rotor CP

Rear cover

Stator CP

Brush holder

Ball bearing

Through bolt

AVR unit

Rotor shaft

Fan

Flywheel

– 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 consumption (input wattage). The power consumption of an electrical appliance is the power

necessary for using it. When using a generator for operating an electrical appliance, the power factor and

starting wattage must be taken into consideration.

In order to determine the right size generator, it is necessary to add the total wattage of all appliances to

be connected to the unit.

Refer to the followings to calculate the power consumption of each appliance or equipment by its type.

(1) Incandescent lamp, heater, etc. with a power factor of 1.0

Total power consumption must be equal to or less than the rated output of the generator.

Example : A rated 3000W generator can turn thirty 100W incandescent lamps on.

(2)

Fluorescent lamps, motor driven tools, light electrical appliances, etc. with a smaller power factor

Select a generator with a rated output equivalent to 1.2 to 2 times of the power consumption of the

load. Generally the starting wattage of motor driven tools and light electrical appliances are 1.2 to 3

times lager than their running wattage.

Example : 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, efficiency should be taken into account as explained in ltem (5) on the following page.

(3) Mercury lamps with a smaller power factor

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

Example : A 400 W mercury lamp requires 800 W to 1200 W power source to be turned on. A rated

3000 W generator can power two or three 400 W mercury lamps.

(4) Initially loaded motor driven appliances such as water pumps, compressors, etc.

These appliances require large starting wattage which is 3 to 5 times of running wattage.

Example : A rated 900 W compressor requires a 4500 W generator to drive it.

NOTE 1: Motor-driven appliances require the aforementioned generator output only at the starting.

Once their motors are started, the appliances consume about 1.2 to 2 times their rated power consumption so that the excess power generated by the generator can be used for other electrical appliances.

NOTE 2: Motor-driven appliances mentioned in items (3) and (4) vary in their required motor starting

power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity, select a generator with a larger capacity.

3. RANGE OF APPLICATIONS

– 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 :

Single-phase motor . . . . . .0.6 to 0.75 (The smaller the motor, the lower the efficiency)

Fluorescent lamp . . . . . . . .0.7 to 0.8

Example 1: A 40W fluorescent lamp means that its luminous output is 40W. Its efficiency is 0.7 and

accordingly, power consumption will be 40÷0.7= 57W. As explained in Item (2), multiply this

power consumption value of 57W by 1.2 to 2 and you will get the figure of the necessary

capacity of a generator. In other words, a generator with a rated output of 1000W capacity

can light nine to fourteen 40W fluorescent lamps.

Example 2

: Generally speaking, a 400W motor means that its work load is 400W. Efficiency of this motor

is 0.7 and power consumption will be 400÷0.7= 570W. When this motor is used for a

motor-driven tool, the capacity of the generator 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.

(Output of electrical appliance)

(Efficiency)

= (Power consumption)

Electrical

appliances

Household

Appliances

Electrical Appliances

Starting

wattage

One of power

consumption

1.2 to 2 times of power

consumption

3 to 5 times

of power

consumption

Electrical

appliances

Rice Cooker

Coffee Maker

Electric grill

Color TV

Hair dryer

Air conditioner

Microwave

Lawn mower

Refrigerator

Vacuum cleaner

Washer

Air Cooler

Deep well pump

Mercury lamp

Power

Consumption

(W)

300 to 1000

450

800 to 1400

100

1200

800 to 1200

400

100 to 260

1100

500

600

40 to 400

Electrical

appliances

Electrical tools /Architecture

Electrical Appliances

Starting

wattage

One of power

consumption

1.2 to 2 times of power

consumption

3 to 5 times

of power

consumption

Electrical

appliances

Soldering iron

Lighting for

young sardines

Drill

Disc Grinder

Electrical hammer

Chain sow

Impact wrench

Vibrator

Drill for shiitake

Air compressor

Winch

water pump

Power

Consumption

(W)

300 to 1000

600

350 to 600

500 to 1200

1000

1200

800 to 1200

400

1000 to 2600

1100

500

– 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 deteriorate the insulation, possibly burning it out. The table below

shows cables and their allowable currents for your reference.

2. Cable length

If a long cable is used, a voltage drop occurs due to the increased resistance in the conductors

decreasing 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.

Allowable

Current

Cable

Resistance

Ω/100m

1.486

0.952

0.517

0.332

100

Voltage drops per 30 meters of cable

R : Resistance (Ω/100m)

Cross

sectional

Voltage drop indicates as V= x R x I x L

I : Electric current (A)

L : Length (m)

The length of wire (L) indicates round length, which is the length from the generator

to the electrical tools and back.

<Example> R : Resistance 1.25mm

=1.48Ω/100m I : Electric current 10A L : Length 30m

The voltage drop of the case described above

30A25A20A15A10A5AAmm

＊＊＊＊8.9V4.5V121.25

＊＊＊8.6V5.7V2.8V172.0

＊＊6.2V4.7V3.1V1.6V233.5

6.0V5.0V4.0V3.0V2.0V1.0V355.5

1.48Ωx 10A x (30m x 2)

100

≒ 8.9 (V)

– 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 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 voltage

range.

For AC

For DC

– 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 components.

(6) TACHOMETER

Use the contactless type tacho meter for checking

engine speed.

– 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.

2) Fast and easy readout by digital indicator.

3) Built-in automatic battery checker indicates the time to change batteries.

4) Tester and accessories are installed in a handy, sturdy case for easy carrying.

SPECIFICATIONS

MODEL Dr.Robin

Part Number 388-47567-08

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

Insulation Resistance

The "Dr.Robin" generator tester can be ordered from Robin generator distributors by the following part number.

Dr.Robin_Part_Number_:_388-47565-08

If you do not have a "Dr.Robin" generator tester, use the instruments described in the following section for checking generator parts.

– 15 –

4-3) MEASURING INSULATION RESISTANCE

4-2) AC OUTPUT MEASURING

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.

(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.） If it is less than 1 MΩ, disassemble the generator and

measure the insulation resistance of the stator, rotor

and control panel individually.

Rated voltage 60Hz-120V

Voltage range 120

128

230

246

50Hz-230V

240

256

50Hz-240V

TO AC RECEPTACLE

SWITCH

A ~

V ~

LOAD

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