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Subaru R1100 service manual Assembly And Disassembly, Precautions, Special Tools

Models: R1100

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5. 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.

(2)For greater convenience, divide the parts into several groups and store them in boxes.

(3)To prevent bolts and nuts from being misplaced or installed incorrectly, place them temporarily back at their original position.

(4)Handle disassembled parts with care; wash them with clean oil. (Do not clean electrical parts with oil nor water.)

(5)Use proper tools correctly for each specific job.

(6)Please be sure to glue the sponge inside the cover. Please replace the sponge if it is deformed, peeled, or damaged, with a new one. The generator performance may be negatively affected by the lack of a sponge or deformed, peeled or damaged sponge.

(7)Tie the electric wires and fuel pipe with wire bands as necessary.

※Please refer to Robin Engine Service Manual EH09 for the assembly and disassembly of the engine.

5-2) SPECIAL TOOLS

Use the proper, specialized tools for disassembly and assembly.

By using the proper, specialized tools, maintenance trouble and damage of the equipment can be avoided.

Parts No.	Name of the tool	Form	Use method
33K9990001	Rotor puller		To remove
33K9990001	Rotor puller		Flywheel with Rotor
			Flywheel with Rotor

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Subaru R1100 service manual Assembly And Disassembly, Precautions, Special Tools

Contents

Models R1100 GENERATORSPUB-GS2363 Rev. 04/07 Page CONTENTS 1-1 SPECIFICATIONS 1. SPECIFICATIONSMODEL R1100OUTPUT POWER 1-2 PERFOMANCE CURVES50Hz 50Hz60Hz OUTPUT POWERFREQUENCY 10002-1 EXTERNAL VIEW 2. GENERAL DESCRIPTIONRECOIL STARTER HANDLE CONTROL PANEL AIR CLEANER FUEL DRAIN SCREW SIDE PANEL L CARRYING HANDLE TANK CAP COVER SPARK PLUG CAP OIL GAUGEENGINE SWITCH 2-2 CONTROL PANELSTOP ENGINE SWITCH RUN CHOKE PILOT LAMP3 OIL SENSOR LAMP 2 OUTPUT LAMP4 AC RECEPTACLES OUT PUT6 DC CIRCUIT BREAKER 5 DC TERMINALS7 AC CIRCUIT BREAKER 2-4 ALTERNATOR 2-3 LOCATION OF SERIAL NUMBER SER No., PRODUCTION NUMBER PROD NoSerial number and Production number Label Rotor CP1 Incandescent lamp, heater, etc. with a power factor of 3. RANGE OF APPLICATIONS3 Mercury lamps with a smaller power factor 5 Appliances without any indication as to power consumption NOTES Wiring between generator and electrical appliances 4-1 INSTRUMENTS 4. MEASURING AND CHECKING PROCEDURESNOTE Be careful of the frequency meters input voltage range 5 MEAGER TESTER 4 CIRCUIT TESTER For measuring resistance, etc6 TACHOMETER Use the contactless type tacho meter for checking engine speedDr.Robin MODEL4-3 MEASURING INSULATION RESISTANCE 4-2 AC OUTPUT MEASURINGRated voltage 60Hz-120V3 CONTROL PANEL 2 ALTERNATOR2 ROTOR ASSEMBLY 4-4 CHECKING FUNCTIONAL MEMBERSNOTE When measuring, tolerance should be considered number variation, ambient temperature etc（3）BRUSH 6 A.V.R AUTOMATIC VOLTAGE REGULATOR 1 Features Checking table for degital circuit tester Checking table for analogue circuit testerOil capacity 0.4 liters Below the lower level ON continuityAbove the lower level OFFnon-continuity Oil Sensor5-1 PRECAUTIONS 5. ASSEMBLY AND DISASSEMBLY5-2 SPECIAL TOOLS 5-3-3 Remove rolling wire, choke wire 5-3 DISASSEMBLY PROCEDURES5-3-1 Remove the side panels Left, Right 5-3-2 Remove the rear cover5-3-4 Remove the recoil starter handle NOTE At this point, the couplers of electrical wires are5-3-5 Remove the control panel connected to the control panel. Instead of5-3-7 Remove rear frame Engine switch in the off position5-3-8 Remove fuel cock bracket NOTE 1 Be sure to close the fuel cock before removing the fuel pipe5-3-11 Remove the fuel pipes 5-3-10 Remove the control panelCouplers Couplers Diode5-3-13 Grounding wire 5-3-12 Remove the air cleaner and carburetor5-3-14 Remove the front frame Remove the Base M6 nut 4 pcs, also M8 x 16 Bolt and washer 4pcs 5-3-15 Remove the BaseTools 12mm Box wrench 5-3-16 Remove the Brush holder5-3-17 Remove the Stator / Rear cover 5-3-19 Remove Blower housing5-3-18 Remove the rotor and Flywheel NOTE 1 Flywheel can be removed with Rotor at the same time5-3-21 Remove the muffler 5-3-20 Remove recoil starter5-3-22 Remove the ignition coil Recoil starter Muffler Ignition coilRemove the cylinder baffle M8 x 16mm Flange bolt 3pcs 5-3-23 Remove the cylinder baffleM6 x 12mm Flange bolt 1pce Tools 10mm Box wrench 12mm Box wrench By performing the above steps, only a bare engine remains5-4-1 Cylinder baffle 5-4 REASSEMBLY PROCEDURESTightening torque 11.0-13.0 N・m 110-130 kgf・cm 8.1-9.6 ft・lbs Tightening torqueRotor through bolt. Take cake when tightening 5-4-6 Air gap adjustment of flywheel and Ignition coil5-4-4 Recoil starter Tightening torque 7.0-9.0 N・m 70-90 kgf・cm 5.2-6.6 ft・lbs5-4-7 Ignition coil and harness 5-4-8 Blower housingTightening torque 3.0-5.0 N・m 30-50 kgf・cm 2.2-3.7 ft・lbs Tightening torque 18.0-20.0 N・m 180-200 kgf・cm 13.3-14.8 ft・lbsInstall the Brush holder NOTE Make sure of the direction of rear cover during installation5-4-9 Rear cover, stator Tightening torque 10.0-11.0 N・m 100-110 kgf・cm 7.4-8.1 ft・lbs5-4-14 Air cleaner 5-4-13 Air cleaner bottom plate and carburetor5-4-11 Base Tightening torque 18.0-20.0 N・m 180-200 kgf・cm 13.3-14.8 ft・lbs5-4-16 Grounding wire 5-4-17 Installing coupler5-4-15 Fuel pipe Tightening torque 3.0-4.0 N・m 30-40 kgf・cm 2.2-2.9 ft・lbs5-4-19 Fuel cock bracket 5-4-18 Fuel tankTightening torque 3.0-4.0 N・m 30-40 kgf・cm 2.2-2.9 ft・lbs 5-4-20 Rear frameTightening torque 3.0-4.0 N・m 30-40 kgf・cm 2.2-2.9 ft・lbs 5-4-21 Case body, control panelTightening torque 3.0-4.0 N・m 30-40 kgf・cm 2.2-2.9 ft・lbs Tightening torqueNOTE Make sure the carburetor chock is closed when turning the engine 5-4-23 Choke wire and rolling wireswitch into CHOKE position 5-4-24 Rear coverPlease wear protective goggles before starting disassembly 5-5 RECOIL STARTER1 Disassembly procedures assembled, so place it on a flat table without dropping, or shaking The reel is disassembled with the spring still2 Assembly procedure Please wear protective goggles before starting assembly4 Inserting the rope. this should be done by two people 3 Checking items after assembly 4 When 6.TROUBLESHOOTING Check if wiring is break or improper connection No DC currentReplace when wiring is break or damage. Connect properly Check if DC coil of stator is normal OKEngine does not start Start failure 50Hz-230V 7. WIRING DIAGRAMGENERATOR DC coilGENERATOR 50Hz-240VDC coil ENGINEGENERATOR 60Hz-120VDC coil ENGINEPage Copyright 2007 Robin America, Inc 940 Lively Blvd. Wood Dale, IL 60191 Phone 630-350-8200 Fax