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SERVICE
MANUAL
Models
R1100
GENERATORS
PUB-GS2363
Rev. 04/07
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CONTENTS Section Title Page 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2 PERFOMANCE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1. SPECIFICATIONS 1-1) SPECIFICATIONS MODEL R1100 Type 2-Pole, Revolving Field type Self Exciting, Single Phase AVR type Frequency Hz 50 50 60 Alternating electric current (AC) 850 850 1100 Maximum output VA 700 700 900 Rated output VA Rated voltage V 230 240 120 2.9 Rated current A 3.0 7.5 Rated power factor 1.0 Direct Current (DC) Output W 100 Voltage V 12 Power Current A 8.3 Model EH09-2D Type Forced air-cooled, 4-cycle, OHV Gasoline Engine Displacement mL(cc) 85.8 Fuel Automotive Unleaded G
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1-2) PERFOMANCE CURVES 50Hz - 230V 53 52 51 1000 50 800 600 400 246 238 200 230 0 01.0 2.03.0 4.0 OUTPUT CURRENT (A) 50Hz - 240V 53 52 51 1000 50 800 600 400 256 248 200 240 0 01.0 2.03.0 4.0 OUTPUT CURRENT (A) – 2 – OUTPUT VOLTAGE (V) FREQUENCY (Hz) OUTPUT VOLTAGE (V) FREQUENCY (Hz) OUTPUT POWER (VA) OUTPUT POWER (VA)
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60Hz - 120V 63 62 61 1000 60 800 600 132 400 128 124 200 120 0 02.0 4.0 6.0 8.0 OUTPUT CURRENT (A) – 3 – OUTPUT VOLTAGE (V) FREQUENCY (Hz) OUTPUT POWER (VA)
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2. GENERAL DESCRIPTION 2-1) EXTERNAL VIEW RECOIL STARTER (HANDLE) CONTROL PANEL AIR CLEANER FUEL DRAIN SCREW SIDE PANEL (L) CARRYING HANDLE TANK CAP COVER SPARK PLUG CAP OIL GAUGE (OIL FILLER) EXHAUST OUTLET SIDE PANEL (R) OIL DRAIN PLUG – 4 –
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2-2) CONTROL PANEL OIL SENSOR LAMP PILOT LAMP AC RECEPTACLES AC CIRCUIT BREAKER DC TERMINALS ENGINE SWITCH DC CIRCUIT BREAKER GROUND TERMINAL (1) ENGINE SWITCH STOP ENGINE SWITCH The engine switch is designed for easy operation with the RUN 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.) (CHOKE) Keep the knob in this position after the engine starts. (The engine can be started with the knob
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(2) OUTPUT LAMP Green light . . . . . . . . Indicates that the generator is generating. Unlit . . . . . . . . . . . . . The generator is not generating. OUT PUT (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
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(5) DC TERMINALS (-) DC TERMINAL (+) DC electric power for battery charge is available. - Red is positive (+) terminal. - Black is negative (-) terminal. DC 12V 8.3A (6) DC CIRCUIT BREAKER DC circuit breakers shut off electric current when the current BUTTON exceeds its limit. KNOB Check for excessive current consumption. After making sure IN (ON) OUT (OFF) everything is in order, push the button to the " ON " position. Fully dischanged battery of large capacity may cause over-curren
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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 Rotor CP Diode Rear cover Stator CP Brush holder Ball bearing Through bolt Rotor shaft AVR unit Flywheel – 8 –
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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. 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
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(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. (Output of electrical appliance) = (Power consumption) (Efficiency) Efficiencies of some electrical appliances are as follows : Single-phase motor . . . . . .0.6 to 0.75 (The smaller the motor, the lower the efficiency) Flu
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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,
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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 For AC For DC 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
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(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. (6) TACHOMETER Use the contactless type tacho meter for checking engine speed. – 13 –
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(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
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4-2) AC OUTPUT MEASURING SWITCH LOAD A ~ F V 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. Rated voltage 60Hz-120V 50Hz-230V 50Hz-240V Voltage range 120-128 230-246 240-256 4-3) MEASURING INSULATION RESISTANCE (1) Connect the megger tester across either one of the two output te
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(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 , replace the stator. Insulation failure cause electrical leak which may result in electrocution. (3) CONTROL PANEL With AC breaker turned ON, measure insulation resistance between each portion of electrical parts and earth (grounding) terminal or control panel itself. Measure with the AC breake
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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. If an accurate value is needed, measure by electric resistance using an Ohm-meter. While doing this, use caution to avoid contact resistance. Generator wire resis
