Related Manuals for Rato R80
Summary of Contents for Rato R80
- Page 1 GASOLINE ENGINE R80-R440 HORIZONTAL SHAFT SERVICE MANUAL CHONGQING RATO POWER MANUFACTURING CORPORATION...
- Page 2 This service manual describes correct methods for maintaining this equipment. If any personal casualty or equipment damage is caused due to disregard of our rules, our company does not assume any responsibility. NOTICE: Copyright is reserved, and no part of this publication may be reproduced without RATO Company’s written permission.
- Page 3 SAFETY MESSAGES Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the generator. Please read these messages carefully. A safety message alerts you to potential hazards that could injure you or others. Each safety message is preceded by a safety alert symbol and one of three words: DANGER, WARNING, or CAUTION.
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Page 4: Table Of Contents
2. DIMENSIONS AND TORQUE ·························································································· 6 2-1 ENGINE DIMENSIONS ··························································································· 6 2-1-1 R100 ······················································································································· 6 2-1-2 R80/R160/R180/R200/R210/R225 ·································································· 7 2-1-3 R270/R280/R300 ····························································································· 8 2-1-4 R390/R420/R440 ····························································································· 9 2-2 TORQUE VALUES ································································································· 10 ... - Page 5 4-1-8 GASOLINE ENGINE IS OVERERHEATED ··············································· 23 4-2 Preparation of servicing ··························································································· 24 4-2-1 Safety precautions ························································································· 24 4-2-2 Special tools ·································································································· 28 4-3 DISASSEMBLING chart ························································································ 29 4-4 Engine ······················································································································ 30 4-4-1 Recoil starter ·································································································· 31 ...
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Page 7: Introduction
1. INTRODUCTION 1-1 PARTS DESCRIPTION Fuel tank cover Air cleaner Fuel tank Muffler Throttle grip Spark plug Recoil starter Choke lever Start handle Drain plug Oil dipstick... -
Page 8: Specification
1-2 SPECIFICATION Model R210 R225 items L×W×H 390×320×345mm 390×320×345mm Dry Weight 16.5 kg 16.5kg Engine Type 4-stroke, OHV, single cylinder Displacement 212 cm3 223cm3 Compression Ratio 8.5±0.3 Bore×Stroke 70×55 mm 70×58mm Maximum Output Power 4.2／3600 rpm 4.4kW/3,600rpm Maximum Torque 12N·m/2500rpm 13N·m/2,500rpm Cooling System Forced Air-cooled... -
Page 9: Service Limit
1-3 SERVICE LIMIT 1-3-1 R210 Parts Item Standard Value Service Limit 3750-3810rpm Maximum Speed (No Load) Gasoline Engine 1.17Mpa Cylinder Compression ≧ （1400rpm） Cylinder Cylinder Bore I.D. 70.0-70.015 mm 70.165mm Cylinder Warpage 0.10mm Head Skirt O.D. 69.965-69.985 mm 69.845mm Piston-to-Cylinder Clearance 0.015-0.050mm 0.12mm Piston... - Page 10 27.547-7.947mm 27.500mm Journal O.D 13.966 -13.984mm 13.916mm Crankcase Camshaft Holder I.D. 14-14.018mm 14.048mm Cover Main Jet 0.85 Carburetor Float Height 13.7±1.5mm Pilot Screw Opening 2-1/8 circle Spark Plug Gap 0.7-0.8mm Spark Plug Resistance 7.5-12.5kΩ Resistance Primary Coil 0.8-1.0Ω Ignition Coil Secondary Coil 5.9-7.1kΩ...
- Page 11 Big end oil clearance 0.25-0.65 mm 0.12mm Big end side clearance 0.1-0.4 mm 1.0mm Crankshaft Crankshaft pin O.D 35.975-35.985 mm 35.92mm Valve clearance 0.15±0.02- 0.20±0.02mm Stem O.D 6.44mm 6.565-6.590 mm 6.4mm 6.535-6.550 mm Valves Guide I.D IN/EX 6.66mm 6.6-6.615 mm Stem clearance 0.11mm 0010-0.040mm...
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Page 12: Dimensions And Torque
2. DIMENSIONS AND TORQUE 2-1 ENGINE DIMENSIONS 2-1-1 R100/R80... -
Page 13: R80/R160/R180/R200/R210/R225
2-1-2 R160/R180/R200/R210/R225... -
Page 14: R270/R280/R300
2-1-3 R270/ R280/R300... -
Page 15: R390/R420/R440
2-1-4 R390/R420/R440... -
Page 16: Torque Values
2-2 TORQUE VALUES Ser. Part description and Torque MODEL Part Connecting components specifications value R100 M10×1.5×15 8.8-A Oil drain plug-flat R160-R225 M10×1.5×15 8.8-A 22±2 Oil drain plug washer-crankcase R270-R440 M12×1.5×18 8.8-A R100 M6×14 8.8-A R160-R225 M6×14 8.8-A 8±2 R270-R440 M6×16 8.8-A Oil sensor Oil sensor-crankcase... - Page 17 subassembly R160-R225 M6×12 8.8-A head subassembly R270-R440 Spark plug-cylinder head R100-R440 M14×1.25 30±4 Spark plug subassembly R100 M6×10 8.8-A Cylinder Cylinder shroud-cylinder R160-R210 M6×8 8.8-A 10±2 shroud head subassembly R270-R4440 M6×12 8.8-A R100 R160-R225 M6×16 8.8-A 10±2 Lower shield Lower shield- crankcase R270-R440 R100 R160-R225...
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Page 18: Standard Torque Values
subassembly R160-R225 M6×35 8.8-A crankcase R270-R440 M6×30 8.8-A 2-3 STANDARD TORQUE VALUES Torque valve Item Specifications N·m Kg·m 5mm bolt, nut 0.55 6mm bolt, nut Standard 8mm bolt, nut torque 10mm bolt, nut 37.5 3.75 12mm bolt, nut... -
Page 19: Maintenance
3. MAINTENANCE 3-1. MAINTENANCE SCHEDULE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance. If the engine must be running during maintenance, make sure the area is well ventilated. -
Page 20: Engine Oil
3-2 ENGINE OIL ● Oil change Oil dipstick 1）Dismount the oil filler cap and oil drain bolt to drain dirty oil. 2）Tighten the oil drain plug Oil drain plug Oil drain hole See 2-2-1Maintenance Standard 3）Add the clean oil from the filler neck. R100 Oil capacity 0.35L R160/R180/R200/R210/R225 Oil capacity... -
Page 21: Air Cleaner
3-3 AIR CLEANER Dual element type 1） Remove the nut, air cleaner cover and wing nut. Remove polyurethane and paper Air cleaner elements. cover 2） Clean polyurethane with detergent, then, blow it dry with compressed air or Polyurethane Wing nut squeeze it dry. -
Page 22: Spark Plug Cleaning And Adjusting
3-5 SPARK PLUG CLEANING AND ADJUSTING 1）Remove carbon or other deposits with a stiff wire brush. Check gasket for damage. 2 ） Measure plug gap between center electrode and side electrode with a spark plug feeler. If necessary, adjust the gap by bending the side electrode. -
Page 23: Governor
4 ） If adjustment is necessary, proceed as follows: a．Hold the rocker arm pivot and loosen the valve lock nut b．Turn the rocker arm pivot to obtain the specified clearance. c．Fix the rocker arm pivot with a spanner, then tighten the lock nut. d．Recheck valve clearance after tightening the valve lock nut. -
Page 24: Disassembling And Servicing
4. DISASSEMBLING AND SERVICING 4-1 TROUBLESHOOTING 4-1-1 Hard starting TROUBLE CAUSE REMEDY There is no enough fuel in fuel Add fuel, open fuel cock. tank and fuel cock is closed. Unclog air vent. Air vent in the fuel tank cover is clogged Fuel supply is not Improper or clogged main... - Page 25 TROUBLE CAUSE REMEDY Piston ring is worn too much Replace or even over its service limit Piston ring is broken. Replace Piston ring is sticking. Clear up carbon fouling. Abnormal Normal Normal Spark plug is not installed Tighten with a gasket in. cylinder fuel ignition...
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Page 26: Engine Lacks Power
Put negative pole (thread) of the spark plug through cylinder cover to connect to ground and pull the recoil start handle to observe the spark. 4-1-2 Engine lacks power TROUBLE CAUSE REMEDY Air in fuel line or fuel line is Drain air or unclog fuel line clogged Main jet is not adjusted properly... -
Page 27: Speed Is Unstable
[键入文字] 4-1-3 Speed is unstable TROUBLE CAUSE REMEDY Piston, cylinder or piston ring is worn Replace the worn part excessively. Piston pin and piston pin hole are worn Replace piston or piston pin excessively. Knocking sound Connecting rod small head is worn Replace connecting rod excessively. -
Page 28: Exhaust Gas Color Is Abnormal
4-1-5 Exhaust gas color is abnormal TROUBLE CAUSE REMEDY Piston, cylinder or piston ring is worn Replace the worn part excessively. Too much carbon deposit in combustion Clear away chamber Too much carbon deposit in combustion Clear away Black smoke chamber Improper gasoline grade or low gasoline Replace with qualified gasoline... -
Page 29: Oil Alert System Malfunction
[键入文字] 4-1-7 Oil alert system malfunction Check the oil alert system with the following method: 1) Disconnect yellow lead of the engine and connect the engine to ground when the engine is running. Be sure the alert lamp lights up, and the engine stops. 2) Disconnect oil level switch lead under the specified condition with the engine stopped, and check the continuity of the yellow and green leads, uncontinuity between yellow and green leads is normal. -
Page 30: Preparation Of Servicing
high speed. Crankshaft main bearing is burnt out Replace main bearing 4-2 PREPARATION OF SERVICING 4-2-1 Safety precautions WARNING： Indicate the possibility of invalid warranty and personal injury or equipment damage if instructions are not followed. Please pay special attention to the following: 1. - Page 31 [键入文字] 12. Safety warning labels: 13. Please carefully read warning labels before operating. Our company will not assume any responsibility, for person injury, or equipment damage caused by disregarding warning labels. （Applique labels are shown as follows） 1. Fuel label 2.
- Page 32 5. Throttle control label 6. Air cleaner maintenance label 7. Choke lever, fuel cock label 8. Oil grade label...
- Page 33 [键入文字] 9. Oil filling label...
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Page 34: Special Tools
Special tools 4-2-2 Tool name Application note 1. Float level gauge Carburetor float level inspection. 2. Valve guide driver Valve guide removal, installation. 3. Retainer assembler Assembling ball bearing. 4. Assembler handle Installing handle and bearing. 5. Inner retainer assembler Assembling ball bearing and time gear. -
Page 35: Disassembling Chart
[键入文字] 4-3 DISASSEMBLING CHART Engine Carburetor Flywheel Starter motor Shroud Recoil starter Air cleaner... -
Page 36: Engine
4-4 ENGINE a． Disassembly, reassembly Fan cover (only used for automatic starter) Control (only Lead support (2) used automatic Disassembly, reassembly： Assembling: Insert it into fan cover starter) Disassemble and reassemble with the recoil starter assembled. Ignition coil lead (black) Engine switch Starter relay lead Disassembly:... -
Page 37: Recoil Starter
[键入文字] 4-4-1 Recoil starter Driving guide Guide tray screw Spring Drive cam Starter coil spring Returning spring Starter reel NOTICE: Wear gloves and eye protection during disassembling, and take care not to allow the return spring to come out ① Insert the recoil starter rope through the groove in the recoil starter reel and make a figure-eight knot at the rope end ②... - Page 38 ③ Set the recoil starter coil spring’s outside hook to the groove of the recoil starter reel. Groove Groove ④ Set the starter drive cam on the recoil starter reel, and install the return spring on the recoil starter reel while hooking it to the side of the driving cam.
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Page 39: Flywheel
[键入文字] 4-4-2 Flywheel High tension cord (check Flywheel the insulation for chap and Spark plug cap damage) replace Starter pulley necessary） Igniter stop wire Impeller Ignition coil Bolt a) Remove the fuel tank, air cleaner, carburetor and recoil starter assy. b) Measure the clearance between the ignition coil and flywheel with the feeler. - Page 40 (Secondary side) Measure the resistance of the secondary side of the coil with the spark plug cap removed, touch one test lead to the high tension cord while touching the other test lead to the coil’s iron core. Secondary side resistance value： 5-7kΩ(recommended value) Measure the resistance of the spark plug cap by attaching one ohmmeter lead to the wire end of the plug cap while touching the other test lead to the spark plug end.
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Page 41: Air Cleaner
[键入文字] 4-4-3 Air cleaner Wing nut Air cleaner cover Reassembly: after reassembling the element and grid into the cover, install the Air cleaner cover to the body element (polyurethane) Air cleaner element Air cleaner element (paper) Elbow seal Noise silencer (only for silence) Collar B Air cleaner elbow... - Page 42 Oil bath type Wing nut Air cleaner cover Air cleaner element (polyurethane) Air cleaner grid Air cleaner case Oil capacity: 60cc Reassembly: After cleaning with solvent, fill with clean oil and install Collar Elbow packing Air cleaner elbow Disassembly/reassembly： ·Remove and install with the choke lever in “ON”...
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Page 43: Carburetor
[键入文字] 4-4-4 Carburetor Carburetor insulator a．Disassembly/reassembly Reassembly： Blow out the passages with Governor rod compressed air and install, noting Throttle return installation direction. After spring installation, connect the high tension cord and fuel hose to the ground. Carburetor gasket Choke handle Insulator gasket Carburetor assy. - Page 44 b．Disassembly/reassembly CAUTION ·Remove the drain plug and drain the carburetor before disassembling ·Prohibit fire. Idle speed mixed ratio adjusting screw Choke lever reassembly： Inspect for wear before installation. Fuel cock Idle speed adjusting screw Main nozzle Float spring Reassembly： Reassembly： Clean thoroughly with Check for top wear or compressed air before...
- Page 45 [键入文字] Inspection ●Float level height Place the carburetor in the position as shown and push the float in by finger and measure the distance between the float top and carburetor body (float height). Specified float height See 1-3Maintenance Standard If the float height is out of specification, replace the float valve and recheck the float height Float level gauge...
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Page 46: Cylinder Head /Valve
4-4-5 Cylinder head /valve 1) Removal/ installation Remove the fuel tank Remove the air cleaner ① ② ③ Remove the recoil starter and shroud ④ Remove the carburetor and insulator Spark plug: Clean and Stud adjust spark plug before installation EX valve guide Cylinder head... - Page 47 [键入文字] Valve spring retainer： Push down on the valve spring and move the retainer to the side so that valve stem slips through the side hole Do not remove the valve spring retainers while the cylinder head is installed to the cylinder, or the valves will drop into the cylinder.
- Page 48 Inspect： a) Inspect the valve guide for smoothness, scratch and damage in the inner surface, and matching between the valve guide and cylinder cover for fastness. VALVE GUIDE b) Use the valve guide reamer, ream REAMER the valve guides to remove any carbon deposits before measuring.
- Page 49 [键入文字] a) Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. b) Drive the valve guide out of the combustion chamber side using valve guide driver. VALVE GUIDE DRIVER CLIP Valve guide Installation height NOTICE: Be careful to avoid damaging the cylinder head when driving out the valve guides.
- Page 50 For best results, be sure the cylinder head is at room temperature before reaming valve guides. a) Coat the reamer and valve guide with cutting oil. b) Rotate the reamer clockwise through the valve guide for the full length of the reamer. Continue to rotate VALVE the reamer clockwise while removing it from the GUIDE...
- Page 51 [键入文字] a) Thoroughly clean the combustion chambers and valve seats to remove carbon deposits. Apply a VALVE FACE light coat of red lead powder or erasable color painting to the valve faces. Insert the valves, and then press the valve several times forcefully.
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Page 52: Crankshaft/Piston
4-4-6 Crankshaft/piston Oil seal Pin（Fix the governor arm with Don’t reuse pin after installing） Apply oil to lip of the oil seal Washer Install it inside the seat. Crankcase cover Bolt Governor arm Gasket (Don’t reuse） Oil seal Oil seal Crankcase Piston Bearing... - Page 53 [键入文字] Bearing gasket（Don’t reuse） Crankcase cover Oil filter cap Oil dipstick Sealing ring Seal ring Oil seal （Don’t damage the edge of the Bolt oil seal when reassembling crankcase cover ） Pin（Fix the governor arm with pin after Piston installing） Oil seal pin clip Spacer...
- Page 54 a) Piston • Install with the marker marking facing upward as shown. • Do not interchange the first ring and the second ring (first ring is chrome plated) • After assembly, check for smooth movement of the piston rings. • Stagger the piston ring end gaps 120° apart. ②Reassembly：...
- Page 55 [键入文字] Check the piston and cylinder for contacting, and check the groove for defects, piston top for burn and cracks. If any of them is damaged, replace it. Clean the carbon deposit Clean the deposit round the piston top and cylinder neck before checking, first soak the carbon deposit with kerosene, then clean with a metal scraper or metal brush.
- Page 56 Difference between cylinder maximum diameter and piston skirt should be considered as piston-to-cylinder clearance. NOTICE: This clearance must be checked before and after repairing. Check with piston upside down in the cylinder, and inserting feeler between piston skirt bearing face and wall, then pull the feeler out, if feeling resistance and moving smoothly out, the thickness of the feeler shall be considered as piston-to-cylinder clearance.
- Page 57 [键入文字] Piston ring Standard Service limit See 1-3Maintenance See 1-3Maintenance First ring/second ring Standard Standard See 1-3Maintenance See 1-3Maintenance Oil ring Standard Standard ③ Check connecting rod If connecting rod is bent or twisted, or its big end shaft hole and small end hole have apparent grooves, or have cracks on one side, the connecting rod should be rejected and replaced with a new one.
- Page 58 c）Connecting rod big end oil clearance Wipe oil off the crank pin and connecting rod bearing mating surface. Set the plastic gauge on the crank pin, then install connecting rod and fasten bolts to specified torque. Torque： See 1-3Maintenance Standard NOTICE: Place the plastic gauge axially.
- Page 59 [键入文字] Standard Service limit IN lifter See 1-3Maintenance Standard See 1-3Maintenance Standard EX lifter See 1-3Maintenance Standard See 1-3Maintenance Standard Check outside diameter of the camshaft, if it is less than the service limit, replace the camshaft. Standard Service limit See 1-3Maintenance Standard See 1-3Maintenance Standard Camshaft wearing cause and its influence on engine performance:...
- Page 60 ⑥Timing gear a） Check timing gear for engagement clearance and align marks of the gears on two sides. Timing gear will be damaged if gear is worn, gear face peels off, and gear teeth are broken. The engagement clearance is bigger due to gear wearing, the noise is bigger. If the timing gear is damaged, please replace it with new one.
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Page 61: Starting Control Box
[键入文字] 4-4-7 Starting control box a． Disassembly/reassembly (Only for starter) 6×12mm(2) Silicon rectifier Blade type fuse (5A) Control box screw Check : 7-8 Reassembly: Check for burn before installation Oil alert Check: P.7-8 Reassembly: Install by aligning with the hole of the control plate Control panel Box installation bracket... - Page 62 b．Check ● Engine switch Check the continuity between lead and fan cover. Switch position Continuity ● Engine switch (with oil alert) Black lead Check the continuity between black lead and engine switch. Switch position Continuity ● Switch (with starter) Check continuity between leads when switch is kept at each position. Lead color （to grounding）...
- Page 63 [键入文字] ● Oil alert lamp Black Connect the black and yellow leads to 6V battery or dry cell, check the alert lamp for lighting up. Black─━ battery（+） Yellow─━battery（-） Yellow （Don’t connect the positive and negative poles wrongly） ※ Don’t use the battery with over 6V, if so, bulb will break. Black /red lead ●...
- Page 64 ELECTRIC DIAGRAM control box starter motor starter relay charging coil...
- Page 65 [键入文字] Ch on gq ing Rato Power Manu factu rin g Corp oratio n Add：No. 99 Jiujiang Road, Shuangfu District, Chongqing China service hotline：400-681-9981 fox：023-85553450 postcode：402247 URL：www.rato.cc E-mail: ratoservice@rato.cc （consultation customer service） t @ t d ） （...