Rato R2200 Service Manual
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Rato R2200 Service Manual

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R2200
R2800
R3000
SERVICE MANUAL
CHONGQING RATO POWER.CO.,LTD

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Summary of Contents for Rato R2200

  • Page 1 · · R2200 R2800 R3000 SERVICE MANUAL CHONGQING RATO POWER.CO.,LTD...
  • Page 2 This manual contains information how to maintain and how to do troubleshooting. Keep this owner’s manual handy, so you can refer to it at any time. This service manual describes correct method of the maintaining this equipment. As a result of this disregard of our rules caused by person casualty and equipment damaged, our company does not assume any responsibility Copyright reserved, and no part of this publication may be reproduced...
  • 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 reminds you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words: DANGER, WARNING, or CAUTION.

  • Page 4: Table Of Contents

    CONTENTS 1. PREFACE ..............................1 1-1 Component Identification ........................ 1 1-2 Specifications ..........................2 1-3 Maintenance Standard ........................3 1-3-1 R2200 ........................... 3 1-3-2 R2800 ........................... 5 1-3-3 R3000 ........................... 7 2. MAINTENANCE ............................ 10 2-1 Maintenance Schedule........................10 2-2 Engine Oil ............................. 11 2-3 Air Cleaner Service ........................
  • Page 5 CONTENTS 3-2-2 Special Tools ........................30 3-3 Dismounting Chart ........................31 3-4 Engines ............................32 3-4-1 Recoil Starter ........................32 3-4-2 Flywheel ..........................35 3-4-3 Air Cleaner ......................... 38 3-4-4 Carburetor .......................... 38 3-4-5 Cylinder Head/Valve ......................44 3-4-6 Crankshaft/Piston ....................... 51 3-5 Generators .............................

  • Page 6: Preface

    1. PREFACE 1. PREFACE 1-1 Component Identification ENGINE SWITCH AC CIRCUIT BREAKER CHOCKER LEVER GROUND TERMINAL AIR CLEANER AC RECEPTACLES FUEL VALVE DC PROTECTOR VOLTMETER RECOIL STARTER GRIP DC RECEPTACLES FUEL METER FUEL TANK CAP SPARK PLUG CAP MUFFLER...

  • Page 7: Specifications

    1. PREFACE 1-2 Specifications Item R2200 R2800 R3000 Engine Style R200 R200 R210 Engine Type Single Cylinder, 4-Stroke, Forced Air Cooling, OHV Displacement (cc) Igniting System Transistorized Magneto Engine Fuel Volume (L) Fuel Consumption(L/hr) 1.25 1.35 Continuing Time (hr) Oil Capacity (L)

  • Page 8: Maintenance Standard

    1. PREFACE 1-3 Maintenance Standard 1-3-1 R2200  Engine Parts Item Standard Service Limit Maximum Speed (No load) 3150-3180rpm Engine Cylinder Compression >1.17Mpa/1400rpm Cylinder Sleeve I.D 68.0mm 68.165mm Head Cylinder Warpage 0.10mm Head Skirt O.D. 67.985mm 67.845mm Piston-to-Cylinder Clearance 0.015-0.05mm 0.12mm...
  • Page 9 1. PREFACE Valve Clearance 0.15± 0.02mm 0.20± 0.02mm Stem O.D 5.48mm 5.318mm 5.44mm 5.275mm Valve Guide I.D IN/EX 5.50mm 5.572mm Stem Clearance 0.02-0.044mm 0.1mm 0.06-0.087mm 0.12mm Seat Width 0.8mm 2.0mm Spring Free Length 34mm 32.5mm Cam Height 27.7mm 27.45mm Camshaft Cam Heignt 27.75mm 27.50mm...

  • Page 10: R2800

    1. PREFACE  Generator Parts Item Standard Service Limit Stator Winding 2.2±5%Ω at 20℃ Stator Winding Resistance Stator Auxiliary 3.2±5%Ω at 20℃ Winding Rotor Excitation Excitation 45.6±5%Ω at 20℃ Resistance Winding Winding Carbon Brush Carbon Brush Length 10mm 1-3-2 R2800 ...
  • Page 11 1. PREFACE Small End I.D 18.002mm 18.07mm Connecting Big End I.D 30.02mm 30.066mm Big Oil Clearance 0.040-0.063mm 0.12mm Big End Side Clearance 0.1-0.7mm 1.1mm Crankshaft Crankshaft pin O.D 29.98mm 29.92mm 0.15± 0.02mm Valve Clearance 0.20± 0.02mm 5.48mm 5.318mm Stem O.D 5.44mm 5.275mm 5.50mm...

  • Page 12: R3000

    1. PREFACE  Generator Parts Item Standard Service limit 1.8±5%Ω at 20℃ Stator Winding Stator Winding Resistance Stator auxiliary 3.5±5%Ω at 20℃ Winding Rotor Excitation Excitation 51.3±5%Ω at 20℃ Resistance Winding Winding Carbon Brush Carbon Brush Length 10mm 1-3-3 R3000 ...
  • Page 13 1. PREFACE Ring Side Clearance： 0.015-0.045mm 0.15mm Second Piston 0.2-0.4mm 1.0mm Ring Enc Gap: Rings 0.15-0.35mm 1.0mm Second 1.5mm 1.37mm Ring Width: 2.5mm 2.37mm Second Small End I.D 18.006mm 18.017mm Connecting Big End I.D 30.215mm 30.225mm Big Oil Clearance 0.04-0.063mm 0.12mm Big End Side Clearance 0.1-0.7mm...
  • Page 14 1. PREFACE Spark Plug Resistance 5kΩ 0.8-1.0Ω Resistance Primary Coil Ignition 5.9-7.1kΩ Secondary Coil Coil （at flywheel） 0.4-0.6mm Air gap  Generator Parts Item Standard Service limit 1.4±5%Ω at 20℃ Stator Winding Stator Winding Resistance Stator Auxiliary 3.9±5%Ω at 20℃ Winding Rotor Excitation Resistance Excitation Winding 59.0±5%Ω...

  • Page 15: Maintenance

    2. MAINTENANCE 2. MAINTENANCE 2-1 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 run, make sure the area is well ventilated.

  • Page 16: Engine Oil

    3. TROUBLESHOOTING 2-2 Engine Oil Draining can be performed rapidly and OIL DIPSTICK completely while the engine is still warm. 1) Remove the oil dipstick and drain UPPER LEVEL plug to drain the oil. 2) Reinstall the drain plug, then tighten the plug securely.

  • Page 17: Fuel Sediment Cup Cleaning

    2. MAINTENANCE element for complete and clean. 2) If the air cleaner element is dirty, please clean the air cleaner element: Wash the air cleaner element in a solution of household detergent and warm water, then rinse thoroughly or wash in nonflammable or high flash point solvent: Drop a few points engine oil in, then, squeeze out.

  • Page 18: Spark Plug Service

    3. TROUBLESHOOTING 2-5 Spark Plug Service Recommended spark plugs: F7RTC or other equivalents 1) Remove the spark plug cap. 2) Clean any dirt around the spark plug base. 3) Use the plug wrench to remove the spark plug. PLUG WRENCH SPARK PLUG CAP 4) Visually inspect the spark plug if the insulator is cracked, if cracked, replace with a new spark plug.

  • Page 19: Valve Clearance Adjustment

    2. MAINTENANCE 2-6 Valve Clearance Adjustment Keep the clearance between engine valve rod end and driving parts for avoiding heat expanding and cold shrinking to effect engine performance. If the valve is too big, it can result in exhausting unsmooth, effecting engine performance and increasing engine noise(valve abnormal), if the valve is too small, the valve will close untight to make the engine operating abnormal and drain valve operating face burn.
  • Page 20 3. TROUBLESHOOTING SPARK PLUG SPARK PLUG CAP Measure the valve clearance in the cold the engine state. VALVE ADJUSTING NUT VALVE LOCKED NUT...
  • Page 21 2. MAINTENANCE  Adjusting valve clearance Valve clearance adjustment method: Loose the locking nut, turn the adjusting nut to get the correct valve clearance. Screw down the locking nut 0.15± 0.02mm Valve clearance 0.20± 0.02mm Adjusting nut Valve clearance Screw down Small Screw off CAUTION:...

  • Page 22: Governor

    3. TROUBLESHOOTING 2-7 Governor ① Reassembly or disassembly BOLT (M6× 10) THROTTLE PLATE BOLT (M6×10) STOPPER SPRING FIXING BOLT GOVERNOR SPRING SCREW (M5×25) GOVERNOR ROD RETURN SPRING GOVERNOR BRACKET NUT（M6）...
  • Page 23 2. MAINTENANCE GOVERNOR ARM GOVERNOR SPRING THROTTLE VALVE(FULLY OPEN) THROTTLE GOVERNOR ROD RETURNING SPRING ②Governor adjustment： a) Dismount the fuel tank b) Loosen the nut M6. Be sure that the carburetor throttle valve is fully open c) Rotate the governor arm shaft fully to the right (governor fully closed position), and retighten the nut.
  • Page 24 3. TROUBLESHOOTING Engine maximum speed 3150-3180rpm Speed too big Turn the bolt counterclockwise. Speed too small Turn the bolt clockwise...

  • Page 25: Troubleshooting

    3. TROUBLESHOOTING 3. TROUBLESHOOTING 3-1 Troubleshooting 3-1-1 Starting Difficult TROUBLE CAUSE REMEDY There is no enough fuel in fuel Fill fuel, open fuel cock. tank and fuel cock is closed. Air vent in the fuel filler cap is Dredge air vent. Fuel supply clogged is not...
  • Page 26 3. TROUBLESHOOTING TROUBLE CAUSE REMEDY Piston ring is worn to or even Replace over its wear limit Piston ring is broken. Replace Piston ring is sticking. Clear up carbon fouling. Tighten with a gasket in. Spark plug is not installed tighten Check cylinder gasket, and the or without a gasket.

  • Page 27: Power Lack

    3. TROUBLESHOOTING  Install the spark plug cap.  Turn the engine switch to ―ON‖position.  Pass negative pole (thread) of the spark plug through cylinder cover to connect grounding and pull the recoil starter grip to observe the spark. 3-1-2 Power Lack TROUBLE CAUSE...

  • Page 28: Speed Unstable

    3. TROUBLESHOOTING 3-1-3 Speed Unstable TROUBLE CAUSE REMEDY Piston, cylinder or piston ring is worn excessively. Replace the worn Knocking sound Piston pin and piston pin hole are worn excessively. Replace piston or piston pin Tie rod small head is worn excessively. Replace tie rod Engine is too hot Shoot trouble...

  • Page 29: Gasoline Engine Is Overheat

    3. TROUBLESHOOTING 3-1-5 Gasoline Engine is Overheat TROUBLE CAUSE REMEDY Oil insufficient or wrong oil ratio in the gasoline Refill engine oil Exhaust pipe blocked up Clean exhaust pipe Shroud leaking Repair damaged part Gasoline engine is Cooling fins blocked by foreign matter Clear cooling fins overheat Cooling fan is loosen and misfunction...

  • Page 30: Unable Generating Electricity

    3. TROUBLESHOOTING 3-1-7 Unable Generating Electricity TROUBLE CAUSE REMEDY Clean the surface of the collector Collector ring carbon brush ring and grind the carbon brush arc contacting poor face. Brush pressure abnormal Replace the spring or adjust it. Stator, rotor output leads contacting Check the adjusting winding for poor.

  • Page 31: No Ac Output Voltage

    3. TROUBLESHOOTING 3-1-9 No AC Output Voltage TROUBLE CAUSE REMEDY Engine speed abnormal Check and adjust Stator main coil defective Check and adjust Brush defective Check and adjust No AC output voltage Excitation voltage too low Check and adjust AVR defective Check and adjust Breaker tripped Reset breakers...

  • Page 32: Stator Winding Overheat

    3. TROUBLESHOOTING Stator and rotor iron core partly friction result iron core Grind the rotor iron core arc to remove iron heating. friction. 3-1-12 Stator Winding Overheat Overload Adjust the load according to specified load. Vent is clogged, Periodically check and remove the foreign matter in the generator for good heat dispersion Stator winding open circuit and connecting to ground.

  • Page 33: Safety Precautions

    3. TROUBLESHOOTING 3-2 Safety Precautions 3-2-1 Safety WARNING： Indicate a possibility of invalid warranty and personal or equipment damage if instructions are not followed. Please pay special attention to the following: 1) Strictly set the engine according to the regulated power on the nameplate. Do not overload, overrun the engine or run it with low load and at low speed in a long time.
  • Page 34 3. TROUBLESHOOTING Never touch it, or you may get burns. Transport or store the engine with it cooling down entirely. 12) Safe warning label: 13) Please carefully read warning label before operating. Our company will not assume any responsibility, for person hurt, or equipment damaged caused by disregarding this warning label.

  • Page 35: Special Tools

    3. TROUBLESHOOTING 3-2-2 Special Tools Tool name Application note · 1) Float lever 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.

  • Page 36: Dismounting Chart

    3. TROUBLESHOOTING 3-3 Dismounting Chart HANDLE FLYWHEEL MOTOR TAIL COVER FUEL TANK VOLTAGE REGULATOR BRUSH MUFFLER CONTROL PANNEL MOTOR BRACKET CUSHION FRAME STATOR ROTOR ENGINE CARBURETOR FLYWHEEL IGNITION COIL AIR CLEANER SHROUD RECOIL STARTER...

  • Page 37: Engines

    3. TROUBLESHOOTING 3-4 Engines 3-4-1 Recoil Starter IMPELLER FLYWEEL NUT M14 RECOIL STARTER REEL COVER SHROUD BOLT(M6×10) BOLT （M6× 10） STARTING CUP RECOIL STARTER GRIP...
  • Page 38 3. TROUBLESHOOTING DRIVE GUIDE LOCKING SCREW SPRING DRIVE CAM RECOIL STARTER SPRING RETURN SPRING RECOIL STARTER REEL NOTICE:  Take care not to allow the return spring to come out. Wear gloves when operating.  Check the broken and wearing before installing the rope. Installation Instruction ①...
  • Page 39 3. TROUBLESHOOTING ② Hang the side hook of the recoil starter spring in the CUTOUT groove of the recoil starter case, set the recoil starter spring into the case with counterclockwise rotating starter spring. ③Set the recoil starter spring outside hook into the groove of GROOVE the recoil starter pulley.

  • Page 40: Flywheel

    3. TROUBLESHOOTING 3-4-2 Flywheel HIGH VOLTAGE IGNITION LINE SPARK PLUG CAP (Check the insulator for damage, if damaged, please replace it) FLYWHEEL STOP ENGINE WIRE STARTING CUP NUT M14 IMPELLER IGNITION COIL BOLT (M6× 25) IGNITION COIL a) Remove the fuel tank, air cleaner, carburetor and recoil starter assy.
  • Page 41 3. TROUBLESHOOTING Check the ignition coil (primary side） Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coil’s primary terminal while touching the other tester lead to the iron core. Primary side resistance value： 0.8-1.0Ω （Secondary side）...
  • Page 42 3. TROUBLESHOOTING FLYWHEEL (Cast iron) IMPELLER STARTER PULLY POSITION BLOCK POSITION HOLE POSITION BLOCK POSITION HOLE...

  • Page 43: Air Cleaner

    3. TROUBLESHOOTING 3-4-3 Air Cleaner CASE AIR CLEARNER CASE GASKET BOLT(M5× 13) GASKET  Check the air cleaner gasket for damage before installation NUT (M6)  Notice the position ELEMENT FRAME AIR CLEANER ELEMENT COVER NOTICE  Don’t wash the foam element with the gasoline, acidity, alkalic or organic solvent ...
  • Page 44 3. TROUBLESHOOTING modification is made. If a carburetor suitable to high altitude is equipped with engine suitable to a lower altitude, the lean air fuel mixture will make engine output power lowering, over-heat and seriously damage. The gasoline enters into the carburetor from the fuel tank and fuel filter. The fuel filter can filter the foreign matters in the gasoline and oxide out of the fuel tank.
  • Page 45 3. TROUBLESHOOTING THROTTLE SHAFT CHOKE SHAFT GASKET （Don’t reuse it） AIR CLEANER GASKET （Don’t reuse it） CARBURETOR INSULATOR CARBURETOR GASKET （Don’t reuse it） Wash the carburetor in the clean place, First, clean the outside surface, and wash the inside the parts with special carburetor detergent or industrial gasoline. Exception for washing impurities, also wash the gasoline colloid on the part surface.
  • Page 46 3. TROUBLESHOOTING PILOT JET IDLE SPEED SCREW WASHER CARBURETOR (Clean with PILOT SCREW compressed before installation) FLOAT PIN FLOAT VALVE MAIN NOZZLE FLOAT (After installing, check for operation by MAIN JET lightly pushing with a finger) DRAIN BOLT GASKET FLOAT CHAMBER (Install Set Bolt (Tighten the so that the drain bolt facing to bolt...
  • Page 47 3. TROUBLESHOOTING NOTICE  Loosen the drain bolt and completely drain the fuel out before installing carburetor.  No fire FLOAT VALVE a) Check the float valve, float seat and float FLOAT VALVE SEAT spring for wear. WORN NORMAL b) Clean with compressed air before MAIN JET installation c) Clean with compressed air before...
  • Page 48 3. TROUBLESHOOTING d) Clean with compressed air before installation. Apply light coat of oil to the O-ring to facilitate installation. O-RING 0-RING IDLE SPEED CARBURETOR BODY e) After washing the carburetor, reset the pilot screw back. Only repairing the carburetor can disassemble it.

  • Page 49: Cylinder Head/Valve

    3. TROUBLESHOOTING f) Inspection Float level height Place the carburetor in the position as shown and measure the distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spring. FLOAT HEIGNT GAUGE Specified float height 13.7mm±...
  • Page 50 3. TROUBLESHOOTING STUD M8X34 GASKET SPARK PLUG EXHAUST VALVE Clean and adjust before installation GASKET CYLINDER HEAD COVER INTAKE VALVE STUD M6X96 CLIP BOLT M6X12 Apply oil to thread Loosen and tighten the bolts crisscross pattern, especially BREATHE TUBE tightening, uniformly and gradually tighten, finally to STUD the specified torque.
  • Page 51 3. TROUBLESHOOTING EXHAUST VALVE Installation: RETAINER SPRING Before installation, remove carbon deposits and inspect the SEAL GUIDE valve. VALVE ROTATOR ADJUSTING NUT ADJUSTING BOLT LIFTER PUSH GUIDE LOCKING NUT CYLINDER HEAD Installation ： Before installation, remove any carbon deposits from the combustion chamber VALVE ROCK...
  • Page 52 3. TROUBLESHOOTING Valve spring retainer： Push down 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 attached to the cylinder, or the valves will drop into the crankcase.
  • Page 53 3. TROUBLESHOOTING ③Valve Guide Inspection： a) Inspect the valve guide for smooth, scratch and damaged in the inner surface, and matching between the valve guide and cylinder cover for fastness. VALVE GUIDE REAMER b) Using the valve guide reamer, ream the valve guides to remove any carbon deposits before measuring.
  • Page 54 3. TROUBLESHOOTING NOTICE: Be careful to avoid damaging the cylinder head when driving out the valve guides. c) Install the new valve guides from the valve spring side of the cylinder head.  Exhaust side: Drive the exhaust valve guide until the clip is fully seated (as shown as fig.) Intake side: Drive the intake valve guide to the specified height (measured from the top...
  • Page 55 3. TROUBLESHOOTING Conforming to service limit, if conforming to, replace the guide and ream the guide, refinish the valve when replacing the valve. ④Valve seat： a) Toughly 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...

  • Page 56: Crankshaft/Piston

    3. TROUBLESHOOTING material from the top edge (contact too high). ------The 45° cutter removes material from the bottom edge (contact too low). Be sure that the width of the finished valve seat is within specification. Standard Service limit 0.8mm 2.0mm Make lightly pass with the 45°...
  • Page 57 3. TROUBLESHOOTING 120° MAKER TOP RING SECOND RING MARK“△” OIL RING CONNECTION ROD REASSEMBLY： Make sure that the longer end marked is toward the piston head with the ―△‖ b) Piston pin clip Piston Pin Clip Install by setting front end of the clip in the piston groove, holding the other end with long nosed pliers, and rotating the clip in.
  • Page 58 Piston skirt O.D Measure the piston skirt O.D with outside micrometer, if out of the service limit, replace it. Type Standard Service Limit R2200/R2800 67.985mm 67.845 mm R3000 69.985mm 69.975 mm b) Piston pin bore to piston clearance Separately measure the piston pin bore I.D and O.D with inside micrometer and outside...
  • Page 59 3. TROUBLESHOOTING NOTICE: This clearance must be checked before and after repairing. Check with piston converting in the cylinder, and inserting feeler between piston skirt bearing face and wall, then pull the feeler out, if feeling resistance and smoothly out, the thickness of the feeler shall be considered as piston-cylinder clearance.
  • Page 60 Check small end diameter If out of the standard or exceed service limit, replace the connecting rod. Type Standard Service Limit R2200/R2800 18.006mm 18.07 mm R3000 18.002mm 18.017 mm b) Check big end diameter If out of the standard or exceed service limit, replace the connecting rod.
  • Page 61 3. TROUBLESHOOTING  Visually inspect camshaft face and camshaft height for damaged, and camshaft and bearing for loosening and wearing, replace as required.  Check camshaft for height dimension, if out of the service limit, replace the camshaft. Standard Service Limit Camshaft Intake Lift 27.7mm 27.45mm...
  • Page 62 3. TROUBLESHOOTING a）Check timing gear for engagement clearance with aligning two side mark on the gear. ALIGNM MARK CAMSHAFT GEAR CAMSHAFT GEAR Timing gear will be damaged in gear worn, gear face peeling off, and gear teeth broken. The engagement clearance is bigger due to gear wearing, the noise is bigger. If the timing gear is damaged, please replace with new one.

  • Page 63: Generators

    3. TROUBLESHOOTING 3-5 Generators 3-5-1 Fuel Tank NUT(M6×25) FUEL TANK RUBBER GASKET WASHER (Φ6×Φ25×2) BUSH FUEL TANK RUBBER GASKET COLLAR OIL TUBE FUEL SWITCH FUEL TANK Wash to remove sediment and dry thoroughly before reinstalling...
  • Page 64 3. TROUBLESHOOTING FUEL FILLER COVER ( Make sure the vent hole is clean and unclogged. Blow clean if necessary) SCREW(M5×12) OIL LEVELER FUEL STRAINER （Make sure the filter not clogged and OIL LEVELER damaged） GASKET Check the float for move smoothly before installation.

  • Page 65: Muffler

    3. TROUBLESHOOTING b) NOTICE  Check fuel tank cover vent for blocked；  Check the fuel strainer for clogged or broken；  Check the fuel hose for aging or cracks；  If finding trouble, replace it in time before installation. 3-5-2 Muffler MUFFLER MUFFLER COVER...
  • Page 66 3. TROUBLESHOOTING Lightly tap the muffler and blow it with compressed air in cleaning carbon deposits. Replace it if the muffler exist in water and is seriously rusted to make noise increasing. NOTICE: Don’t clean with iron wire or the muffler material out to lower the muffler performance.

  • Page 67: Generators

    3. TROUBLESHOOTING 3-5-3 Generators Removal/Installation： R2200 ROTOR （Make sure to clean the dunghill, oil, butter and others） MOTOR BRACKET WASHER （Φ23×Φ8×3） STATOR BOLT（M6×135） CARBON BRUSH TORQUE： 8-10 N.m BOLT（M5× 12） torque：5-7N.m BOLT（M8×180） Torque：28-30N.m Loose and tighten the bolt adopt the...
  • Page 68 3. TROUBLESHOOTING ROTOR（Make sure to clean the dunghill, oil, butter and others） MOTOR BRACKET CONNECTION BOARD STATOR WASHER （Φ23×Φ8×3） CARBON BRUSH BOLT （M5×12） torque： 5-7N.m Model Specification Torque R2800 M8×1×210 28-30N.m R3000 M8×1×220 28-30N.m BOLT Loose and tighten the bolt adopt the method of cross, especially tighten BOLT （M5×16）...
  • Page 69 3. TROUBLESHOOTING 2800 /R3000 Rotor Removal COLLECTOR RING Make sure to clean the foreign matters, oil, butter and others with lent-free cloth if necessary. If the collector ring rust or scrape lightly, remove the rotor and repaired by gauze. RATOR Fill the board and cloth under the rotor to prevent it from dropping.
  • Page 70 3. TROUBLESHOOTING 2) Motor Wiring Diagram R2200 BLUE YELLOW / GREEN （Grounding wire） GRAY WHITE BLUE BLUE GRAY BLUE GRAY GRAY...
  • Page 71 3. TROUBLESHOOTING R2800/R3000 YELLOW / GREEN （Grounding wire） GRAY BLUE GRAY WHITE GRAY BLUE BLUE 3) Carbon Brush Carbon Brush Grinding BRUSH Check the contacting face between the carbon brush and the collector ring for contacting EMERY faceless than 75% of the cross section of the BRUSH carbon brush after the running about 150hrs, If contacting face less than, grind the carbon brush...
  • Page 72 If the length less than 6MM, please replace. 4）Check the Generator Field Winding Dismount the carbon brush, measure the resistance of collector ring. Model Resistance 45.6±5%Ω at 20 degrees centigrade R2200 51.3±5%Ω at 20 degrees centigrade R2800 59.0±5%Ω at 20 degrees centigrade R3000...
  • Page 73 Collect or Ring If the result isn’t accord with the standard value, please clean the collector ring thoroughly. Replace the rotor if necessary. ① Main Winding R2200 R2800/R3000 BLUE BLUE Test the resistance of alternating current output terminal with ohmmeter.
  • Page 74 3. TROUBLESHOOTING WARNING If the insulation resistance decreased obviously, it means that the insulation is damaged. If you don’t repair it in time, it will result in creepage and endanger the man and equipment security. Make sure often test the insulation resistance of the winding to understand the insulation instance.

  • Page 75: Control Panel

    3. TROUBLESHOOTING  Generator Winding Breaker Circuit Testing Use the multimeter to test. Put the red pen and the black pen to the winding’s terminal. If the meter wave normally, it means the winding isn’t broken; if the meter needle is quiet, it means the tested winding is broken.
  • Page 76 3. TROUBLESHOOTING • Remove the bolt(M6× 12) • Remove the control panel. 1）Engine Switch Remove the wire of the switch terminal. Check for continuity between the terminals with ohmmeter as shown. 1-2 and 3-4 are connecting when the engine switch to OFF position, while they are not connecting when the engine switch to ON position.
  • Page 77 3. TROUBLESHOOTING 4）Rectifier testing Multimeter Black/Red Tested Ser. No. Meter Pen Contacting Multimeter pointing Judgment parts point The Black to―—‖, Meter needle waves clockwise, the Positive The Red to ―a‖ resistance value is clock to zero. continuity Normal The Black to ‖a‖ ， Meter needle is quiet, the Not continuity The Red to ―—‖...

  • Page 78: Wiring Diagram

    4. WIRING DIAGRAM 4. WIRING DIAGRAM 4-1 Electric Diagram R2200...
  • Page 79 4. WIRING DIAGRAM R2800/R3000...

  • Page 80: Appendix

    APPENDIX APPENDIX TORQUE Item Size Performance Grade No． Torque（N· m） Fuel tank Assembly M6× 25 8.8-B 10± 2 Leveler Assy.oil M5× 10 8.8-B 6± 1 Assembly M8× 16 24± 2 Muffler Assy M8× 30 8.8-A 26± 2 Muffler outer cover M6×...
  • Page 81 APPENDIX STANDARD TORQUE VALUE Fasteners Specification Torque（N· m） 5mm Bolt, Nut 4.5-6 6mm Bolt, Nut 8-12 8mm Bolt, Nut 18-25 10mm Bolt, Nut 29-34 12mm Bolt, Nut 49-59 4mm Screw 1.5-2.6 5mm Screw 3.5-5 Bolt, Nut 6mm Screw 7-11 5mm Flange Bolt 3.6-6.9 6mm Screw 7-11...

This manual is also suitable for:

R2800R3000

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