Rato R80 Maintenance Manual
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Rato R80 Maintenance Manual

Type v horizontal axis
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R80-R420 Type V Horizontal Axis
Maintenance Manual
Chongqing RATO Technology Co., Ltd.

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  • Page 1 R80-R420 Type V Horizontal Axis Maintenance Manual Chongqing RATO Technology Co., Ltd.
  • Page 2 This Manual covers specifications that shall be followed in the process of regular maintenance and troubleshooting of general-purpose gasoline engines. Make sure the equipment's maintenance staff can refer to this Manual at any time. This Manual describes correct methods to repair this equipment. The Company does not undertake any liability for any personal casualty and equipment damage caused due to ignoring these rules.
  • Page 3 Safety Warnings The personal and property safety of you and others is very important. Please carefully read the three kinds of extremely important safety warnings that we have described in the Maintenance Manual and on the decals of the gasoline engines. There is the symbol front of each safety warning.

  • Page 4: Table Of Contents

    CONTENTS Part I Introduction ........................1 1-1 Components of general-purpose gasoline engine ............1 1-2 Parameters ........................2 1-3 Maintenance standards ....................3 Part II Dimension and Torque ....................12 2-1 Dimensions of general-purpose gasoline engine ............12 2-2 Torque parameters ..................... 16 2-3 Standard torque parameters ..................

  • Page 5: Part I Introduction

    Part I Introduction Part I Introduction 1-1 Components of general-purpose gasoline engine Starter handle Fuel drain bolt Oil level gauge Fuel tank filter cover Fuel tank Muffler Governing handle Spark Hand- plug operated starter Choke handle...

  • Page 6: Parameters

    Part I Introduction 1-2 Parameters Model R80-V Parameters L×W×H 310×290×310 mm Net weight 10 kg Type of gasoline engine Four-stroke, overhead valve, single-cylinder Displacement 78.5cm Compression ratio 9.0:1 Cylinder diameter x 52×37 mm stroke Maximum output power 1.8kw / 3600rpm Maximum torque 4N.m / 2500rpm...

  • Page 7: Maintenance Standards

    Part I Introduction Cooling system Forced air cooling Ignition system Breakerless transistorized coil ignition (TCI) Spark plug BPR6ES(NGK), NHSP LD F7RTC, F7TC Lubrication system Splash type Power take-off shaft Counterclockwise direction Model R420-V Parameters L×W×H 465×415×440 mm Net weight 28kg Type of gasoline engine Four-stroke, overhead valve, single-cylinder Displacement...
  • Page 8 Part I Introduction Cylinder Cylinder bore diameter 52-52.015mm 52.165 Cylinder Warping head cover Outer diameter of piston skirt 51.975-51.985mm 51.9 Piston-cylinder clearance 0.015-0.04mm 0.12 Piston Inner diameter of piston pinhole 10 .002-10.008mm 10.048 Outer diameter of piston pin 9.992-9.998mm 9.954 Piston pin-piston pinhole clearance 0.004-0.016mm 0.03...
  • Page 9 Part I Introduction diameter 0.015-0.052mm Intake Lifter clearance 0.015-0.052mm 0.12 Exhaust 0.8mm Valve seat contact 25.0mm width Free length spring Cam height Intake 29.4mm 29.2 Camshaft Exhaust 29.4mm 29.2 Outer diameter of journal 12.966-12.986mm 12.91 Crankcase Inner diameter of camshaft bore 13.0-13.018mm 13.048 cover...
  • Page 10 Part I Introduction Piston ring side clearance: top ring/ring 2 0.015-0.045mm 0.15mm Oil ring Piston ring closing clearance: top 0.2-0.4mm 1.0mm ring/ring 2 Piston ring 0.15-0.35mm 1.0mm Oil ring 1.5mm 1.37mm Piston ring width: top ring/ring 2/oil 2.5mm 2.37mm ring Inner diameter of small end 18.011mm 18.07mm...
  • Page 11 Part I Introduction Cam height Intake 27.7mm 27.45mm Camshaft Exhaust 27.75mm 27.50mm Outer diameter of journal 13.984mm 13.916mm Crankcase Inner diameter of camshaft bore 14.0mm 14.048mm cover Master nozzle 0.85 Float height Carburetor 13.7±1.5mm Turning circle of adjusting screw of 2-1/8 circle mixing ratio Spark plug Clearance...
  • Page 12 Part I Introduction Piston pin-piston pinhole clearance 0.004-0.016mm 0.08mm Piston ring side clearance: 0.025-0.06mm 0.15mm ring/ring 2 Oil ring 0.20-0.40mm 1.0mm Piston ring closing clearance top ring Piston ring 0.30-0.50mm 1.0 mm Ring 2 0.2-0.7mm 1.0mm Scraping ring 2.8-3.0mm 1.37mm Piston ring width: top ring / ring 2 2.45-2.75mm 2.0mm...
  • Page 13 Part I Introduction Outer diameter of journal 16.166-16.184mm 16.12mm Crankcase Inner diameter of camshaft bore 16.2-16.218mm 16.248mm cover Master nozzle Φ2 Float height Carburetor 1-3mm Turning circle of adjusting screw of 2-7/8 circle mixing ratio Spark plug Clearance 0.7-0.8mm Spark plug Resistance 9.5-10.5kΩ...
  • Page 14 Part I Introduction ring/ring 2 Oil ring 0.2-0.4 mm 1.0mm Piston ring closing clearance: top 0.2-0.7 mm 1.0mm ring/ring 2 3.7-3.9 mm 1.37mm Oil ring 2.95-3.15 mm 2.0mm Piston ring width: top ring/ring 2/oil ring Inner diameter of small end 20.011-20.022 mm 20.07mm Inner diameter of big end...
  • Page 15 Part I Introduction cover Master nozzle Φ2 Float height Carburetor Turning circle of adjusting screw of mixing ratio Spark plug Clearance 0.7-0.8mm Spark plug Resistance 9.5-10.5kΩ Resistance Primary side 0.6-0.9Ω Secondary Ignition coil 5.6-6.9kΩ side Ignition coil 0.3-0.5mm clearance...

  • Page 16: Part Ii Dimension And Torque

    Part II Dimension and Torque Part II Dimension and Torque 2-1 Dimensions of general-purpose gasoline engine 2-1-1 R80-V 2-1-2 R210-V...
  • Page 17 Part II Dimension and Torque 2-1-2 R300-V...
  • Page 18 Part II Dimension and Torque 2-1-3 R420-V...
  • Page 19 Part II Dimension and Torque...

  • Page 20: Torque Parameters

    2-2 Torque parameters 2-2-1 Serial Fastening Specifications & Torque Connecting Model Fastener name position model value components R80-V M10×1.5×15 8.8-A Fuel drain bolt R210-V Hexagon 22 ± Fuel drain bolt M10×1.5×15 8.8-A - flat washer - flange bolt R300- crankcase M12×1.5×18 8.8-A...
  • Page 21 Part II Dimension and Torque R300- M8×35 10.9-A 42±2 gasket - R420-V crankcase R80-V Rocker arm M8×1.25 8.8-A Rocker arm R210-V Hexagon shaft bolt - M8×1.25 8.8-A 24±2 shaft bolt flange bolt cylinder head R300- M8×1.25 8.8-A assembly R420-V Cylinder head...

  • Page 22: Standard Torque Parameters

    Part II Dimension and Torque carburetor - Accelerator R80-V control M6×8 8.8-A Accelerator R210-V Hexagon assembly - control M6×12 8.8-A 10±2 flange bolt crankcase - R300- assembly M6×12 8.8-A cylinder head R420-V assembly Governing bracket Governing assembly - Hexagon bracket...

  • Page 23: Part Iii Maintenance

    Part III Maintenance Part III Maintenance 3-1 Maintenance list Good maintenance is the best guarantee to realize safe, economical and zero-fault operation. It is also conducive to environmental protection. The exhaust gas of the generator contains toxic carbon monoxide. Please shut down the gasoline engine for maintenance.

  • Page 24: Oil

    2) Tighten the fuel drain bolt. gauge Tightening torque: see Tab. 2-2-1. 3) Fill clean oil from the filling inlet. Fuel drain bolt Oil capacity of R80-V gasoline engine 0.35L Oil capacity of R210-V gasoline engine 0.6L Oil capacity of R300-R420 gasoline engine 1.1L...

  • Page 25: Air Filter

    Part III Maintenance 3-3 Air filter Combined type 1） Remove the nut, the air filter cover and the butterfly nut, as well as the filter elements made of polyurethane and paper. 2） Clean the polyurethane filter element with cleaning agent. Then, blow dry it with compressed air or wring it out.

  • Page 26: Cleaning Of Fuel Filter

    Part III Maintenance 3-4 Cleaning of fuel filter ● Fireworks are strictly prohibited during cleaning. ● After tightening, it should be confirmed that there is no fuel leakage. Set the fuel switch to the "OFF" position and O ring tighten the filter oil cup.
  • Page 27 Part III Maintenance Cylinder head cover bolt Cylinder cover guard Cylinder gasket 2) Place the piston at the upper dead point of compression. 3) Insert the feeler gauge into the clearance between the rocker arm and the valve to measure the valve clearance.

  • Page 28: Governor

    Part III Maintenance 3-7 Governor 1) Remove the fuel tank. 2) Loosen the fastening nut of the governing bracket. At this time, check whether the carburetor throttle is fully open (turns to the left to the end). 3) Turn the governing bracket to the right to the end (the position where the governor is completely closed), and tighten the bolt and the nut.

  • Page 29: Part Iv Disassembly And Maintenance

    Part IV Disassembly and Maintenance Part IV Disassembly and Maintenance 4-1 Fault judgement 4-1-1 Start difficulty Phenomenon Cause Remedy No fuel in fuel tank Refuel Clogged venthole of Dredge fuel tank cap Main measuring hole is Re-adjust or clean, blow Impeded fuel improperly adjusted or through...
  • Page 30 Check valve clearance and valve tightness, Valve leakage repair when necessary If gasoline engine is still unable to be started, please send it to authorized dealer of the RATO Power for overhaul. ⚫ Spark detection ...
  • Page 31 Part IV Disassembly and Maintenance  Pull the starter handle to release unburned gas out of the cylinder.  Assemble spark plug cap.  Turn the gasoline engine switch to the "ON" position.  Ground the negative electrode (threaded part) of spark plug via the cylinder head cover, pull the starter handle to observe the spark condition.
  • Page 32 Part IV Disassembly and Maintenance 4-1-3 Unstable speed Phenomenon Cause Remedy Excessive wear of piston, cylinder and piston Replace worn parts ring Excessive wear of piston pin and pin hole Replace the piston or piston pin There is knocking noise in the gasoline Excessive wear of small end of connecting Replace the connecting rod engine...
  • Page 33 Part IV Disassembly and Maintenance 4-1-5 Abnormal exhaust gas color Phenomenon Cause Remedy Excessive wear of piston, cylinder and piston Replace worn parts ring Gasoline engine overheating Find the cause and eliminate the fault Black smoke There is carbon deposit in the combustion Clear carbon deposit chamber.
  • Page 34 Part IV Disassembly and Maintenance normal if it is not conductive between wires. 3) When turning off the gasoline engine, drain off the oil, disconnect the oil level switch wire, and check the conductivity between yellow and green wires. It is normal if it is conductive between wires.

  • Page 35: Pre-Maintenance Preparations

    Part IV Disassembly and Maintenance 4-2 Pre-maintenance Preparations 4-2-1 Safety factors Failure of observing the following precautions will cause the void of warranty commitment provided with gasoline engine, and it may damage the gasoline engine or cause personal injury. Therefore, before operating gasoline engine, the user shall pay special attention to following points: 1) Carry out the matching in strict accordance with the nominal power.
  • Page 36 Part IV Disassembly and Maintenance not smoke or make naked flame or spark in the place where gasoline engine is fueled or in fuel storage site. 9) Do not overfill the fuel tank to cause overflowing of fuel. If there is fuel spilling, it must be thoroughly removed, and gasoline engine shall not be started until spilled fuel is volatilized.
  • Page 37 Part IV Disassembly and Maintenance 3. Displacement labels (those of some models are not listed because of page restriction. Displacement labels of different models are the same except the number on the label) 4. Trademark label 5. Accelerator label 6. Air filter maintenance label 7.
  • Page 38 Part IV Disassembly and Maintenance 8. Oil listing label 9. Oil filling label...
  • Page 39 Part IV Disassembly and Maintenance...

  • Page 40: Disassembly Chart

    Part IV Disassembly and Maintenance 4-2-2 Special tools Tool name Application location·Remarks Serial No. Float height gauge Inspection of oil level of the carburetor Disassembly and installation of valve Valve guide replacer guide Outer seat ring assembler Assembly of the ball bearing Installation of the handle on the assembler Assembler handle and installation of the bearing...

  • Page 41: Gasoline Engine

    Part IV Disassembly and Maintenance 4-4 Gasoline engine (electric starting type is taken as an example in the following figure. manual starting type is installed with different parts, and disassembled in a similar manner) Disassembly and assembly Fan guard (only for automatic starter specification) Wire holder (2) Control box (only for automatic...
  • Page 42 Part IV Disassembly and Maintenance 4-4-1 Hand starter components Drive guide plate Guide disc fastening screw Spring Driving cam Starter coil spring Return spring Starter drawstring coil When disassembling, be careful not to make the starter coil spring pop out, and wear gloves.
  • Page 43 Part IV Disassembly and Maintenance ③. Hook the outer side of the starter coil spring installed in the drawstring coil cover in the groove of the starter drawstring coil. ④. Install the driving cam on the starter drawstring coil, then install the return spring in the hole on the starter drawstring coil and hook its other end on the driving cam.
  • Page 44 Part IV Disassembly and Maintenance 4-4-2 Flywheel HV ignition wire Spark plug Flywheel (Inspect the insulator for cracks or damage and replace if Starter cup necessary) Flywheel nut Blow-out line Impeller Ignition coil Bolt a) Disassembly: fuel tank; air filter; carburetor; starter assembly. b) Use a thickness gauge to measure the clearance between ignition coil and flywheel.
  • Page 45 Part IV Disassembly and Maintenance e) Check the ignition coil (Primary side) Make contact between tester terminal and wire terminal and coil core, to measure the resistance value of coil primary. The resistance of primary coil: 1.0-1.5 Ω (recommended value) (Secondary side) Remove the cap of spark plug, to connect one end of the tester to HV harness, and make contact between the other end and coil core, to measure resistance value on the secondary side of the...
  • Page 46 Part IV Disassembly and Maintenance Flywheel  Align the four locating blocks on the impeller with the four holes on the rear side of the flywheel.  Align the locating block of the starter cup with the hole in the center of the flywheel. Flywheel Impeller Starter cup...
  • Page 47 Part IV Disassembly and Maintenance 4-4-3 Air filter Butterfly nut Air filter cover Assembly: Install the air filter element and the grille into the filter cover first, and then install it on the elbow of the air filter. Air filter Air filter element element (made of paper)
  • Page 48 Part IV Disassembly and Maintenance Oil bath type Butterfly nut Air filter shell Air filter element (made of polyurethane) Air filter grille Oil pan of air filter Oil capacity: 60cc Assembly: Clean it with cleaning oil, and then fill it with clean gasoline oil and install it.
  • Page 49 Part IV Disassembly and Maintenance 4-4-4 Carburetor a. Disassembly and assembly Carburetor heat shield Governing pull Assembly: Use the compressed air to Throttle return remove dirt and dust in the spring passage first, and pay attention to the direction of the inner and outer sides during installation.
  • Page 50 Part IV Disassembly and Maintenance b. Disassembly and assembly ● Before the disassembly of the carburetor, the fuel drain bolt must be unscrewed to drain off the fuel inside. ● No Open Flames. Choke lever Throttle limit screw Adjusting screw of auxiliary air Assembly: Check the wear of the front end first...
  • Page 51 Part IV Disassembly and Maintenance c. Inspection ● Float height Place the carburetor as shown in the figure, and push the float in with fingers. Measure the size (float height) between the float and the shell at the position where the foot of the float valve starts to act.
  • Page 52 Part IV Disassembly and Maintenance 4-4-5 Cylinder head/valve 1) Disassembly\assembly ① Remove the fuel tank ② Remove the air filter ③ Remove the starting system and air guide cover ④ Remove the carburetor and heat insulation pad Stud Spark plug M8×34 Cylinder head Clean and adjust...
  • Page 53 Part IV Disassembly and Maintenance Apply the sealant evenly on the inside of the cylinder head cover, without breaking before installation. The width of the sealant line: 2/3 width of the inner cover + 2/3 width of the outer cover, should not exceed the width of the inner and outer covers. Flat sealing silicone rubber is recommended.
  • Page 54 Part IV Disassembly and Maintenance Exhaust valve Assembly: Valve Valve Before installation, spring spring check the valve cone for seat defects and excessive carbon deposits. Valve gutter Camshaft components Valve locking Valve adjustment bolt Valve Valve rocker arm Valve lifter Intake valve lifter Installation:...
  • Page 55 Part IV Disassembly and Maintenance Valve spring retainer: Move the front end of the valve stem horizontally in the central hole of the spring retainer and remove it. If the cylinder head is assembled on the cylinder, the spring retainer may fall into the cylinder, which should be noted.
  • Page 56 Part IV Disassembly and Maintenance a) Check if the inner surface of valve guide is smooth without scratches and scuffing; and if the fitting between valve guide and cylinder cover is solid. Valve guide reamer b) Before measuring the inner diameter of the valve guide pipe, remove carbon deposit inside valve guide pipe by valve guide reamer.
  • Page 57 Part IV Disassembly and Maintenance Valve guide puller When removing the valve guide, be careful not to damage the cylinder head. c) Install the new valve guide from the valve spring side of the cylinder head.  Exhaust valve side: knock the exhaust valve guide until the retainer ring fully contacts the cylinder cover (as shown in the figure).
  • Page 58 Part IV Disassembly and Maintenance Valve guide reamer d) After installation, check whether the valve guide is damaged, and replace it if it is damaged. Reamer: When reaming preciously valve guide with a reamer, be sure to be at room temperature to get good result.
  • Page 59 Part IV Disassembly and Maintenance e) Clearance between the valve stem and the valve guide pipe: Subtract outer diameter of valve stem from corresponding inner diameter of valve guide pipe to obtain the clearance between valve guide pipe and valve stem. If the clearance between valve stem and valve guide exceeds maintenance limit, replace a new guide, to judge if the clearance can be within maintenance limit.
  • Page 60 Part IV Disassembly and Maintenance c) Grind the valve seat by 45° grinder to create a smooth valve seat being concentric with the valve guide, rotate it clockwise and not it is not allowed to rotate counterclockwise. Tool: valve grinder Valve seat grinding handle...
  • Page 61 Part IV Disassembly and Maintenance Standard Maintenance limit See Tab. 1-3 See Tab. 1-3 e) Slightly grind by 45° grinder to remove any burr on the edge of valve seat. f) After reshaping the valve seat, check the width of valve seat. Use only the colorant on valve cone face, insert the valve and press the valve several times with effort, but ensure that the valve does not rotate on the valve seat.
  • Page 62 Part IV Disassembly and Maintenance 4-4-6 Crankshaft/Piston Oil seal  Do not reuse it. Pin (use it for fixing  Add grease to the after installing the governing arm) Washer Installed on the inside of the base Crankcase cover Bolt Governing Crankcase sealing gasket...
  • Page 63 Part IV Disassembly and Maintenance Bearing Crankcase sealing gasket (can't be reused) Crankcase cover Oil plug Sealing ring Oil level gauge Sealing ring Oil seal (Do not damage the edge of Bolt the oil seal when assembling the crankcase cover) Pin (use it for fixing after Snap ring of...
  • Page 64 Part IV Disassembly and Maintenance ① Installation a) Piston  Make manufacturer's mark face up when assembling. Be careful not to confuse the ring 1 with the ring 2 (the ring 1 is chrome plated).  Make sure that piston ring moves freely after assembling. ...
  • Page 65 Part IV Disassembly and Maintenance Snap ring of piston pin Notch c) Connecting rod cover Align connecting rod with the edge of the connecting rod cover when assembling. Alignment mark ② Piston inspection Inspect the contact between the piston and cylinder, ring groove defect, top ablation and cracking, etc.
  • Page 66 Part IV Disassembly and Maintenance Standard Service limit See Tab. 1-3 See Tab. 1-3 b) The clearance between piston pin hole and piston pin Use the inside micrometer and the outside micrometer to measure the inner diameter of the piston pin seat hole and the outer diameter of the piston pin respectively. And then calculate its clearance value based on measured result.
  • Page 67 Part IV Disassembly and Maintenance pull it out smoothly, the thickness of the gauge at this time is the clearance between the cylinder and the piston. Standard Service limit See Tab. 1-3 See Tab. 1-3 d) Clearance of piston ring side During inspection, place each ring in its respective piston ring groove.
  • Page 68 Part IV Disassembly and Maintenance Piston ring Standard Service limit Ring 1/ring 2 See Tab. 1-3 See Tab. 1-3 Oil ring See Tab. 1-3 See Tab. 1-3 ③ Inspection of connecting rod When the connecting rod is bent or twisted, or its big end hole or small end hole is severely grooved, or there is a crack on one side, it shall be scrapped and replaced with new one.
  • Page 69 Part IV Disassembly and Maintenance Standard Service limit See Tab. 1-3 See Tab. 1-3 c) Big-end oil-film clearance  Wipe oil off crankshaft pin and connecting rod bearing pad surfaces.  Set a plastic feeler gauge outside the crankshaft pin, install the connecting rod, and tighten the bolt to the specified torque.
  • Page 70 Part IV Disassembly and Maintenance Plastic feeler gauge scale Plastic feeler gauge ④ Inspection of camshaft The camshaft is main driving part of valve train of gasoline engine, which controls intake and exhaust valves to open or close. Its structural feature is: On the shaft, there are the cam and supporting journal meeting the requirements for controlling air intake and exhaust.
  • Page 71 Part IV Disassembly and Maintenance Standard Maintenance limit Camshaft intake lift See Tab. 1-3 See Tab. 1-3 Camshaft exhaust lift See Tab. 1-3 See Tab. 1-3  Inspect the outer diameter of the camshaft. When it is less than the service limit, the camshaft should be replaced.
  • Page 72 Part IV Disassembly and Maintenance Timing point Crankshaft gear Camshaft gear Alignment between crankshaft and balance shaft The main damage of timing gear is the wear of gear tooth, tooth face peeling or roughness, gear deflection, gear tooth breakage, etc. Due to the wear of gear teeth, the greater the meshing clearance is, the greater the noise will be.
  • Page 73 Part IV Disassembly and Maintenance 4-4-7 Starting control box a. Disassembly and assembly (Only for automatic starter specification) Safety plate (5A) 6×12mm(2) Assembly: Control box Special screw Silicon Before installation, check rectifier whether it is about to burn out. Oil alarm device Assembly: Carry out installation by aligning the hole of the control panel.
  • Page 74 Part IV Disassembly and Maintenance b. Inspection ● Gasoline engine switch Check the conduction performance between the wire and the fan guard. Position of the gasoline engine switch Conductivity Not conductive Conductive ● Gasoline engine switch (with oil alarm device) Check the conduction performance between the black wire and the gasoline engine switch body.
  • Page 75 Part IV Disassembly and Maintenance ● Combination switch (with automatic starter) When the switch is in each position, check the conduction performance between the wires. Wire color Black/red (Grounding) Black/white White Switch position ○ ○ Grounding ○ ○ START Inspection shall be carried out with the fuse connected. Black/white Black/red White...
  • Page 76 Part IV Disassembly and Maintenance ● Oil alarm indicator Connect on the black/red and yellow wires of the oil alarm device. 6V battery or dry battery, make sure that the alarm indicator is on. Black/red - (+) of the battery Yellow - (-) of the battery ※...

  • Page 77: Electrical Schematic Diagram (Electric Starting Type)

    Part IV Disassembly and Maintenance 4-5 Electrical schematic diagram (electric starting type) Combination switch Black Grey Yellow Green White Control box Fuse Rectifiers Combination switch Starter motor Ignition coil Circuit breaker Starter electromagnetic coil Battery Charging coil Spark plug Oil sensor...
  • Page 79 Chongqing RATO Technology Co., Ltd. Address: Area B, Shuangfu Industrial Park, Jiangjin District, Chongqing Service hotline: 400-681-9981 Fax: 023-85553450 Post code: 402247 Website: www.rato.cc E-mail: ratoservice@rato.cc (service consultation) parts@rato.cc (parts ordering)

This manual is also suitable for:

R80-vR210-vR300-vR420-v

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