Rato R2000IS Maintenance Manual Download Page 1

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1.6KVA INVERTER GENERATOR

MAINTENANCE MANUAL

Summary of Contents for R2000IS

Page 1: ...1 6KVA INVERTER GENERATOR MAINTENANCE MANUAL ...

Page 2: ... read this manual anytime This maintenance manual describes the correct maintaining methods Any personal injury or death or equipment damage which because ignorance on these regulations our company would remove the responsibility NOTICE All rights reserved by our company Any reprinting without the written permission of our company is expressly prohibited ...

Page 3: ...afety notice has a symbol Failure to follow this instruction could result in extreme severe injury Failure to follow this instruction might result in severe injury Failure to follow this instruction might result in injury Failure to follow this instruction your generator or other property would be damaged If no torque written please refer to appendix Torque Table ...

Page 4: ...restor 2 5 火花消除器 7 Spark arrestor 2 6 火花塞 8 Valve clearance adjustment 2 7 气门间隙调整 9 FAILURE PREDICTION AND REPAIR 第三部分故障判定和修理Error Bookmark not defined Failure prediction 3 1 故障判定 Error Bookmark not defined Start difficultly 3 1 1 起动困难 Error Bookmark not defined Power insufficient 3 1 2 动力不足 Error Bookmark not defined Speed unstable 3 1 3 速度不稳 Error Bookmark not defined Can t ignite 3 1 4 不能点火 Er...

Page 5: ...agram 3 3 拆卸图表 Error Bookmark not defined Gasoline engine 3 4 汽油机 Error Bookmark not defined Starter recoil fly wheel ignition coil 3 4 1 手起动部件飞轮点火线圈 Error Bookmark not defined Carburetor 3 4 2 化油器 Error Bookmark not defined Stepping motor 3 4 3 调速步进电机 Error Bookmark not defined Cylinder head 3 4 4 气缸头配气机构 Error Bookmark not defined Crankshaft piston 3 4 5 曲轴活塞 Error Bookmark not defined Gener...

Page 6: ...l 3 5 6 控制面板部件 Error Bookmark not defined Appearance diagram 3 5 7 外观总成 Error Bookmark not defined Wire connecting diagram 第四部分线路接线图 Error Bookmark not defined Wire connecting schematic diagram 4 1 接线原理图 Error Bookmark not defined Appendix 附录 Error Bookmark not defined ...

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Page 8: ...ORMATION 第一部分引言 1 1 Main Components 发电机组成部分 Left Cover Handle Fuel cap Control panel Muffler Fuel tank Right cover 燃油观察窗机油尺 Fuel tank Motor assy Recoil starter subassembly Control panel Fuel observing hole Air cleaner Oil level gauge ...

Page 9: ...8 Rated power kVA 1 6 Power Factor 1 Waveform deviation factor 3 Noise 3 4 load 65dB DC output V A 12V 8A Engine Engine model R80 i Engine type OHV Displacement cc 79 7 Fuel type Gasoline Engine Fuel tank capacity L 4L Rated load continuum running time h 4 Engine oil capacity mL 380ml Spark plug model TORCH A5RTC Starting system Recoil starter Diameter L W H mm 498 290 459 Net weight kg 22 ...

Page 10: ... 0 015 0 05 0 15 0 30 0 12 0 6 Connecting rod Inner diameter of smaller end Inner diameter of bigger end Oil clearance of bigger end Big end side gap 11 006 11 017 22 22 013 0 02 0 043 0 45 0 95 11 050 22 040 0 1 1 15 Crankshaft Crank outer diameter 21 97 21 98 21 94 Valve Valve clearance Intake Exhaust Outer diameter of valve stem Inner diameter of intake valve guide Outer diameter of exhaust val...

Page 11: ...Each time 20h or the first month of begin to use 3 50h or every 3 months 3 100h or every 6 months 3 300h or every year 3 Engine oil Check oil level Replace Air cleaner Check Clear 1 Fuel cup Clear Spark plug Clear Replace Valve clearance Re adjust 2 Cylinder head cover Clear Every 300h 2 Fuel tank and strainer Clear Every two years 2 Fuel hose Replace Every two years 2 1 Please increase the mainte...

Page 12: ...l 1 Take the oil dipstick and clean the oil 2 Put dipstick in crankcase but tighten it and check the oil level 3 If the oil level is low please add recommended oil until the upper level If skin contacts to engine oil too frequently this might result in skin cancer Please clean the oil on your skin clearly with soap and water immediately For environmental protection please dispose the oil properly ...

Page 13: ... could result in fire or explosion Please clean the element with soap water of uninflammable solvent Start the generator without air cleaner assembly is prohibited which will increase engine abrasion 1 Loosen bolts as marked remove cover take the screw remove air cleaner cover 2 Check air cleaner element make sure it is complete and clean 3 If the element is dirty please clean foam element with de...

Page 14: ...ck open fuel switch check if any fuel leakage on fuel strainer 7 Assemble cover back Spark arrestor 2 5 火花消除器 Gasoline is flammable and explosive Smoking open fire and spark are prohibited in working area After generator is reassembly please check if any fuel leakage before starting the generator and make sure work area is dry Hyperthermal muffler could result in serious scale Please maintain muff...

Page 15: ...replace it If spark plug could be used then clean the carbon deposition on it with wire brush 4 Adjusting the gap of spark plug you can bend the electrode slightly to keep the gap between 0 60 0 80 mm 5 Check the spark plug retainer When assemble spark plug turn it in screw with hand to avoid improper assembly 6 After put spark plug on retainer press it tightly with spark plug wrench The torque of...

Page 16: ...it would make the valve can t be sealed totally which might result in abnormal performance or burning the working surface of relevant parts of valve Generally after 100h or 1 year using you have to check the valve clearance and adjust it Disassemble these parts in turn spark plug cap spark plug cylinder head cover and gasket Pull the starter coil to make the piston on the top dead center Measure t...

Page 17: ...ce Both valves open behind which will decrease the time of air intake and exhaust lower the opening height of valves make engine has insufficient air intake and can t exhaust clearly and result in power decrease Besides it will increase the hit between relevant parts of valve and increase parts abrasion Insufficient valve clearance In engine working heat will expand parts which push valves away an...

Page 18: ...damaged Repair the float oil blow fluently Fuel is dirty or deterioration replace oil oil mixed with water replace oil Too much fuel in the cylinder Discharge of oil and dry the spark plug electrodes The fuel marking No is wrong use the correct label Fuel suppl y is norm al High voltage wire spark is normal The spark plug bad Electrode dirty carbon deposition Clearing away the dirt and carbon depo...

Page 19: ... as per the torque required and in a certain sequence Air leakage of the valve Check the valve clearance and the valve airtightness and repair it when necessary l If the generator still cannot be started please send it to our authorized distributor for maintenance and repair Spark plug inspection warning l Ensure that there is no overflowing fuel oil outside the generator and the sparkplug is not ...

Page 20: ...ing blowing open The switch of oil tank is blocked Clean and replace the bad parts There is carbon deposit in the combustion chamber Clear away the carbon deposit The air filter is blocked Clean the filter element r Improper compression The piston cylinder and the piston ring are worn Replace the wearing parts There is air leakage in the junction surface of the cylinder body and the cylinder cover...

Page 21: ...qualified gasoline Failure of ignition of the generator There is water in the float chamber Clean the float chamber The electrode clearance of the spark plug is not correct Adjust the electrode clearance Fault of the ignition coil Check and replace the damaged parts 3 1 4 Failure of ignition Phenomenon Causes Methods of elimination Failure of ignition Fuel supply series The fuel oil is used up Add...

Page 22: ...n cover Repairing the damaged place Blocking due to the sundries in the cooling fans Clearing the cooling fans The deformation of the connecting rod will cause wearing of the piston and the cylinder hole Replacing the connecting rod The cylinder piston and piston ring are worn Replacing the wearing parts Improper adjustment of the speed controller of the generator which will cause that the rotatio...

Page 23: ...nd to company repair station The circuit connection errors or fall off To pick up the Lines Rectifier is damaged and DC winding open circuit replace the rectifier components stators 3 1 8 Generator stator winding overheating Over load Operators must be stipulated in the generator to adjust load to avoid overload Generator air duct was blocked core box of dust covered the surface of the coil is not...

Page 24: ...rator output 5 Green light off the red light flash three times after the interval 3S repeat represents inverter temperature is too high no generator output 6 Green light off the red light flash five times after the interval 3S repeat represents the front end of generatrix voltage is too high no generator output 7 Green light off the red light flash six times after the interval 3S repeat represents...

Page 25: ... of generator 6 Operators should be familiar with the working principles and structure of the generator and know how to operate emergency stop buttons and all the control parts Be sure to conduct regular maintenance and timely eliminate the faults found it s prohibited continuing to run the generator after faults happen to it 7 Please be sure to keep the generator at least one meter from buildings...

Page 26: ...l not be liable for the personal injuries or equipment damages caused by ignoring the warning label 3 2 2 Special Tools Tool Name Purpose and Remarks 1 Motor stop lock tooling 2 Motor Puller 3 The valve adjusting tooling when motor tighten add torsion The removal of the motor adjust the valve clearance ...

Page 27: ...e Muffler side cover 3 in 1 knob Motor rotor stator Motor wind scooper Muffler Recoil starter Wind scooper Trigger Fly wheel Carburetor Air filter assembly Power motor assembly Baseplate Lift right shell Fuel tank Inverter Panel Panel bed Muffler wind scooper ...

Page 28: ... To adjust the flywheel clearance before fastening Recoil starter Ventilatio n hood Recoil starter parts flywheel Disassembly Should use a special tool 3 2 2 to remove nut Assembly Torque 45 4N m Oil seal Disassembly check whether the flange clearance is too large or other problems Please update with new one if it happens 3 4 Engine 3 4 1Recoil Starter flywheel Ignition Coil Recoi Magnetic coil Ig...

Page 29: ...be coated with grease Driven CAM Check if there is any damage pay attention to the installation direction To reset spring to pull the tray then pull on the rope to pull on the rope on the dish cover plate installation Rope disc Starting the reset spring Be careful when disassemble and do not make the return spring pop up In addition should be put on the gloves Should be put the outside hook in the...

Page 30: ...rd claws b Knotting on the end of the rope and then the other end of the rope pull hole some wear out And then pull on the rope plate coil five laps in counterclockwise direction Let the start rope through the starter cap hole in the department to make a pull rope 8 Knot c Install the driven CAM Torsional driven plate and middle bolt d Pull the starter rope several times check if the driven CAM re...

Page 31: ...condary side of the coil resistance value 3kΩ Charge Coil Put the tester follow the picture with charge coil to test the charge coil resistance value Charge coil resistance value 350Ω 3 4 2 Carburetor Disassemble the Carburetor Letin Gasket Heat pad gasket carburetor gasket choke stents Motor support Bolt M5 12 2 torque 1 5 2 5N m Cable line plate Speed governing Bolt M3 5 2 Torque 1 1 5 N m Motor...

Page 32: ...pay attention to clean the gasoline gum on the surface of the parts The parts need with compressed air blowing off cloth or paper will not be used to wipe in case of pollution again Blocked poke holes should not use steel wire and other hard objects it will protect carburetor performance by changing the aperture changes and it can used or compressed air to clean out of gasoline 1 The Carburetor St...

Page 33: ...ressed air to clean before installation d Use compressed air to clean and Lubricate o ring before installation 3 4 3 Speed control stepping motor Check the motor socket within 2 resistance on the diagonal resistance value 50Ω 7 Ω If it beyond the value pls change a new motor When the electric motor rotating parts center axis it should not be a hairpin loose phenomenon If it is please change a new ...

Page 34: ...nt Gasket crankcase Cylinder head bolt M6 50 4 Unscrew and tighten bolts should be according to the cross Torque value 12 14 N m double end bolt in take double end bolt out take Bolt M6 14 4 Unscrew and tighten bolts should be according to the cross Torque value 11 13N m Cylinder head cover gasket Cylinder head cover pipe one side on the cylinder epicranium on other side pick up in the tank cover ...

Page 35: ...t mixed the valve Outtake valve Should be confirm the valve is no damage before installation Spark plug Clean the spark plug before installation Torque value 25 28 N m Oil drip pan Spring Rocker shaft Valve rocker Check if there is any damagement before installation esprcially the hole and tappet assembly Valve adjusting bolt Check if there is any damagement before installation Locked nut Spring s...

Page 36: ...n or crack With above situations you d better to change with the new one Standard Maintenance Limit 3 97 3 985 mm intake 3 935 3 95 mm outtake 3 900 mm intake 3 88 mm outtake Valve spring length Measure the valve spring length If lower than the standard or out of maintenance period please use new one Valve guide pipe Check a check whether the valve guide pipe surface smooth or not and without scra...

Page 37: ...ock the exhaust duct until the retaining ring in contact with the cylinder cover completely Intake valve side Tapping into the valve guide until the prescribed height measured from the top of the valve guide to the cylinder head surface d After installation please check whether there is any damage on valve guide pipe if there are any damages please use new one Reamer It is better to hinge the ream...

Page 38: ...limit you should decide to replace a new catheter to clearance within the limit of maintenance if so replace the valve guide and stick ground valve guide When replace the valve guide you need rebuild the valve seat Valve seat a Completely clear the carbon deposition which on the combustion chamber and the valve seat then smearing a thin layer of red lead powder or other different wipe easily adhes...

Page 39: ...valve at the bottom of the edge contact too low Standard Maintenance limit 0 6 0 8mm 2mm e Using the 45 slight grinding mill to remove any burr on the edge of the valve seat f After rebuilt the valve seat should be check the width of the valve seat In the valve cone colorants only insert valve and pushing valve a few times but not sure that the valve on the valve seat Valve seat s cone stained uni...

Page 40: ...rasives use valve grinding tool rotation to the valve seat to get up to speed h Check valve clearance after installation 3 4 5 Crankshaft Piston Installation a Piston Use supplier mark up during installation Be careful not to put first ring confused with second ring a ring with chrome plating After installation to confirm piston ring Make each piston ring opening to avoid the direction of the pist...

Page 41: ...ton and cylinder top ring groove defect ablation and crack etc If the damage is serious you should use the new one Remove the carbon deposit The carbon deposit located on the top of the piston and cylinder flowing edge part You should be cleared away before testing carbon deposit Firstly use kerosene wet saturated carbon deposit and then be removed using a blunt knife or metal brush a Piston skirt...

Page 42: ...on skirt diameter Be tested the gap before and after repairing When you checking the inverted piston should be in the cylinder put the appropriate thickness gauge on the pressure surface between the cylinder wall and piston skirt and then take out feeler gauge if you feel some certain resistance but you also can smooth out that is clearance between the piston and cylinder Standard Using limit 0 01...

Page 43: ...ring opening gap is small usable fine flat file filing The file should be put inside the cylinder to check until clearance is fitting Detect the connecting rod If the connecting rod bending distortion or cracking etc you should the replacement of new parts a Detection of small diameter If lower than the standard limit or out of using limit Replace with new one Standard Using limit 11 006 11 017mm ...

Page 44: ...n the maintenance period you should replace the camshaft Standard Maintenance limit Camshaft height intake 20 54mm 20 24mm Camshaft height outtake 20 54mm 20 24mm Check the camshaft neck diameter if it is less than the standard you should replace camshaft Standard Maintenance limit 11 965 11 99mm Using with the standard Wear reasons and affect for the engine performance Camshaft is wearing and tea...

Page 45: ...wear tooth surface spalling or coarse the deflection of gear gear tooth broken etc Due to the tooth wear the bigger the meshing clearance the greater the noise If the timing gear surface touch lack of Angle injury or damage it should replace new one It is best to replace the entire new parts in order to match the meshing Location mark Camshaft gear crankshaft gear Note ...

Page 46: ...er installation Oil tube To ensure the vent is clean and not blocked If necessary use compressed air to clean up Check whether there is any blockage or damage on mesh first and then to install fuel tank strainer Firstly to remove the dirt at the bottom and dry thoroughly and then to install CAP Fuel tank Oil meter ...

Page 47: ...he fuel filter is blocked or damaged Weather the fuel hose is presence of aging and rupture If have any problems you should replace a new one before installation 3 5 2 Muffler Muffler Spark eliminator clean the carbon deposition before installation Cover Gasket for outlet NUT M6 2 Torque value 8 12 N m Note ...

Page 48: ...tap and use compressed air to remove If the muffler reservoir drops corrosion severely so that the exhaust noise increases should be replaced with new parts Do not clean with iron wire otherwise it may result in sound deadening material to fall out thereby reducing the noise reduction performance Muffler gasket cannot be reused Muffler may very hot keep the gasoline engine out of reach of passer a...

Page 49: ...sure no cracking rubber hardened or wear Bolt M6 20 4 bushing Chassis suspension seat Nut M5 4 Nut M6 6 Nut M6 8 Torque value 8 12 N m Cushion rubber Rack bottom plate combination cushion rubber Installed under the electric motor to ensure that no rubber cracking hardening or wear Installed under the electric motor to ensure that no rubber cracking hardening or wear ...

Page 50: ...5 7N m Rotor Clean dust or oil on the tapered portion of the crankcase and the rotor and then install Put the main output winding wire in the bottom of the engine and then put the engine in the engine damping seat on the baseboard Nut M12 1 25 Torque value 26 30 N m Plug ...

Page 51: ...ue 28 30 N m Make the motor stator wires through the supporting hole positioning the setting holes on the motor support Bolt M5 30 2 Torque 6 8 N m Utilize the disassembly thread on the rotor install the appropriate rotor puller special tools to disassemble Bolt M6 12 2 Torque 8 12 N m ...

Page 52: ...ace the outlet No alternating current output check the AC outlet whether damage If damaged replace the outlet Check whether the voltage between the electric motor stator and power windings If there is voltage replace the inverter If there is no voltage replace the stator Note To be careful when removing and installing the stator to avoid damage winding wire and wire insulation ...

Page 53: ...nal of insulated wire winding connect to one terminal of test megger through insulation wire And the other terminal connected to the core Then handing megger from slow to fast Hands along with yaw when the hands steady which is the value indicated is the winding insulation resistance Generator windings circuit detection Using a multimeter electrical barrier test Using multimeter red black pen were...

Page 54: ...APPENDIX 47 3 5 5 Inverter unit 1 Removing and installing Support Inverter Shock Pads fuel tank Rectifi er Inverter Bolt M6 12 6 Bottom Plate Refer P43 ...

Page 55: ...g test megger Low voltage detect low voltage socket if the voltage is zero or below 5V check the engine speed is normal or motor winding output voltage is too low Input is shorted circuit three phase Red light green light off and no output Using test megger High voltage detect high voltage socket if the voltage is zero or less than 150V check the engine speed is normal or motor winding output volt...

Page 56: ...switch When the spring plate in a compressed state with an ohmmeter measure resistance between two output terminals If infinite resistance replace the micro switch Rectifier Rectifier bridge internal circuit as picture shown above Multimeter to check each terminal of the rectifier bridge on off It s When the rectifier bridge instructions show on off its instructions below normal ...

Page 57: ...mponts 1 Remove and Equipped Multimeter Red Pin Test Blue Blue Red Blackk Black Pin Tes t Blue Off Off On Blue Off On On Red On On On Black Off Off Off Mounts Control Switch Fuel Wire Control Panel Energy sa ving AC Socket DC Socket Terminal Gro und Checking the leakage after equipped Self tapping screwsX4 If not necessary please don t remove Indicat or From Left to Right Oil Alert Over load Alert...

Page 58: ... oil switch is turned on the choke is fully open state the engine can be run properly When the combination switch in the CHOKE the ignition circuit is in working condition that two output terminals micro switch off oil switch is turned on the choke in the closed state When the switch is in the respective positions The continuity between the switch terminals to be checked WIRE Removing the wire har...

Page 59: ...ted AC indicator green goes off and the fault indicator red lights up but the engine will not stop running operation When the fault indicator lights up and the unit when there is no output please take the following countermeasures 1 Turn off electrical equipment connected stop the engine 2 Turn off all the connected electrical equipment total power to the range of the rated output 3 Check whether ...

Page 60: ... circuit breaker with a multimeter The conduction should be on when the button of Circuit breaker is pressed 3 5 7 Exterior Assembly Decorative plates RH Decorative plates R Support Fr am RH Rubber Fue l inject Support Frame LF cover decor ative panel LH Hexagon flange stairs Screw torque 6 8 N M Cross Screw 9 ...

Page 61: ...Fourth Parts W 54 ART Wiring diagram agram ...

Page 62: ...l Panel Assy ST4 2 16 4 8 A 3 1 9 Support Control Panel M6 12 8 8 A 9 1 10 M5 16 4 8 A 4 1 11 Cover Decorative Plate RH LH M5 12 4 8 A 3 1 12 Support Fuel Switch ST4 2 16 4 8 A 4 1 13 Rotater M4 16 4 8 A 3 1 14 Cover LH RH Rubber Fuel injection ST4 2 16 4 8 A 3 1 15 Cover LH RH Handle bar M5 16 4 8 A 3 1 16 Impeller M6 10 8 8 A 9 1 17 Magnetic rotor housing combinations M12 1 25 8 A 28 2 18 Rectif...

Page 63: ...que N m SCREW BOLT 5mm SCREW BOLT 4 5 6 6mm SCREW BOLT 8 12 8mm SCREW BOLT 18 25 10mm SCREW BOLT 29 34 12mm SCREW BOLT 49 59 4mm SCREW 1 5 2 6 5mm SCREW 3 5 5 6mm SCREW 7 11 5mm Flange bolts 3 6 6 9 6mm SCREW 7 11 5mm Flange bolts 3 6 6 9 6mm Flange bolts 10 14 8mm Flange bolts 20 26 10mm Flange bolts 35 45 ...

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Rato R2000IS, Maintenance Manual

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