Rato R2200 Service Manual Download Page 4

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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 ....................................................................................................................... 11

2-4 Fuel Sediment Cup Cleaning ......................................................................................................... 12

2-5 Spark Plug Service ........................................................................................................................ 13

2-6 Valve Clearance Adjustment ......................................................................................................... 14

2-7 Governor ....................................................................................................................................... 17

3. TROUBLESHOOTING .......................................................................................................................... 20

3-1 Troubleshooting ............................................................................................................................. 20

3-1-1 Starting Difficult ................................................................................................................ 20

3-1-2 Power Lack ........................................................................................................................ 22

3-1-3 Speed Unstable .................................................................................................................. 23

3-1-4 Unable Igniting .................................................................................................................. 23

3-1-5 Gasoline Engine is Overheat .............................................................................................. 24

3-1-6 Abnormal Sound ................................................................................................................ 24

3-1-7 Unable Generating Electricity ............................................................................................ 25

3-1-8 Voltage Too Low ................................................................................................................ 25

3-1-9 No AC Output Voltage ....................................................................................................... 26

3-1-10 No DC Output Voltage ..................................................................................................... 26

3-1-11 Stator Iron Core Overheat ................................................................................................ 26

3-1-12 Stator Winding Overheat .................................................................................................. 27

3-1-13 Rotor Winding Overheat .................................................................................................. 27

3-2 Safety Precautions ......................................................................................................................... 28

3-2-1 Safety ................................................................................................................................. 28

Summary of Contents for R2200

Page 1: ...R2200 R2800 R3000 SERVICE MANUAL CHONGQING RATO POWER CO LTD...

Page 2: ...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...

Page 3: ...l 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 These mean You WILL be KILLED or SERIOUSLY HURT if you...

Page 4: ...Clearance Adjustment 14 2 7 Governor 17 3 TROUBLESHOOTING 20 3 1 Troubleshooting 20 3 1 1 Starting Difficult 20 3 1 2 Power Lack 22 3 1 3 Speed Unstable 23 3 1 4 Unable Igniting 23 3 1 5 Gasoline Engi...

Page 5: ...il 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 58 3 5 1 Fuel Tank 58 3 5 2 Muffler 60 3 5 3 Generators...

Page 6: ...onent Identification 1 FUEL METER FUEL TANK CAP SPARK PLUG CAP MUFFLER ENGINE SWITCH RECOIL STARTER GRIP CHOCKER LEVER AC CIRCUIT BREAKER DC PROTECTOR FUEL VALVE GROUND TERMINAL AC RECEPTACLES AIR CLE...

Page 7: ...6 0 6 Generator Charging Voltage DC V 12 Charging Current DC A 8 3 Rated Frequency Hz 50 Rated Voltage V 220 230 Rated Output Power kW 2 2 5 2 7 Maximum Output Power kW 2 2 2 8 3 Generator Set Length...

Page 8: ...Piston Pin O D Piston Pin to Piston Pin Bore Clearance 67 985mm 0 015 0 05mm 18 002mm 18 0mm 0 002 0 014mm 67 845mm 0 12mm 18 048mm 17 954mm 0 06mm Piston Rings Ring Side Clearance Second Ring Enc Gap...

Page 9: ...72mm 0 1mm 0 12mm 2 0mm 32 5mm Camshaft Cam Height Cam Heignt Journal O D IN EX 27 7mm 27 75mm 13 984mm 27 45mm 27 50mm 13 916mm Crankcase Cover Camshaft Bracket I D 14 0mm 14 048mm Carburetor Main Je...

Page 10: ...Maximum Speed No Load Cylinder Compression 3150 3180rpm 1 17Mpa 1400rpm Cylinder Head Sleeve I D 68 0mm 68 165mm Cylinder Head Warpage 0 10mm Piston Skirt O D Piston to Cylinder Clearance Piston Pin...

Page 11: ...15 0 02mm 0 20 0 02mm 5 48mm 5 44mm 5 50mm 0 02 0 044mm 0 06 0 087mm 0 8mm 34mm 5 318mm 5 275mm 5 572mm 0 1mm 0 12mm 2 0mm 32 5mm Camshaft Cam Height Cam Heignt Journal O D IN EX 27 7mm 27 75mm 13 984...

Page 12: ...on Brush Carbon Brush Length 10mm 6mm Parts Item Standard Service limit Engine Maximum Speed No Load Cylinder Compression 3150 3180rpm 1 17kpa 1400rpm Cylinder head Sleeve I D 69 985mm 70 025mm Cylind...

Page 13: ...kshaft Pin O D 30 190mm 30 175mm Valve Valve Clearance Stem O D Guide I D Stem Clearance Seat Width Spring Free Length IN EX IN EX IN EX IN EX 0 15 0 02mm 0 20 0 02mm 5 48mm 5 44mm 5 50mm 0 02 0 044mm...

Page 14: ...ding 1 4 5 at 20 Stator Auxiliary Winding 3 9 5 at 20 Rotor Excitation Winding Resistance Excitation Winding 59 0 5 at 20 Carbon Brush Carbon Brush Length 10mm 6mm Spark Plug Cap Resistance 5k Ignitio...

Page 15: ...als shown in the Maintenance schedule below REGULAR SERVICE PERIOD Each use First month or 20 Hrs 3 Every 3 months or 50 Hrs 3 Every 6 months or 100 Hrs 3 Every year or 300 Hrs 3 Engine Oil Check leve...

Page 16: ...gine oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation Do not throw it in the dust...

Page 17: ...ne oil in then squeeze out 3 Reinstall the air cleaner element and the cover 2 4 Fuel Sediment Cup Cleaning 1 Turn the fuel valve to the OFF position Remove the sediment cup o ring and strainer 2 Clea...

Page 18: ...essary by carefully bending the side electrode 6 The gap should be 0 70 0 80 mm 7 Check that the spark plug washer is in good condition 8 Install the spark plug on and screw down it with plug wrench c...

Page 19: ...alve is too small the valve will close untight to make the engine operating abnormal and drain valve operating face burn After operating one year or 1000h check and adjust the valve Dismount the cylin...

Page 20: ...3 TROUBLESHOOTING 15 Measure the valve clearance in the cold the engine state SPARK PLUG SPARK PLUG CAP VALVE ADJUSTING NUT VALVE LOCKED NUT...

Page 21: ...valve opening delay will shorten the intake and exhaust time lower the opening height of the valve and change normal distributing phase to result in power lowering from the intake lack and exhaust un...

Page 22: ...ROUBLESHOOTING 17 2 7 Governor Reassembly or disassembly SCREW M5 25 GOVERNOR ROD STOPPER SPRING THROTTLE PLATE Pin BOLT M6 10 RETURN SPRING NUT M6 GOVERNOR BRACKET BOLT M6 10 GOVERNOR SPRING FIXING B...

Page 23: ...n the nut TORQUE VALUE 10N m d Check to see that the governor arm and throttle valve move freely f Check the maximum engine speed Maximum speed adjustment a Start the engine and allow it to warm up to...

Page 24: ...3 TROUBLESHOOTING 19 Engine maximum speed 3150 3180rpm Speed too big Turn the bolt counterclockwise Speed too small Turn the bolt clockwise...

Page 25: ...ugh Float is damaged or sticking Repair float Fuel supply is normal Fuel is too filthy or deteriorated Replace There is water in fuel Replace Too much fuel in engine Drain extra fuel dry up spark plug...

Page 26: ...ighten cylinder head bolts in stipulated order to stipulated torque Air leakage in the valves Check valve Clearance and tightness repair if necessary If still can t starting have the engine to our aut...

Page 27: ...clogged up Clean replace damaged part Too much carbon deposit in combusting chamber Clear away Too much car bon fouling in muffler and exhaust pipe Clear away Poor compression Air cleaner is clogged...

Page 28: ...ce Adjust Something wrong with induced coil and so on Check and replace damaged parts 3 1 4 Unable Igniting TROUBLE CAUSE REMEDY Unable igniting Fuel supply system Fuel is finished Refill fuel Carbure...

Page 29: ...produce speed high Readjust engine governor 3 1 6 Abnormal Sound TROUBLE CAUSE REMEDY Beating sound Piston piston ring or cylinder is worn Replace the worn part Connection rod or piston pin and piston...

Page 30: ...them one by one and insulate them Check main winding and excitation loop for open circuit Check and connect the broken part AVR failure Replace AVR 3 1 8 Voltage Too Low TROUBLE CAUSE REMEDY Voltage...

Page 31: ...wiring Rectification bridge damaged or DC winding open circuit Replace the rectification bridge and stator 3 1 11 Stator Iron Core Overheat CAUSE REMEDY Stator voltage too high operation and iron cor...

Page 32: ...cuit repair or replace the winding 3 1 13 Rotor Winding Overheat The engine operating at lower than rate speed and ventilation condition poor resulting in heat dispersion engine outputting rate voltag...

Page 33: ...r to make the engine cool normally 6 The operator should be familiar with the working principle and structure of the gasoline engine knowing how to make an emergent stop and the operation of all contr...

Page 34: ...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 labe...

Page 35: ...mond lap 450 7 Diamond lap 320 8 Flywheel driver 9 Bearing extractor 10 Valve guide reamer Carburetor float level inspection Valve guide removal installation Assembling ball bearing Installing handle...

Page 36: ...Dismounting Chart AIR CLEANER CARBURETOR RECOIL STARTER SHROUD FLYWHEEL IGNITION COIL MOTOR TAIL COVER CONTROL PANNEL VOLTAGE REGULATOR BRUSH FUEL TANK MUFFLER FLYWHEEL HANDLE STATOR ROTOR CUSHION FR...

Page 37: ...3 TROUBLESHOOTING 32 FLYWEEL NUT M14 STARTING CUP IMPELLER SHROUD BOLT M6 10 RECOIL STARTER GRIP BOLT M6 10 RECOIL STARTER REEL COVER 3 4 Engines 3 4 1 Recoil Starter...

Page 38: ...ing Check the broken and wearing before installing the rope Installation Instruction Pass the recoil starter rope through the rope in the recoil starter pulley and make a figure eight knot at the rope...

Page 39: ...the groove of the recoil starter pulley Set the starter drive cam on the recoil starter pulley and install the return spring on the recoil starter pulley while hooking it on the side of the driving ca...

Page 40: ...oil and flywheel with the feeler c Adjust the clearance of the ignition and flywheel d Adjusting method Loosen the bolt and move the ignition coil up and down for adjusting the clearance then screw do...

Page 41: ...th the spark plug cap removed touching one test lead to the high tension cord while touching the other tester lead to the coil s iron core Secondary side resistance value 5 9 7 1k Measure the resistan...

Page 42: ...3 TROUBLESHOOTING 37 FLYWHEEL Cast iron POSITION HOLE POSITION HOLE IMPELLER POSITION BLOCK POSITION BLOCK STARTER PULLY...

Page 43: ...a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw If you always operate the engine at altitudes higher than sea level 1000 meters over have our authorized dealer perf...

Page 44: ...nd oxide out of the fuel tank If having quality defectiveness partly foreign matters will enter into the carburetor Otherwise the gasoline contains some composition which can form the colloid after lo...

Page 45: ...rface Blow the washed parts clean with compression air and don t use cloth and paper against recontamination Don t use the steel wire and other hard material to open the blocked hole to prevent carbur...

Page 46: ...e installation FLOAT After installing check for operation by lightly pushing with a finger GASKET FLOAT CHAMBER Install so that the drain bolt facing to choke valve DRAIN BOLT Set Bolt Tighten the bol...

Page 47: ...the fuel out before installing carburetor No fire a Check the float valve float seat and float spring for wear b Clean with compressed air before installation c Clean with compressed air before insta...

Page 48: ...the pilot screw back Only repairing the carburetor can disassemble it If the pilot screw is broken replace with new one Disassemble the broken pilot screw from the carburetor Put the spring onto the r...

Page 49: ...cified float height 13 7mm 1 5 If the height is out of specification replace the float valve and recheck the float height Tool Float level gauge g Carburetor idle speed adjusting Start the engine to p...

Page 50: ...Removal Loosen and tighten the bolts in a crisscross pattern in 2 or 3 steps TORQUE 26N m BOLT M6X12 Apply oil to thread Loosen and tighten the bolts in a crisscross pattern especially tightening uni...

Page 51: ...rod ends are firmly seated in the lifters EXHAUST VALVE Installation Before installation remove carbon deposits and inspect the valve INTALE VALVE Installation Don t interchange with the exhaust valve...

Page 52: ...2 Inspect Service Repair Valve stem outside diameter Inspect the valve stem outside diameter with the micrometer if finding out of the standard or service limit or if visually inspecting the burn and...

Page 53: ...he valve guide reamer ream the valve guides to remove any carbon deposits before measuring If the valve guide inside diameter is lower than standard or out of the service limit replace the guide STAND...

Page 54: ...guide with cutting oil b Rotate the reamer clockwise through the valve guide for the full length of the reamer c Continue to rotate the reamer clockwise while removing it from the valve guide Tools V...

Page 55: ...e valve c several times forcefully Be sure the valve does not rotate on the seat The transferred marking compound will show any area of the seat that is not concentric d Using 45 cutter remove enough...

Page 56: ...red face insert the valve and press it forcefully several times be sure the valve does not rotate on the seat The seating surface as shown by the transferred marking compound should have good contact...

Page 57: ...MARK MAKER 120 TOP RING SECOND RING OIL RING b 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 Do no...

Page 58: ...iston 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...

Page 59: ...e of the ring and upper and lower face Standard Service Limit 0 015 0 045mm 0 15mm e Piston ring closed clearance Flatly place the piston into the cylinder with pushing the piston head to working posi...

Page 60: ...Check big end diameter If out of the standard or exceed service limit replace the connecting rod Camshaft check The camshaft is main driving part of the train valve mechanism which control the intake...

Page 61: ...rd Service Limit 13 984mm 13 916mm Camshaft wearing cause and to engine performance influence Poor lubrication will result in camshaft abnormal wearing such as oil viscosity low impurity too much and...

Page 62: ...ed 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 NOTICE...

Page 63: ...NG 58 3 5 Generators 3 5 1 Fuel Tank FUEL TANK RUBBER GASKET BUSH WASHER 6 25 2 NUT M6 25 FUEL TANK RUBBER GASKET OIL TUBE FUEL SWITCH FUEL TANK Wash to remove sediment and dry thoroughly before reins...

Page 64: ...k Clean the fuel tank and dry it completely After Cleaning install the strainer on the fuel tank and connect the fuel tube Check for leaking Install the bolt M6 25 washer 6 25 2 bush fuel tank rubber...

Page 65: ...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 Disassemble the muffler...

Page 66: ...s seriously rusted to make noise increasing NOTICE Don t clean with iron wire or the muffler material out to lower the muffler performance Don t reuse the muffler gasket WARNING The muffler can glow h...

Page 67: ...MOTOR BRACKET CARBON BRUSH BOLT M5 12 torque 5 7N m MOTOR TAIL COVER BOLT M5 12 torque 5 7N m WASHER 23 8 3 BOLT M8 180 Torque 28 30N m Loose and tighten the bolt adopt the method of cross especially...

Page 68: ...2 torque 5 7N m CONNECTION BOARD BOLT M5 16 bolt Model Specification Torque R2800 M6 155 10 12N m R3000 M6 165 10 12N m BOLT M5 12 torque 5 7N m AVR STATOR Model Specification Torque R2800 M8 1 210 28...

Page 69: ...h hammer in order to remove the rotor RATOR Fill the board and cloth under the rotor to prevent it from dropping CLOT H BOAR D COLLECTOR RING Make sure to clean the foreign matters oil butter and othe...

Page 70: ...3 TROUBLESHOOTING 65 2 Motor Wiring Diagram R2200 YELLOW GREEN Grounding wire RED BLUE GRAY BLUE GRAY RED BLUE BLUE GRAY WHITE GRAY...

Page 71: ...or contacting faceless than 75 of the cross section of the carbon brush after the running about 150hrs If contacting face less than grind the carbon brush contacting face Put the No 00 emery cloth bet...

Page 72: ...r other obvious defective 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 R2200 45 6...

Page 73: ...f alternating current output terminal with ohmmeter Model Resistance R2200 2 2 5 at 20 R2800 1 8 5 at 20 R3000 1 4 5 at 20 Engine Insulation Resistance Testing Insulation resistance means resistance b...

Page 74: ...r is connected with iron core Next wave the megohmmeter from slowly to fast and the meter needle follows wave When the meter needle is stable the value indicated by the needle is the winding to ground...

Page 75: ...winding isn t broken if the meter needle is quiet it means the tested winding is broken 3 5 4 Control Panel Remove the wire harness connecting with the motor BOLT M6 12 PANEL SEAT WIRE HARNESS1 WIRE H...

Page 76: ...wn 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 Please pay attention to connect the wire correctly If the conne...

Page 77: ...ue is clock to zero Continuity Open circuit 2 The Black to a The Red to Part 2 Meter needle waves clockwise the resistance value is clock to zero Positive continuity Normal The Black to The Red to a M...

Page 78: ...4 WIRING DIAGRAM 73 4 WIRING DIAGRAM 4 1 Electric Diagram R2200...

Page 79: ...4 WIRING DIAGRAM 74 R2800 R3000...

Page 80: ...2 8 8 A 10 2 8 Muffler block M8 12 8 8 A 20 2 9 Panel Subassembly control M6 12 8 8 B 10 2 10 Panel control M4 10 8 8 A 2 5 0 5 11 Case panel rear M4 8 8 A 2 5 0 5 12 Bracket motor M6 12 8 8 B 10 2 13...

Page 81: ...t 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 6mm Screw 7 11 5mm Flange Bolt 3 6 6 9 6mm Screw 7 11 5mm Flange Bol...

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Rato R2200, Service Manual

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