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Rato R80, Maintenance Manual, Page: 4 / 79

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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 ....................................................................................... 18

 

Part III Maintenance ............................................................................................................... 19

 

3-1 Maintenance list ......................................................................................................... 19

 

3-2 Oil .............................................................................................................................. 20

 

3-3 Air filter ..................................................................................................................... 21

 

3-4 Cleaning of fuel filter ................................................................................................ 22

 

3-6 Adjustment of valve clearance ................................................................................... 22

 

3-7 Governor .................................................................................................................... 24

 

Part IV Disassembly and Maintenance ................................................................................... 25

 

4-1 Fault judgement ......................................................................................................... 25

 

4-2 Pre-maintenance Preparations ................................................................................... 31

 

4-3 Disassembly chart ...................................................................................................... 36

 

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)

.......................................................................................................................................... 37

 

4-5 Electrical schematic diagram (electric starting type) ................................................ 73

 

 

Summary of Contents for R80

Page 1: ...R80 R420 Type V Horizontal Axis Maintenance Manual Chongqing RATO Technology Co Ltd...

Page 2: ...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 the...

Page 3: ...Manual and on the decals of the gasoline engines There is the symbol in front of each safety warning Details are as follows Failure to follow instructions will lead to extremely serious injuries Failu...

Page 4: ...Maintenance list 19 3 2 Oil 20 3 3 Air filter 21 3 4 Cleaning of fuel filter 22 3 6 Adjustment of valve clearance 22 3 7 Governor 24 Part IV Disassembly and Maintenance 25 4 1 Fault judgement 25 4 2 P...

Page 5: ...art I Introduction 1 1 Components of general purpose gasoline engine Starter handle Fuel drain bolt Oil level gauge Fuel tank cover Fuel tank Air filter Governing handle Hand operated starter Choke ha...

Page 6: ...ed air cooling Ignition system Breakerless transistorized coil ignition TCI Spark plug E4TC Lubrication system Splash type Power take off shaft direction Counterclockwise Model Parameters R210 V R300...

Page 7: ...erhead valve single cylinder Displacement 420cm3 Compression ratio 8 5 1 Cylinder diameter x stroke 90 66mm Maximum output power 9 5kw 3600rpm Maximum torque 28N m 2500rpm Cooling system Forced air co...

Page 8: ...il ring Piston ring closing clearance top ring ring 2 Oil ring Piston ring width top ring ring 2 oil ring 0 03 0 07 mm 0 15 0 3mm 0 1 0 6mm 1 5mm 2 5mm 0 15 1 1 1 37 2 37 Connecting rod Inner diameter...

Page 9: ...f camshaft bore 13 0 13 018mm 13 048 1 3 2 R210 V Part Item Standard Service limit Gasoline engine Maximum no load speed Cylinder pressure 3750 3810rpm 1 17Mpa 1400rpm Cylinder Cylinder bore diameter...

Page 10: ...f big end Big end oil film clearance Small end side clearance 18 011mm 30 02mm 0 040 0 063mm 0 1 0 7mm 18 07mm 30 066mm 0 12mm 1 1mm Crankshaft Outer diameter of main journal 29 98mm 29 92mm Valve Val...

Page 11: ...sistance 7 5 12 5k Ignition coil Resistance Ignition coil clearance Primary side Secondary side 0 8 1 0 5 9 7 1k 0 4 0 6mm 1 3 3 R300 V Part Item Standard Service limit Gasoline engine Maximum no load...

Page 12: ...ll end oil film clearance Big end side clearance 15 011 15 022mm 33 025 33 039mm 0 013 0 03mm 0 25 0 65mm 15 27mm 33 07mm 0 12mm 1 0mm Crankshaft Outer diameter of main journal 32 975 32 985mm 32 92mm...

Page 13: ...ide 0 6 0 9 5 6 6 9k 0 3 0 5mm 1 3 4 R420 V Part Item Standard Service limit Gasoline engine Maximum no load speed Cylinder pressure 3750 3850rpm 1 2 Mpa 1400 rpm Cylinder Cylinder bore diameter 90 90...

Page 14: ...1 0mm Crankshaft Outer diameter of main journal 35 975 35 985 mm 35 92mm Valve Valve clearance Outer diameter of valve stem Conduit inner diameter Lifter clearance Valve seat contact width Free length...

Page 15: ...nozzle Float height Turning circle of adjusting screw of mixing ratio 2 1 3 Spark plug Clearance 0 7 0 8mm Spark plug cap Resistance 9 5 10 5k Ignition coil Resistance Ignition coil clearance Primary...

Page 16: ...Part II Dimension and Torque 12 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 13 2 1 2 R300 V...

Page 18: ...Part II Dimension and Torque 14 2 1 3 R420 V...

Page 19: ...Part II Dimension and Torque 15...

Page 20: ...00 R420 V Hexagon flange bolt M6 25 10 9 A M7 32 10 9 A M8 35 10 9 A 12 1 13 1 15 1 Connecting rod cover crankshaft components connecting rod 4 Crankcase cover R80 V R210 V R300 R420 V Hexagon flange...

Page 21: ...r of cylinder block R80 V R210 V R300 R420 V Hexagon flange bolt M6 10 8 8 A M6 8 8 8 A M6 12 8 8 A 10 2 Air director of cylinder block cylinder head assembly 12 Lower cover R80 V R210 V R300 R420 V H...

Page 22: ...V Hexagon flange bolt M6 28 8 8 A M6 32 8 8 A 10 2 Charging coil assembly crankcase 20 Pressing plate of charging coil R80 V R210 V R300 R420 V Hexagon flange bolt M6 10 8 8 A M6 10 8 8 A 10 2 Pressin...

Page 23: ...sure that the generator works in good condition The maintenance schedule is as follows Inspection time Inspection item Operation inspection First 20 hours Operating for every 50 hours Operating for ev...

Page 24: ...e 0 6L Oil capacity of R300 R420 gasoline engine 1 1L Recommended gasoline engine oil General purpose oil SAE15W 40 SJ or SAE10W 30 gasoline engine oil equivalent to API SJ At low temperatures below 1...

Page 25: ...lace it if it is too dirty If there is too much oil in the polyurethane filter element the filter holes will be blocked Oil bath type 1 Clean the oil pan with cleaning oil and dry it 2 Fill the clean...

Page 26: ...e clearance between the central electrode and the side electrode Bend the side electrode to adjust the clearance in case of an unsatisfactory clearance Clearance of spark plug 0 7 0 8 mm Standard spar...

Page 27: ...djustment in the following order a Fix the valve rocker arm shaft with the wrench and loosen the lock nut b Loosen the valve rocker arm shaft and adjust the valve clearance to the specified one c Fix...

Page 28: ...t 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 4 Check whether the governing bracket and the th...

Page 29: ...or deteriorated Replace fuel There is water in fuel Replace fuel There is excessive fuel in the cylinder Drain the fuel and wipe and dry spark plug electrode Fuel label is incorrect Use the fuel accor...

Page 30: ...t face of cylinder pad and cylinder body and cylinder cover And tighten cylinder cover bolts according to specified torque and sequence Valve leakage Check valve clearance and valve tightness repair w...

Page 31: ...e valve hole and main hole are blocked in the carburetor Clean and blow through Fuel tank switch is clogged Clean and replace damaged part Carbon deposit in the muffler and exhaust pipe Clear carbon d...

Page 32: ...water in float chamber Clean the float chamber Electrode clearance of spark plug is improper Adjust electrode clearance Ignition coil failure etc Check and replace damaged parts 4 1 4 Starter motor s...

Page 33: ...oken through with carbon deposit and short circuit Replace the spark plug The side electrode of the spark plug fell off Replace the spark plug and remove fallen object Falling off of HV wire Re weldin...

Page 34: ...Exhaust port is blocked Clean exhaust port Leakage of air director Repair damaged place Sundries blockage in the middle of cooling fins Clean cooling fins Deformation of connecting rod causes the wear...

Page 35: ...regularly and tighten them in time 4 Clean the air filter element regularly and replace it if necessary 5 This engine is air cooled gasoline engine so the debris and dirt on cooling fins air director...

Page 36: ...r poorly ventilated place 11 When the gasoline engine is running and within a period of time after it is shut down it is strictly forbidden to touch the muffler to avoid scalding In order to avoid get...

Page 37: ...s 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...

Page 38: ...Part IV Disassembly and Maintenance 34 8 Oil listing label 9 Oil filling label...

Page 39: ...Part IV Disassembly and Maintenance 35...

Page 40: ...n the assembler and installation of the bearing 5 Inner seat ring assembler Assembly of the ball bearing and the timing gear 6 Diamond grinder 45 Correction of intake and exhaust valve seat surface 7...

Page 41: ...oil level switch Gray wire wire connected to the charging coil Fan guard only for automatic starter specification Disassembly and assembly Can be installed and disassembled when the impact starter is...

Page 42: ...the drawstring through the starter drawstring coil and make a 8 knot at the drawstring end Hook the inner side of the starter coil spring in the groove of the drawstring coil cover and rotate the coi...

Page 43: ...the return spring in the hole on the starter drawstring coil and hook its other end on the driving cam Install the spring the drive guide plate and the guide plate fastening screw in sequence Pull th...

Page 44: ...c Adjustment clearance between ignition coil and flywheel d Adjustment steps loosen the bolts adjust clearance by moving the ignition coil up and down and tighten the bolts Flywheel nut Starter cup Im...

Page 45: ...1 0 1 5 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 o...

Page 46: ...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 Locating hole Loc...

Page 47: ...only for silent type Elbow washer Air filter elbow Disassembly and assembly During installation and disassembly make the choke lever in the operating position and the fuel valve in the closed position...

Page 48: ...g 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 Air filter elbow Disassembly and assembly During installation and...

Page 49: ...head Carry out installation in the reverse order Assembly After removing the fuel hose from the carburetor insert it into the boss of the choke lever to prevent fuel leakage Assembly Use the compresse...

Page 50: ...rain bolt Mounting bolt Make sure that there is no fuel leakage after installation Assembly Use the compressed air to remove dirt in the passage before installation Assembly Check the wear of the fron...

Page 51: ...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 Specified float height See Tab 1 3 Rep...

Page 52: ...nstallation Stud M8 34 Stud M6 96 Pin Cylinder head gasket Exhaust pipe Cylinder head bolt Installation removal Tighten the bolts crosswise for 2 3 times Bolt M6X12 Oil should be applied to the thread...

Page 53: ...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 i...

Page 54: ...d excessive carbon deposits Intake valve Installation Do not confuse air valves Intake valve head diameter 25 mm Exhaust valve head diameter 24 mm Be careful not to damage the valve stem when assembli...

Page 55: ...stment Outside diameter of valve lifter Use a micrometer to check the outside diameter of valve lifter If the diameter is lower than standard or exceeds the maintenance limit or the valve surface has...

Page 56: ...on deposit inside valve guide pipe by valve guide reamer If the inner diameter of the valve guide pipe is below the standard or exceeds the maintenance limit the guide pipe should be replaced Standard...

Page 57: ...alve side knock the exhaust valve guide until the retainer ring fully contacts the cylinder cover as shown in the figure Intake valve side knock the intake valve guide to the specified height measured...

Page 58: ...fully screwed into the air valve guide pipe Continue to rotate clockwise to pull out the valve reamer from the valve guide Tool valve guide reamer b Thoroughly remove dirt and debris from cylinder cov...

Page 59: ...valve guide and stick valve guide Re trim valve seat when replacing the valve guide pipe Valve seat a Thoroughly remove carbon deposit out of combustion chamber and valve seat and apply a thin layer...

Page 60: ...inder d Use 32 and 45 grinders to reduce and adjust the valve seat to make it be in contact with middle part of valve cone face Grind top edge of valve seat by 32 grinder contacting too high Grind bot...

Page 61: ...lve 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 If the valve seat cone face is evenly stained with colorant as...

Page 62: ...ing the governing arm Oil seal Do not reuse it Add grease to the lip Washer Installed on the inside of the base Balance shaft Bearing 6207 Oil seal Piston Piston pin Snap ring of piston pin Oil sensor...

Page 63: ...the crankcase cover Pin Oil plug Pin use it for fixing after installing the governing arm Governing gear gasket Oil seal Connecting rod Piston pin Snap ring of piston pin Piston Crankcase Camshaft Oil...

Page 64: ...of various piston rings keep away from the direction of piston pin and scatter by 120 b Snap ring of piston pin Jack the front end at the piston groove to clamp the other end with a nose plier and mo...

Page 65: ...ken it shall be replaced Remove carbon deposits Carbon deposit is accumulated on the top of piston and the edge of upper port of the cylinder Carbon deposits shall be cleared up before the inspection...

Page 66: ...d on measured result Standard Service limit See Tab 1 3 See Tab 1 3 c Piston cylinder clearance The difference between the maximum diameter of the cylinder and the diameter of the piston skirt is the...

Page 67: ...ervice limit See Tab 1 3 See Tab 1 3 e Piston ring closing clearance Put piston ring horizontally into the cylinder push the ring to working position with piston head and then measure its opening clea...

Page 68: ...is severely grooved or there is a crack on one side it shall be scrapped and replaced with new one a Inspection of inner diameter of small end If it is below the criterion or exceeds the maintenance l...

Page 69: ...de the crankshaft pin install the connecting rod and tighten the bolt to the specified torque Torque see Tab 1 2 Place the plastic feeler gauge radially Remove the connecting rod cap and measure with...

Page 70: ...he cam is working it bears the periodic impact load and the cam working surface and the lifter have intense friction which is easy to wear or scratch Therefore the cam is required to have wear resista...

Page 71: ...ubrication Factors such as low oil viscosity many impurities and small circulating oil volume is unable to form complete oil film on the camshaft surface to cause it to be in a state of high speed dry...

Page 72: ...ooth breakage etc Due to the wear of gear teeth the greater the meshing clearance is the greater the noise will be If gear face of timing tooth is bruised or damaged or rupture angle it shall be repla...

Page 73: ...embly Before installation check whether it is about to burn out Oil alarm device Assembly Carry out installation by aligning the hole of the control panel Control panel Reset switch 1A Assembly Be car...

Page 74: ...the fan guard Position of the gasoline engine switch Conductivity ON Not conductive OFF Conductive Gasoline engine switch with oil alarm device Check the conduction performance between the black wire...

Page 75: ...ic starter When the switch is in each position check the conduction performance between the wires Wire color Switch position Black red Grounding Black white White OFF ON START Inspection shall be carr...

Page 76: ...red of the battery Yellow of the battery Never use batteries above 6V Otherwise the bulb will be blown Silicon rectifier Check the conductivity between the two terminals It is normal in case of being...

Page 77: ...hematic diagram electric starting type Black Grey Yellow White Red Green Combination switch Control box Rectifiers Fuse Oil sensor Spark plug Charging coil Ignition coil Starter electromagnetic coil S...

Page 78: ......

Page 79: ...td 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 consultatio...

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