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Part IV Disassembly and Maintenance 

25 

Part IV Disassembly and Maintenance 

4-1 Fault judgement 

4-1-1 Start difficulty 

Phenomenon 

Cause 

Remedy 

Normal 

cylinder 

compression 

Normal 

spark 

of the 

spark 

plug 

Abnormal 

fuel 

system 

Impeded fuel 

flow or 

no fuel flow 

No fuel in fuel tank 

Refuel 

Clogged venthole of 
fuel tank cap 

Dredge 

Main measuring hole is 
improperly adjusted or 
blocked 

Re-adjust or clean, blow 
through 

Float needle valve hole 
is blocked 

Remove needle valve for 
repairing, cleaning and 
blowing through 

The float is stuck or 
damaged 

Repair the float 

Unobstructed 

fuel flow 

Fuel is too dirty 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 according to 
specified label 

Normal 

fuel 

supply 

system 

Spark of 
HV wire 

is normal 

Spark plug 

is poor 

Electrode is dirty with 
carbon deposit 

Remove the dirt and carbon 
deposit 

Insulator is damaged. 
Electrode is severely 
ablated. 

Replace the spark plug 

Electrode clearance is 
incorrect 

Adjust electrode clearance 

HV wire 

has no 

spark 

Spark plug 

is normal 

HV wire is damaged 

Replace the HV wire 

Ignition coil is damaged  Replace the ignition coil 

Magnet is demagnetized  Replace the flywheel 

The clearance between 
ignition coil and 
flywheel is abnormal 

Adjust the clearance between 
ignition coil and flywheel 

 

 

 

 

Содержание R80

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 17: ...Part II Dimension and Torque 13 2 1 2 R300 V...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 78: ......

Страница 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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