Rato R5500, Service Manual

Page 1: ...R5500 R5500D SERVICE MANUAL CHONGQING RATO POWER CO LTD...

Page 2: ...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 ass...

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: ...Component Identification FUEL METER FUEL TANK CAP SPARK PLUG CAP MUFFLER RECOIL STARTER GRIP CHOCKER LEVER AC CIRCUIT BREAKER DC PROTECTOR FUEL VALVE GROUND TERMINAL AC RECEPTACLES AIR CLEANER GENERA...

Page 5: ...inuing Time hr Oil Capacity L 1 1 Generato r Charging Voltage DC V 12 Charging Current DC A 8 3 Rated Frequency Hz 50 Rated Voltage V 220 230 Rated Output Power kW 5 Maximum Output Power kW 5 5 Batter...

Page 6: ...5mm 0 12mm 20 042mm 19 95mm 0 08mm Piston Rings Ring Side Clearance Second Ring Enc Gap Second Ring Width Second 0 030 0 060mm 0 20 0 40mm 0 2 0 7mm 2 0mm 0 15mm 1 0mm 1 0mm 1 75mm Connecting Rod Smal...

Page 7: ...ing 102 13 2mm 2 1 4 Spark Plug Gap 0 7 0 8mm Spark Plug Cap Resistance 7 5 12 5k Ignition Coil Resistance Air Gap Primary Coil Secondary Coil 0 8 1 0 5 9 7 1k 0 4 0 6mm Generator Parts Item Standard...

Page 8: ...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 9: ...soon as possible after handling used oil Please dispose of used engine oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service statio...

Page 10: ...oint solvent Drop a few points engine 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 sedi...

Page 11: ...ectrode The gap should be 0 70 0 80 mm 5 Check that the spark plug washer is in good condition 6 Install the spark plug on and screw down it with plug wrench compress the plug washer Cover the spark p...

Page 12: ...se valve abnormal if the clearance 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 300h check and adjust...

Page 13: ...earance too big Intake and exhaust 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 f...

Page 14: ...embly GOVERNOR ROD SCREW M5 25 STOPPER SPRING THROTTLE PLATE PIN BOLT M6 10 RETURN SPRING install the short end against the adjust support NUT M6 GOVERNOR BRACKET BOLT M6 10 GOVERNOR SPRING install th...

Page 15: ...valve move freely e Check the maximum engine speed Maximum speed adjustment a Start the gasoline engine and allow it to warm up to normal operating temperature b If the maximum speed not conforming to...

Page 16: ...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 17: ...e and tightness repair if necessary If still can t starting have the gasoline engine to our authorized dealer for repairing SPARK PLUG TESTING WARNING When testing the spark plug never hold the high t...

Page 18: ...bon deposit in combusting chamber Clear away Air cleaner is clogged up Clean air cleaner filter element Poor compression Piston or cylinder or piston ring is worn Replace the worn Air leakage from the...

Page 19: ...earance 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 Ca...

Page 20: ...tment of engine governor to 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...

Page 21: ...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 too l...

Page 22: ...circuit Replace the rectification bridge and stator 3 1 11 Stator Iron Core Overheat CAUSE REMEDY Stator voltage too high operation and iron core loss increasing results in iron core overheat Adjust g...

Page 23: ...eat The engine operating at lower than rate speed and ventilation condition poor resulting in heat dispersion engine outputting rate voltage at low speed increasing exciting current result in the roto...

Page 24: ...n time in order to make the engine cool normally 6 The operator should be familiar with the working principle and structure of the generator knowing how to make an emergent stop and the operation of a...

Page 25: ...12 Safe warning label 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 26: ...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 27: ...ng Chart STATOR ROTOR GASOLINE ENGINE AIR CLEANER CARBURETOR RECOIL STARTER SHROUD FLYWHEEL IGNITION COIL CONTROL PANNEL BRUSH CUSHION FRAME MOTOR BRACKET MOTOR TAIL COVER AUTOMATIC VOLTAGE REGULATOR...

Page 28: ...3 TROUBLESHOOTING 26 FLYWEEL NUT M14 STARTING CUP IMPELLER SHROUD BOLT M6 10 RECOIL STARTER GRIP BOLT M6 10 RECOIL STARTER 3 4 Gasoline Engines 3 4 1 Recoil Starter...

Page 29: ...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 30: ...f 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 cam Install th...

Page 31: ...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 32: ...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 resistance...

Page 33: ...3 TROUBLESHOOTING 31 FLYWHEEL POSITION HOLE POSITION HOLE IMPELLER POSITION BLOCK POSITION BLOCK STARTER PULLY...

Page 34: ...d readjusting the pilot screw If you always operate the engine at altitudes higher than sea level 1000 meters over have our authorized dealer perform this carburetor modification If not should lower l...

Page 35: ...he gasoline contains some composition which can form the colloid after long sediment and attach in the carburetor parts such as main jet oil path and float chamber surface The air enter into the carbu...

Page 36: ...ion Don t use the steel wire and other hard material to open the blocked hole to prevent carburetor performance from changing holes diameter Use the gasoline and compression air to clean it FLOAT PIN...

Page 37: ...ck the float valve float seat and float spring for wear b Clean with compressed air before installation c Clean with compressed air before installation d Clean with compressed air before installation...

Page 38: ...he pilot screw is broken replace with new one Disassemble the broken pilot screw from the carburetor Put the spring onto the replaced pilot screw and then install it onto the carburetor Turn the pilot...

Page 39: ...oat height 13 7 1 5mm 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 preheat it...

Page 40: ...lation 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 tighteni...

Page 41: ...ds 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 IN 25...

Page 42: ...iameter with the micrometer if finding out of the standard or service limit or if visually inspecting the burn and damaged on the valve face please replace with new one Standard Service Limit 6 59mm I...

Page 43: ...e out of the combustion chamber side using valve guide driver NOTICE Be careful to avoid damaging the cylinder head when driving out the valve guides c Install the new valve guides from the valve spri...

Page 44: ...on If the valve does not operate smoothly the guide may have been bent during installation Replace the valve guide if it is bent or damaged f Check the valve stem to guide clearance g The valve stem t...

Page 45: ...oth and concentric seat Turn cutter clockwise never counterclockwise Tool Valve Seat Cutter d Use the 32 45 cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face...

Page 46: ...The seating surface as shown by the transferred marking compound should have good contact all the way around g Apply abrasive to the valve seat face suitable for running in when rotating valve seat wi...

Page 47: ...RING PISTON PIN CLIP CUTOUT 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 not align the end...

Page 48: ...O D Measure the piston skirt O D with outside micrometer if out of the service limit replace it Standard Service Limit 87 985mm 87 85mm b Piston pin bore to piston clearance Separately measure the pi...

Page 49: ...to clearance of the ring and upper and lower face Standard Service Limit 0 030 0 060mm 0 15mm e Piston ring closed clearance Flatly place the piston into the cylinder with pushing the piston head to w...

Page 50: ...heck big end diameter If out of the standard or exceed service limit replace the connecting rod Standard Service Limit 36 025mm 36 07mm Camshaft check The camshaft is main driving part of the train va...

Page 51: ...mshaft wearing cause and to engine performance influence Poor lubrication will result in camshaft abnormal wearing such as oil viscosity low impurity too much and recycling oil little can t let the ca...

Page 52: ...f 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 Please replace the gear with a new s...

Page 53: ...NG 51 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 54: ...and connect the fuel tube Check for leaking Install the bolt M6 25 washer 6 25 2 bush fuel tank rubber gasket b NOTICE Check fuel tank cover vent for blocked Check the fuel strainer for clogged or br...

Page 55: ...arbon deposits in the long time operation and seriously trouble the exhaust system To get the best performance the muffler must be periodically removed the carbon deposits Lightly tap the muffler and...

Page 56: ...TROUBLESHOOTING 54 WARNING The muffler can glow heat Please place the gasoline engine out touch of the passerby and children Don t place the flammable materials near the exhaust vent during operation...

Page 57: ...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 M6 135 Torque 8 10N m Loose and tighten the bolt adopt the method of cross especially t...

Page 58: ...ethod of cross especially tighten the bolts equally and gradually and tighten to the standard value ROTOR Make sure to clean the dunghill oil butter and others MOTOR BRACKET CARBON BRUSH BOLT M5 12 MO...

Page 59: ...gram YELLOW GREEN Grounding wire RED BLUE GRAY BLUE GRAY RED BLUE BLUE GRAY WHITE GRAY COLLECTOR RING Make sure to clean the foreign matters oil butter and others with lent free cloth if necessary If...

Page 60: ...ing 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 between the c...

Page 61: ...ck the length of the carbon brush for 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 collect...

Page 62: ...ng Owing to isolated by insulation material between them if only the insulation isn t damaged the resistance is rather high WARNING If the insulation resistance decreased obviously it means that the i...

Page 63: ...sulation wire with a copper ring of the connecting ring and another is connected with iron core Next wave the megohmmetr from slowly to fast and the meter needle follows wave When the meter needle is...

Page 64: ...inuity between the terminals with ohmmeter as shown 1 2 and 3 4 are connecting when the engine switch to OFF position while they are not connecting when the engine PANEL 1 2 3 4 BOLT M6 12 PANEL SEAT...

Page 65: ...tention to connect the wire correctly If the connection of the ohmmeter is abnormal please replace the switch 2 Voltmeter The terminal of the voltmeter should be connected 3 Breaker The breaker should...

Page 66: ...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 Meter n...

Page 67: ...4 WIRING DIAGRAM 4 WIRING DIAGRAM 4 1 Electric Diagram...

Page 68: ...4 WIRING DIAGRAM...

Page 69: ...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 70: ...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...

Page 71: ...s Zone B Shuangfu Industry Park Jiangjin District Chongqing China Tel 86 23 85553441 Fax 86 23 85553450 Postcode 402247 Http www rato cc E mail ratoservice rato cc consultation service parts rato cc p...