Rato R80, Service Manual

Page 1: ...GASOLINE ENGINE R80 R440 HORIZONTAL SHAFT SERVICE MANUAL CHONGQING RATO POWER MANUFACTURING CORPORATION...

Page 2: ...it at any time This service manual describes correct methods for maintaining this equipment If any personal casualty or equipment damage is caused due to disregard of our rules our company does not a...

Page 3: ...that could injure you or others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These messages mean You WILL be KILLED or SERIOUSLY INJURED if...

Page 4: ...12 3 MAINTENANCE 13 3 1 Maintenance schedule 13 3 2 engine oil 14 3 3 Air cleaner 15 3 4 Cleaning of the fuel filter 15 3 5 spark plug cleaning and adjusting 16 3 6 valve clearance adjustment 16 3 7...

Page 5: ...ng 24 4 2 1 Safety precautions 24 4 2 2 Special tools 28 4 3 DISASSEMBLING chart 29 4 4 Engine 30 4 4 1 Recoil starter 31 4 4 2 Flywheel 33 4 4 3 Air cleaner 35 4 4 4 Carburetor 37 4 4 5 Cylinder head...

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Page 7: ...1 1 INTRODUCTION 1 1 PARTS DESCRIPTION Throttle grip Fuel tank Recoil starter Muffler Spark plug Choke lever Air cleaner Fuel tank cover Start handle Drain plug Oil dipstick...

Page 8: ...m Transistorized Magneto Ignition TCI Spark Plug BPR6ES NGK NHSP LD F7RTC F7TC Lubrication System Forced Splash PTO Shaft Rotation Counterclockwise Model items R420 L W H 465 415 440mm Dry Weight 28kg...

Page 9: ...Oil Ring Ring End Gap Top Second Ring Oil Ring Ring Width Top Second Oil Ring 0 035 0 070mm 0 2 0 35mm 0 2 0 7mm 1 5 1 450 mm 2 5 2 450 mm 0 15mm 1 0mm 1 0mm 1 37mm 2 37mm Connecting Rod Small End I...

Page 10: ...ssion 3750 3850rpm 1 2Mpa 1400rpm Cylinder head Sleeve I D 90 90 015mm 90 17mm Cylinder head Warpage 0 10mm Piston Skirt O D Piston to cylinder clearance Piston pin bore I D Piston pin O D Piston pin...

Page 11: ...6 550 mm 6 6 6 615 mm 0010 0 040mm 0 050 0 080mm 0 65 0 95 38 5 39 5mm 6 44mm 6 4mm 6 66mm 0 11mm 0 13mm 2 0mm 37 5mm camshaft Cam height Journal O D IN EX 32 59mm 32 07 15 966 15 984 mm 32 54mm 32 02...

Page 12: ...6 2 DIMENSIONS AND TORQUE 2 1 ENGINE DIMENSIONS 2 1 1 R100 R80...

Page 13: ...7 2 1 2 R160 R180 R200 R210 R225...

Page 14: ...8 2 1 3 R270 R280 R300...

Page 15: ...9 2 1 4 R390 R420 R440...

Page 16: ...Crankcase cover R100 R160 R420 M6 25 8 8 A M8 32 8 8 A 11 2 28 2 Crankcase cover crankcase gasket crankcase 5 Flywheel subassembly R100 R160 R225 R270 R300 R390 R440 M12 1 25 8 A M14 1 5 8 A M16 1 5...

Page 17: ...15 Recoil starter R100 R160 R225 R270 R440 M6 8 8 8 A M6 8 8 8 A M6 8 8 8 A 10 2 Recoil starter shroud 16 Air cleaner R100 R440 M6 8 A 10 2 Air cleaner gasket carburetor 17 Throttle control subassembl...

Page 18: ...R440 M6 35 8 8 A M6 30 8 8 A crankcase 2 3 STANDARD TORQUE VALUES Item Specifications Torque valve N m Kg m Standard torque 5mm bolt nut 5 5 0 55 6mm bolt nut 10 1 0 8mm bolt nut 21 2 4 10mm bolt nut...

Page 19: ...for keeping the generator in a good operating condition Perform the service and inspection at the intervals shown in the Maintenance Schedule below Time option Each use First month or 20 Hrs 3 Every...

Page 20: ...ded oil General oil SAE15W 40 SJ class or equivalent API classified SJ class SAE10W 30 oil In a low temperature range below 10 use oil with the grade higher than SAE10W 30 In a cold environment temper...

Page 21: ...uch oil will jam the strainer holes Oil bath type 1 Clean the air cleaner case with cleaning oil and dry it 2 Add the clean oil to specified level and install the air cleaner case back 3 Clean the pol...

Page 22: ...nti wave interference ability 3 6 VALVE CLEARANCE ADJUSTMENT CAUTION Valve clearance adjustment must be per formed with the engine cold 1 Remove the cylinder head cover bolt head cover and gasket CAUT...

Page 23: ...the valve lock nut 3 7 governor 1 Remove the fuel tank 2 Loosen the nut on the governor arm Check the throttle to ensure it is fully open turn to left to extreme position 3 Turn the governor support r...

Page 24: ...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 ele...

Page 25: ...order to stipulated torque value Air leakage in the valves Check valve clearance and tightness repair if necessary If engine still can t start take the engine to our authorized dealer to repair it z S...

Page 26: ...art Too much carbon deposit in combusting chamber Clear away Air cleaner is clogged Clean air cleaner filter element Intake pipe is leaking Repair or replace Poor compression Intake pipe is leaking Re...

Page 27: ...rk There is water in float chamber Clean Improper clearance between spark plug and electrodes Adjust Something wrong with induced coil and so on Check and replace damaged parts 4 1 4 Motor is unable t...

Page 28: ...l supply system Fuel has run out Add fuel Carburetor is clogged Check fuel line and unclog it Float is leaking Repair Needle valve is stuck Dismantle float chamber and eliminate the sticking Ignition...

Page 29: ...check the continuity of the yellow and green leads continuity between yellow and green leads is normal 4 1 8 GASOLINE ENGINE IS OVERERHEATED TROUBLE CAUSE REMEDY Gasoline engine is overheated Oil ins...

Page 30: ...ensure the engine can cool normally 6 The operator should be familiar with the working principle and structure of the gasoline engine know how to make an emergency stop and the operation of all contr...

Page 31: ...ning labels before operating Our company will not assume any responsibility for person injury or equipment damage caused by disregarding warning labels Applique labels are shown as follows 1 Fuel labe...

Page 32: ...26 5 Throttle control label 6 Air cleaner maintenance label 7 Choke lever fuel cock label 8 Oil grade label...

Page 33: ...27 9 Oil filling label...

Page 34: ...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 and bearing A...

Page 35: ...29 4 3 DISASSEMBLING CHART Engine Air cleaner Carburetor Recoil starter Shroud Flywheel Starter motor...

Page 36: ...yellow lead Gray lead Connect to charging coil lead Fan cover only used for automatic starter Disassembly reassembly Disassemble and reassemble with the recoil starter assembled Black white lead Conn...

Page 37: ...e through the groove in the recoil starter reel and make a figure eight knot at the rope end Hang the side hook of the recoil starter spring to the groove of the recoil starter case set the recoil sta...

Page 38: ...tall the return spring on the recoil starter reel while hooking it to the side of the driving cam Install the spring driving guide and fixing screw one after another Insert the recoil starter rope thr...

Page 39: ...and down for adjusting the clearance then screw down the bolt Check the ignition coil Primary side Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coil s prim...

Page 40: ...e Measure the resistance of the spark plug cap by attaching one ohmmeter lead to the wire end of the plug cap while touching the other test lead to the spark plug end Resistance value 5k 5 10k 5 recom...

Page 41: ...ise silencer only for silence Elbow seal Air cleaner elbow Disassembly reassembly remove and install with the choke lever and fuel valve in the ON position Clean the inside of the elbow with compresse...

Page 42: ...Collar Air cleaner case Oil capacity 60cc Reassembly After cleaning with solvent fill with clean oil and install Air cleaner elbow Disassembly reassembly Remove and install with the choke lever in ON...

Page 43: ...w out the passages with compressed air and install noting installation direction After installation connect the high tension cord and fuel hose to the ground Insulator gasket Carburetor assy Carbureto...

Page 44: ...for any sign of fuel leakage Reassembly Clean thoroughly with compressed air before installation reassembly Inspect for wear before installation Idle speed adjusting screw Idle speed mixed ratio adjus...

Page 45: ...position as shown and push the float in by finger and measure the distance between the float top and carburetor body float height Specified float height See 1 3Maintenance Standard If the float heigh...

Page 46: ...ket Cylinder head cover Valve adjusting bolt Cylinder head Installation Before installation remove any carbon deposits from the combustion chamber and inspect the valve seats Measure the cylinder comp...

Page 47: ...de diameter Inspect the valve stem outside diameter with the micrometer if it is found out of the standard or service limit or if it has visible burn and damage on the valve face please replace it wit...

Page 48: ...e and cylinder cover for fastness b Use the 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...

Page 49: ...c Install the new valve guides from the valve spring side of the cylinder head Exhaust side Drive the exhaust valve guide until the clip is fully seated as shown in the fig Intake side Drive the intak...

Page 50: ...and centered in the valve guide insert the valve and check operation If the valve does not operate smoothly the guide may have been bent during installation Replace the valve guide if it is bent or da...

Page 51: ...ise never counterclockwise d Continue turning the cutter as you lift it from the valve seat Tool Valve seat cutter Use the 32 45 cutters to narrow and adjust the valve seat so that it contacts the mid...

Page 52: ...ly Push it in firmly until contact is made with the bearing surface Be careful not to damage the oil seal Bolt Crankcase Bearing Governor arm Bolt Crankcase cover Gasket Don t reuse Pin Oil seal Pin F...

Page 53: ...il seal when reassembling crankcase cover Pin Fix the governor arm with pin after installing Spacer Oil seal Connection rod Piston pin Piston pin clip Piston Crankcase Crankshaft Reassembly Push in fi...

Page 54: ...rings Stagger the piston ring end gaps 120 apart Reassembly a 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 t...

Page 55: ...t O D Measure the piston skirt O D with an outside micrometer if it is out of the service limit replace it Standard Service limit See 1 3Maintenance Standard See 1 3Maintenance Standard b Piston pin b...

Page 56: ...to its groove The piston ring should be freely turned without loosening and sticking Then measure by inserting the feeler into clearance of the ring and upper and lower face Standard Service limit See...

Page 57: ...t grooves or have cracks on one side the connecting rod should be rejected and replaced with a new one a Check small end diameter If it is out of the standard or exceeds service limit replace the conn...

Page 58: ...dard See 1 3Maintenance Standard Camshaft check The camshaft is main driving part of the valve timing mechanism which controls the intake and exhaust valves opening and closing Feature The shaft is eq...

Page 59: ...lubrication caused by factors such as low oil viscosity too many impurities and little recycling oil will result in camshaft abnormal wearing making it hard for the camshaft surface to have a complet...

Page 60: ...ace peels off and gear teeth are broken The engagement clearance is bigger due to gear wearing the noise is bigger If the timing gear is damaged please replace it with new one NOTICE Please replace th...

Page 61: ...pe fuse 5A Reassembly Check for burn before installation Oil alert Check P 7 8 Reassembly Install by aligning with the hole of the control plate Control panel Resetting button 1A Reassembly Be careful...

Page 62: ...tch with oil alert Check the continuity between black lead and engine switch Switch position Continuity ON No OFF Yes Switch with starter Check continuity between leads when switch is kept at each pos...

Page 63: ...dry cell check whether the alert lamp lights up Black battery Yellow battery Don t connect the positive and negative poles wrongly Don t use the battery with over 6V if so bulb will break Silicon rec...

Page 64: ...58 ELECTRIC DIAGRAM control box starter motor starter relay charging coil...

Page 65: ...anufacturing Corporation Add No 99 Jiujiang Road Shuangfu District Chongqing China service hotline 400 681 9981 fox 023 85553450 postcode 402247 URL www rato cc E mail ratoservice rato cc consultation...