Rato R160 User manual

GASOLINE ENGINE
R100-R440 HORIZONTAL SHAFT
SERVICE MANUAL
CHONGQING RATO POWER
MANUFACTURING CORPORATION

This manual contains information about how to perform routine maintenance and how to do
troubleshooting.
Keep this manual handy, so you can refer to 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 assume any responsibility.
NOTICE:
Copyright is reserved, and no part of this publication may be reproduced without RATO
Company’s written permission.

SAFETY MESSAGES
Your safety and the safety of others are very important. We have provided important safety
messages in this manual and on the generator. Please read these messages carefully.
A safety message alerts you to potential hazards 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 you don’t follow
instructions.
You CAN be KILLED or SERIOUSLY INJURED if you don’t follow
instructions.
You CAN be INJURED if you don’t follow instructions.
Your generator or other property could be damaged if you don’t
follow instructions.

CONTENTS
1. INTRODUCTION ···················································································· 1!
1-1 PARTS DESCRIPTION ······································································ 1!
1-2 SPECIFICATION·············································································· 2!
1-3 SERVICE LIMIT ·············································································· 5!
2. DIMENSIONS AND TORQUE ·································································· 19!
2-1 ENGINE DIMENSIONS···································································· 19!
2-1-1 R100 ························································································· 19!
2-1-2 R160/R180/R200/R210/R225 ······················································ 19!
2-1-3 R270/R280/R300 ····································································· 20!
2-1-4 R390/R420/R440 ····································································· 21!
2-2 TORQUE VALUES ········································································· 22!
2-2-1 torque values ·········································································· 22!
2-3 STANDARD Torque valueS ······························································· 24!
3. MAINTENANCE ··················································································· 25!
3-1. Maintenance schedule ······································································ 25!
3-2 engine oil ······················································································ 26!
3-3 Air cleaner····················································································· 27!
3-4 Cleaning of the fuel filter ··································································· 27!
3-5 spark plug cleaning and ····································································· 28!
adjusting···························································································· 28!
3-6 valve clearance adjustment ································································· 28!
3-7 governor ······················································································· 29!
4. DISASSEMBLING AND SERVICING ························································· 30!
4-1 Troubleshooting ·············································································· 30!
4-1-1 Hard starting ·········································································· 30!
4-1-2 Engine lacks power····································································· 2!
4-1-3 Speed is unstable ······································································· 3!
4-1-4 Motor is unable to start ································································ 3!
4-1-5 Exhaust gas color is abnormal ························································ 4!

4-1-6 Unable to ignite ········································································· 4!
4-1-7 Oil alert system malfunction ·························································· 5!
4-1-8 GASOLINE ENGINE IS OVERERHEATED ····································· 5!
4-2 Preparation of servicing ······································································· 6!
4-2-1 Safety precautions ······································································ 6!
4-3 DisASSEMBLING chart ···································································· 46!
4-4 Engine ························································································· 47!
4-4-1 Recoil starter ·········································································· 48!
4-4-2 Flywheel ··············································································· 50!
4-4-3 Air cleaner············································································· 52!
4-4-4 Carburetor ············································································· 54!
4-4-5 Cylinder head /valve ································································· 57!
4-4-6 Crankshaft/piston ····································································· 63!
4-4-7 Starting control box ·································································· 71!

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

2
1-2 SPECIFICATION
Model
items
R100
R160
L×W×H
310×290×320mm
390×320×345mm
Dry Weight
8.8 kg
15.5kg
Engine Type
4-stroke, OHV, single cylinder
Displacement
98 cm3
163cm3
Compression Ratio
8.5±0.3:1
Bore×Stroke
56×40 mm
68×45mm
Maximum Output Power
1.8／3600 rpm
3.4kW/3,600rpm
Maximum Torque
4.7N·m/2500rpm
9N·m/2,500rpm
Cooling System
Forced Air-cooled
Ignition System
Transistorized Magneto Ignition(TCI)
Spark Plug
BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System
Forced Splash
PTO Shaft Rotation
Counterclockwise
Model
items
R180
R200
L×W×H
390×320×345mm
390×320×345mm
Dry Weight
16kg
16kg
Engine Type
4-stroke, OHV, single cylinder
Displacement
179cm3
196cm3
Compression Ratio
8.5:1
Bore×Stroke
65×54mm
68×54mm
Maximum Output Power
3.5kW/3,600rpm
4.0kW/3,600rpm
Maximum Torque
9N·m/2,500rpm
11N·m/2,500rpm
Cooling System
Forced Air-cooled
Ignition System
Transistorized Magneto Ignition(TCI)
Spark Plug
BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System
Forced Splash
PTO Shaft Rotation
Counterclockwise
Model
items
R210
R225
L×W×H
390×320×345mm
390×320×345mm

3
Dry Weight
16.5 kg
16.5kg
Engine Type
4-stroke, OHV, single cylinder
Displacement
212 cm3
223cm3
Compression Ratio
8.5±0.3
Bore×Stroke
70×55 mm
70×58mm
Maximum Output Power
4.2／3600 rpm
4.4kW/3,600rpm
Maximum Torque
12N·m/2500rpm
13N·m/2,500rpm
Cooling System
Forced Air-cooled
Ignition System
Transistorized Magneto Ignition(TCI)
Spark Plug
BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System
Forced Splash
PTO Shaft Rotation
Counterclockwise
Model
items
R270
R280
L×W×H
420×395×430mm
420×395×430mm
Dry Weight
26kg
26kg
Engine Type
4-stroke, OHV, single cylinder
Displacement
270cm3
277cm3
Compression Ratio
8.2：1
Bore×Stroke
77×58mm
78×58mm
Maximum Output Power
5.8kW/3,600rpm
6kW/3,600rpm
Maximum Torque
16.8N·m /2,500rpm
18N·m /2,500rpm
Cooling System
Forced Air-cooled
Ignition System
Transistorized Magneto Ignition(TCI)
Spark Plug
BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System
Forced Splash
PTO Shaft Rotation
Counterclockwise
Model
items
R300
R390
L×W×H
420×395×430mm
465×415×440mm
Dry Weight
26kg
27.5kg
Engine Type
4-stroke, OHV, single cylinder
Displacement
301cm3
389cm3

4
Compression Ratio
8.2：1
8：1
Bore×Stroke
80×60mm
88×64mm
Maximum Output Power
6kW/3,600rpm
7.6kW/3,600rpm
Maximum Torque
18N·m /2,500rpm
23N·m /2,500rpm
Cooling System
Forced Air-cooled
Ignition System
Transistorized Magneto Ignition(TCI)
Spark Plug
BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System
Forced Splash
PTO Shaft Rotation
Counterclockwise
Model
items
R420
R440
L×W×H
465×415×440mm
465×415×440mm
Dry Weight
28kg
28.5kg
Engine Type
4-stroke, OHV, single cylinder
Displacement
420cm3
438cm3
Compression Ratio
8.5：1
8.5：1
Bore×Stroke
90×66mm
92×66mm
Maximum Output Power
8.5kW/3,600rpm
9.8kW/3,600rpm
Maximum Torque
25N·m /2,500rpm
27N·m /2,500rpm
Cooling System
Forced Air-cooled
Ignition System
Transistorized Magneto Ignition(TCI)
Spark Plug
BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System
Forced Splash
PTO Shaft Rotation
Counterclockwise