Rato R1000I User manual

R1000I Maintenance Manual
Chongqing RATO Technology Co., Ltd.

This Manual contains the specifications to be in compliance with for routine service and maintenance
as well as troubleshooting of general purpose generator.
Make sure that maintenance personnel of this equipment can refer to this Manual at any time.
This Manual describes correct methods to service this equipment. Our Company shall not bear liability
for neither personal injury nor equipment damage caused by ignoring these regulations.
Note:
The copyright of this Manual belongs to the Company, which is not allowed to be reproduced without
written consent of the Company, violators must be prosecuted.

Safety Warning
Your personal and property security and that of others are very important. Please read carefully our
three vital safety warnings written in the maintenance manual and in the decal of the generator, with
the symbol preceding each one. Details are as follows:
If you do not follow the instructions, you will be seriously injured.
Failure to follow instructions will most likely result in serious injury.
If you do not follow the instructions, you may suffer from minor injury.
Failure to follow instructions may result in damage to your generator
and other properties.

Part 1 Introduction
1-1 Components of general purpose generator
Control panel
Right
appearance
cover plate
Cover
gasket of air
filter housing
Left
appearance
cover plate
Side shield of
muffler
Starting rope
handle
Fuel tank cap
Fuel tank
Panel seat
Handle

1-2 Parameter
Item
R1000i
Gasoline
engine
Gasoline engine
R56-i
Type of gasoline engine
Four-stroke, valve-on-the-side, single cylinder
Displacement (cc)
56
Ignition system
Capacitor discharge ignition (CDI)
Volume of fuel tank (L)
2.8
Continuous working period (hr)
3.5
Engine oil capacity (L)
0.28
Generator
Voltage (DC) (V)
5
Current (DC) (A)
1~2
Rated frequency (Hz)
50HZ
Rated voltage (V)
230V
Rated output power (kW)
1.0
Maximum output power (kW)
1.1
Generator
set
Length (mm)
336
Width (mm)
327
Height (mm)
306
Net weight (kg)
12.5
Phase number
Single phase
General
purpose
modules
Air filter
●
Muffler
●
Fuel tank
●
Fuel volume indicator
/
Voltmeter
/
Voltage regulator (AVR)
/
Engine oil alarm system
●
circuit breaker
/
Accessories of electric starter
●

1- 3 Repair Standard
Parts
Item
Standard
Use limit
Gasoline
engine
Maximum unoad speed
Cylinder pressure
4800± 100
700~900Kpa/1400rpm
--
--
Cylinder
I.D. of cylinder
45~45.015
45.065
Piston
Piston skirt outer diameter
Piston - cylinder clearance
I.D. of piston pinhole
O.D. of piston pin
Piston pin - piston pinhole clearance
44.97~44.99
0.01~0.045
10.002~10.008
9.994~10
0.002~0.014
44.92
0.13
10.018
9.984
0.034
Piston ring
Piston ring set side-gap: first Ring/second ring
Piston ring sets close gap:
Ring 1/ Ring 2
0.015~0.05
--
--
0.1~0.25
0.1~0.25
0.12
--
--
0.55
0.55
Connecting rod
I.D. of small end
I.D. of big end
Oil clearance of bigger end
Clearance of big end side
10.017~10.006
15.0~15.011
0.035~0.055
0.016~0.038
10.044
15.05
0.12
0.238
Crankshaft
O. D. of crank
14.973~14.984
14.943
Air valve
Valve clearance Intake / Exhaust
O. D. of valve stem intake Intake
Exhaust
Exhaust Contact width of intake/exhaust valve seat
Free length of spring
0.03~0.08
3.97~3.985
3.935~3.95
0.6~0.8
21.9
--
--
5.560
1.9
20.9
Camshaft
Cam Height Intake
Exhaust
O.D. of journal
16
16
9.965~9.99
15.7
15.7
--
Crankcase
cover
I.D. of camshaft hole
10~10.018
10.048

Spark plug
Clearance
0.6-0.8
--
Spark plug cap
resistance
10kΩ
--

1-4 size
327
336
306

Part II Maintenance
2-1 Service List
Good maintenance and service is the best guarantee for safe, economical and zero-failure operation.
It also contributes to environmental protection.
The exhaust gas of the generator contains toxic carbon monoxide, please stop the
gasoline engine for maintenance. If you have to implement the maintenance when
generator running, please make sure the working area is draughty.
Regular maintenance and service can ensure that the generator is working in good condition. The
maintenance schedule is as follows:
Regular maintenance schedule
Every
time of
use
20h or in the first
month of initial
use (3)
50h or
every 3
months (3)
100h or
every 6
months (3)
300h or
every
year (3)
Engine oil
Check oil level
○
Replace
○
○
Air filter
Inspection
○
Clear
○(1)
Fuel cup
Clear
○
Spark plug
Clear
○
Replace
Valve clearance
Readjustment
○(2)
Cylinder head
Cleaning
Every 300 hours (2)
Fuel tank and
filter
Cleaning
Every 2 years (2)
Fuel hose
Replace
Every 2 years (2)
(1) Please increase the maintenance frequency if generator used in dusty area.
(2) These items should be maintained by franchised dealer.
(3) These items should be maintained in proper time interval as requested to insure
generator’s life

2-2 Service and Maintenance
2-2-1 Engine oil
⚫After allowing gasoline engine to warm up
(Startup gasoline engine to run at no-load
for 10 minutes), let it stand for another 10
minutes, only that can ensure to drain
engine oil quickly and completely.
Remove oil dipstick.
Capacity of gasoline engine oil:
Recommended oil:
SAE 15W -40
Recommended oil grade
API standard SE level or higher
Long-term and frequent exposing engine oil
may cause skin cancer. Although this is not
inevitable, it is still recommended to avoid
direct contact as far as possible, wash up
the contacted skin with soap and water
immediately and thoroughly upon such
contact.
From the perspective of environmental
protection, please properly dispose of the
waste oil after use. We strongly recommend
that you should: put the waste oil into a
sealed container and take it to the local
service station or waste oil recycling center.
Remember: Do not throw it into the garbage
or dump it on the ground or in the ditch.
Oil level gauge
Oil level
Upper limit
Oiling port
Oil level dipstick
Lower
limit
Oil level
Upper limit

2-2-2 Air filter
Getting dirty of air filter may prevent air
from flowing into the carburetor. In order to
prevent carburetor failure, the air filter shall
be maintained regularly. (see 2-1
Maintenance List for the cycle, and see the
figure below for the method). If being used
in dusty environment, it shall be maintained
more frequently.
Using gasoline or
inflammable solvent to clean the filter
element may cause fire or explosion. Use
soapy water or a nonflammable solvent.
Open the cover of air filter housing. Inspect air
filter element to ensure it is in good condition
and clean.
If the foam filter element is dirty, please clean it:
Wash it in hot water containing household
cleaner, or in non-flammable or high-flash point
solvent; and then rinse with clean water, and
then squeeze it clean. Then apply a few drops
of oil and squeeze evenly.
2-2-3 Spark plug
1. Remove the handle
2. Remove protective plate
3. Pull out spark plug cap
Air filter housing cover
Air filter element

2. Visually inspect the insulator of spark plug for
damage. If the insulator is damaged, replace
it with a new one
If the electrode has carbon deposition, clean it
by wire brush.
Measure the gap of spark plug with a thickness
gauge Proper gap shall be 0.70 ~ 0.80mm. If it
is needed to be adjusted, please tap it (when
the gap is too large) or gently pry the electrode
up with a slotted screwdriver (when the gap is
too small).
1. Inspect whether the gasket of spark plug is in
good condition.
2. Mount the spark plug, and tighten it on
cylinder head with a spark plug socket
wrench, and mount the spark plug cap.
If mounting a new spark plug, tighten the
washer by additional 1/2 turns after pressing
the gasket out.
If you are reinstalling a used spark plug,
tighten 1/8-1/4 turn after pressing the washer.
Torque value of spark plug: 22±2N.m

Part 3 Failure Determination and Repair Preparation
3-1 Safety Factors
Failure to observe the following precautions will result in the invalidation of the
warranty provided with the generator and may damage the generator or cause personal injury.
Therefore, before using the generator, Operators should pay special attention to the following points:
1. It shall be matched strictly according to the power demarcated in the maintenance manual, and it is
strictly forbidden to run under overload, over-speed or low speed for a long term.
2. Using the fuel oil and engine oil of specified ratings, conduct sufficient sediment and filtering before
using them. Refueling appliance shall be maintained clean, and engine oil shall be replaced
regularly.
3. Check if the fastening bolts on generator are tight enough regularly and tighten them in time
4. Clean air filter elements regularly and replace them when necessary.
5. This machine is a wind-cooled generator, so be sure to clean the sundries and dirt on its parts like
cooling fin and wind scooper in time to ensure the normal cooling performance of generator.
6. Operators should be familiar with the working principles and structure of the generator and know
how to stop it in emergency and operate all the control components. Be sure to conduct regular
maintenance and timely eliminate the faults found; it’s prohibited continuing to run the generator
after faults happen to it.
7. Please be sure to keep the generator at least one meter from buildings and other equipment when
operating it and keep good ventilation; do not put any inflammable (like gasoline and matches)
beside the generator or close to the running generator to prevent the fire risk.
8. Refuel the generator at the place with good ventilation and with it standstill and no smoking, open
fire or spark in the place where the generator is refueled or in the fuel storage place.
9. Do not overfill the oil tank and the fuel oil shall not overflow. If there is fuel overflowing, overflowed
fuel must be cleaned thoroughly, and the generator shall not be started up until the fuel is volatilized
off.
10. Do not operate the generator in a confined or poorly ventilated area.
11. When the generator is running or just stopped for a period of time, do not touch the muffler to avoid
being burned. In order to prevent burn or fire, in order to avoid scalding or fire, the generator shall
be transported or stored after cooling.
12. Safety Warning Label
Please read the warning label carefully before using the generator; our company shall not be liable
for the personal injuries or equipment damages caused by ignoring the warning label.

3-2 Fault Diagnosis
The condition of indicator light flashing when the inverter is alarming (error 2%):
The green indicator on indicates that it is working normally and there is output;
The green indicator on and red indicator flashing on indicates that it is overloaded and there is output;
Green light is off, and the red light flashes 1 time, and then flashes 1 time again after an interval of 3s,
which indicates that the voltage at the front end of the bus is too low, and there is no output;
Green light is off, and red light flashes 2 times, and then flashes 2 times again after an interval of 3s,
which indicates that the engine speed is too low, and there is no output;
Green indicator is off, red indicator flashes 3 times, and then flashes 3 times once again after an
interval of 3s, which indicates that inverter temperature is height and the has no output;
Green light is off, red light flashes 5 times, and then flashes 5 times again after an interval of 3s, which
indicates that the voltage at the front end of the bus is too high, and there is no output;
Green light is off, red light flashes 6 times, and then flashes 6 times again after an interval of 3s, which
indicates after the overload is disconnected,
Inability to start
Ignition system
Testing spark plug
Fuel system
Check the ignition
coil
Carburetor
Oil Line Test
Oil protection test
Valve Train
Cylinder
pressure test
Valve Clearance Test
Operating
abnormal
sound
Unstable
speed
Crank and connecting
rod mechanism
Difficult starting
Starting and
flameout
Starting
rebound
Abnormal
sound inside
the box
Abnormal
sound outside
the box
Hunting
Speed too low
Speed too high
Intake system
Exhaust
system
Muffler test

Abnormal
output
Operating
abnormal
sound
Voltage too high
or too low
Appearance
parts
No
output
Socket without
output
No DC output
Frame
Magneto
Whole
machine
problem
Control
panel
Dynamical
problem
Power
Maintenanc
e
Inability to
start

3-3 Maintenance Tools
Tool
Designation
Model
Use Position
T-sleeve
5mm-12mm
Screwdriver
Flat and cross
clamp forceps
nose plier and
Thumb forceps
Hammer
Vernier caliper
100MM
Inside
micrometer
100MM
Outside
micrometer
100MM
Multimeter

3-4 Disassembly
3-4-1 Disassembly graph
Muffler
Frame
Engine
Magneto
Hand starting
components
Control panel
Inverter
Chassis
Damping Pad

Part 4 Maintenance
4-1 fuel tank/handle tube
Fuel tank
Mounting precautions
Before the Assembly, inspect first whether the vent hole of fuel tank cover is clogged.
Whether the fuel filter is blocked or damaged.
Whether the fuel hose is aged and cracked.
If there is any problem, replace in time before the Assembly.
Handle
Fuel tank cap
Fuel filter screen
Fuel tank
Fuel cock set
Cross recess head screw
Self-tapping screw

4-2 Hand starting components / motor /air filter
Hand starting components
When disassembling, be careful not to spring out the starter coil spring, and wear
gloves when operating.
Air filter element
Air filter housing cover
Magneto stator assembly
Hexagon flange bolt M5*28
Magneto Rotor Shell Assembly
Hexagon nut with flange
Impeller
Hexagon flange bolt M6*12
Starter Recoil Assembly
Tightening screw
of guide disc
Drive guide plate
Return spring
Spring
Drive cam
Starter reel spring
Starter cord reel