Rato R2000IS User manual

1.6KVA INVERTER GENERATOR
MAINTENANCE MANUAL

This maintenance manual contents regulations which should comply to in daily
maintenance and trouble removal on generator.
Please make sure serviceman could read this manual anytime.
This maintenance manual describes the correct maintaining methods. Any
personal injury or death or equipment damage, which because ignorance on
these regulations, our company would remove the responsibility.
NOTICE
：
All rights reserved by our company. Any reprinting without the written
permission of our company is expressly prohibited.

SAFETY NOTICE
Your human safety and property are very important as well as others .Please ready following
safety notice in this manual and on generator decals, each safety notice has a symbol .
Failure to follow this instruction could result in extreme severe injury.
Failure to follow this instruction might result in severe injury.
Failure to follow this instruction might result in injury.
Failure to follow this instruction, your generator or other property would be
damaged.
If no torque written, please refer to appendix -- Torque Table.

CONTENTS
CONTENTS
GENERAL INFORMATION 第一部分 引言 ....................................................................... 1
Main components 1-1 发电机组成部分 .......................... Error! Bookmark not defined.
General parameter .............................................................................................................. 2
Repair standard .................................................................................................................. 3
MAINTENANCE 第二部分 保养 ......................................................................................... 4
Maintenance table 2-1 保养一览表 ................................................................................... 4
Engine Oil 2-2 机油 ......................................................................................................... 5
Air cleaner 2-3 空滤器 ...................................................................................................... 6
Clean fuel strainer 2-4 燃油滤清器的清理 ....................................................................... 7
Spark arrestor 2-5 火花消除器 ......................................................................................... 7
Spark arrestor 2-6 火花塞 .................................................................................................. 8
Valve clearance adjustment 2-7 气门间隙调整 ................................................................ 9
FAILURE PREDICTION AND REPAIR 第三部分 故障判定和修理Error! Bookmark not
defined.
Failure prediction 3-1 故障判定 ....................................... Error! Bookmark not defined.
Start difficultly 3-1-1 起动困难 ................................ Error! Bookmark not defined.
Power insufficient 3-1-2 动力不足 ........................... Error! Bookmark not defined.
Speed unstable 3-1-3 速度不稳 ................................. Error! Bookmark not defined.
Can't ignite 3-1-4 不能点火 ...................................... Error! Bookmark not defined.
Oil overheating 3-1-5 汽油机过热 ............................ Error! Bookmark not defined.

CONTENTS
Abnormal sound 3-1-6 异响 ...................................... Error! Bookmark not defined.
No DC output 3-1-7 没有直流输出电压 .................. Error! Bookmark not defined.
3-1-8 Generator Stator Winding too hot 发电机定子绕组过热Error! Bookmark
not defined.
Indicator light judgment 3-1-9 指示灯闪烁判定 ...... Error! Bookmark not defined.
Repair preparation 3-2 维修前的准备 ............................. Error! Bookmark not defined.
Safety factors 3-2-1 安全因素 ................................... Error! Bookmark not defined.
Special tools 3-2-2 专用工具 .................................... Error! Bookmark not defined.
Disassemble diagram 3-3 拆卸图表 ................................. Error! Bookmark not defined.
Gasoline engine 3-4 汽油机 ............................................. Error! Bookmark not defined.
Starter recoil/fly wheel/ignition coil 3-4-1 手起动部件/飞轮/点火线圈 ......... Error!
Bookmark not defined.
Carburetor 3-4-2 化油器 ............................................ Error! Bookmark not defined.
Stepping motor 3-4-3 调速步进电机 ........................ Error! Bookmark not defined.
Cylinder head 3-4-4 气缸头/配气机构 ..................... Error! Bookmark not defined.
Crankshaft/piston 3-4-5 曲轴/活塞 ........................... Error! Bookmark not defined.
Generator 3-5 发电机 ....................................................... Error! Bookmark not defined.
Fuel tank 3-5-1 油箱 .................................................. Error! Bookmark not defined.
Muffler3-5-2 消声器 ................................................. Error! Bookmark not defined.
Frame seat assy 3-5-3 机架底座组合 ........................ Error! Bookmark not defined.
Motor assy 3-5-4 电机部件 ...................................... Error! Bookmark not defined.

CONTENTS
Inverter 3-5-5 逆变器部件 ........................................ Error! Bookmark not defined.
Control panel 3-5-6 控制面板部件 .......................... Error! Bookmark not defined.
Appearance diagram 3-5-7 外观总成 ....................... Error! Bookmark not defined.
Wire connecting diagram 第四部分 线路接线图 .................. Error! Bookmark not defined.
Wire connecting schematic diagram 4-1 接线原理图 ...... Error! Bookmark not defined.
Appendix 附录 ......................................................................... Error! Bookmark not defined.

GENERAL INFORMATION
1
GENERAL INFORMATION
第一部分 引言
1-1 Main Components 发电机组成部分
Left Cover
Handle
Fuel cap
Control
panel
Muffler
Fuel
tank
Right cover
燃油观察窗
机油尺
Fuel tank
Motor assy.
Recoil starter subassembly
Control panel
Fuel observing hole
Air cleaner
Oil level gauge

GENERAL INFORMATION
2
General parameter
Generator model
R2000iS/ R2000iSP
Motor
Type
Silent inverter generator
Frequency /Hz
50Hz/60Hz
Rated voltage /V
100V/120V/220V/230V/240V
Max power /kVA
1.8
Rated power /kVA
1.6
Power Factor
1
Waveform deviation factor/%
≤3%
Noise (3/4 load)
65dB
DC output / V-A
12V/8A
Engine
Engine model
R80-i
Engine type
OHV
Displacement /cc
79.7
Fuel type
Gasoline
Engine
Fuel tank capacity /L
4L
Rated load continuum running
time /h
4
Engine oil capacity /mL
380ml
Spark plug model
TORCH-A5RTC
Starting system
Recoil starter
Diameter
L*W*H /mm
498×290×459
Net weight /kg
22

GENERAL INFORMATION
3
Repair standard
Components
Items
Standard
Limitation
Gasoline engine
Max unload speed
Cylinder pressure
5800
0.45Mpa at
600rpm
--
--
Cylinder
Inner diameter
48.6~48.615
48.655
Piston
Piston skirt outer diameter
Piston-cylinder clearance
Inner diameter of piston pin hole
Piston pin outer diameter
Clearance between Piston pin and piston pin hole
48.57~48.59
0.01~0.045
11.002~11.01
10.994~11
0.002~0.016
48.52
0.135
11.02
10.984
0.036
Piston ring set
Piston ring sets side-gap：first ring/second ring
Piston ring sets close gap:
first ring/second ring
0.015~0.05
--
--
--
0.15~0.30
0.12
--
--
--
0.6
Connecting rod
Inner diameter of smaller end
Inner diameter of bigger end
Oil clearance of bigger end
Big-end side gap:
11.006~11.017
22~22.013
0.02~0.043
0.45~0.95
11.050
22.040
0.1
1.15
Crankshaft
Crank outer diameter
21.97~21.98
21.94
Valve
Valve clearance Intake / Exhaust
Outer diameter of valve stem
Inner diameter of intake valve guide
Outer diameter of exhaust valve guide
Exhaust / Intake
Contact width of valve seat
Spring free length
0.03~0.08
0.03~0.08
4~4.012
4~4.012
0.6~0.8
28.5
--
--
4.060
4.060
2
27.5
2
Camshaft
Height of cam Intake
Exhaust
Journal outer diameter
20.54
20.54
11.965~11.99
20.24
20.24
--
Crankcase
cover
Inner diameter of camshaft hole
12~12.018
12.048
Spark plug
Clearance
0.6-0.8
--
Cap of spark
plug
Resistance
10kΩ
--

MAINTENANCE
4
MAINTENANCE
第二部分 保养
Maintenance table 2-1
保养一览表
Regular maintenance contributes to safety, economic, no malfunction and environmental
protection.
Exhaust contents toxic carbon monoxide, please stop the engine before
maintenance. If you have to implement the maintenance when generator
running, please make sure the working area is draughty.
Regular maintenance table:
Regular maintenance table
Each time
20h or the first
month of
begin to 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 cleaner
Check
○
Clear
○(1)
Fuel cup
Clear
○
Spark plug
Clear
○
Replace
Valve clearance
Re-adjust
○(2)
Cylinder head
cover
Clear
Every 300h (2)
Fuel tank and
strainer
Clear
Every two years (2)
Fuel hose
Replace
Every two 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.

MAINTENANCE
5
Oil 2-2
机油
1) Put generator on horizontal plane.
2) Loosen the bolts as marked, remove the
cover. (Pull the cover back slightly and
then pull it up)
3) Loosen the oil dipstick and empty the oil in
crankcase.
4) Put generator on horizontal plane, adding
new oil until to the upper limit. Tighten the
oil dipstick.
5) Assemble the cover, tighten bolts.
Note
：
Every time before use generator, place it
on horizontal plane, stop the engine and check
oil level.
1.Take the oil dipstick and clean the oil.
2.Put dipstick in crankcase but tighten it and
check the oil level.
3.If the oil level is low, please add
recommended oil until the upper level.
If skin contacts to engine
oil too frequently, this might result in
skin cancer. Please clean the oil on your
skin clearly with soap and water
immediately.
For environmental protection, please
dispose the oil properly. We recommended
that put oil in a sealed container and send it
to relevant recycle bin. Do not throw oil
into refuse dump or other place.
Recommended engine oil:
SAE 15W -40
Recommended engine oil standard:
API Standard: SE or higher
Oil capacity: 0.38L
Cover

MAINTENANCE
6
Air cleaner 2-3
空滤器
Dirty air cleaner will affect the air into carburetor. For reducing carburetor faulty, please
maintain the air cleaner regularly (As maintenance table shows) and increase the
maintenance frequency if generator used in dusty area.
Use gasoline or inflammable solvent to clean air cleaner element could
result in fire or explosion. Please clean the element with soap water of
uninflammable solvent.
Start the generator without air cleaner assembly is prohibited, which
will increase engine abrasion.
1) Loosen bolts as marked, remove cover, take the screw ③ remove air cleaner cover④.
2) Check air cleaner element make sure it is complete and clean.
3) If the element is dirty, please clean foam element with detergent, squeeze the water and
then drop a drop of oil, squeeze the element.
4) Assemble the element and air cleaner cover.
Cover

MAINTENANCE
7
Clean fuel strainer 2-4 燃油滤清器的清理
Fuel strainer is designed for preventing dust into
carburetor. If generator isn’t used for a long
time, please clean fuel strainer after empty fuel
tank.
1) Remove the cover (refer to air cleaner
maintenance step 1), empty fuel tank.
2) Squeeze clip④，pull it down, and pull
the fuel hose⑤ out, which connected
to fuel tank.
3) Remove fuel strainer⑥.
4) Clean fuel strainer with gasoline.
5) Dry it and assemble it back.
6) Assemble fuel hose and clip back, open
fuel switch, check if any fuel leakage
on fuel strainer.
7) Assemble cover back.
Spark arrestor 2-5 火花消除器
Gasoline is flammable and
explosive. Smoking, open fire and spark are
prohibited in working area.
After generator is reassembly,
please check if any fuel leakage before
starting the generator and make sure work
area is dry.
Hyperthermal muffler could
result in serious scale. Please maintain
muffler after it cool-down.
In regard to clean spark arrestor, please refer to
maintenance table. Remove spark arrestor after
generator cool-down. If spark arrestor is
damaged, please replace it. Clean the carbon
deposition with wire brush. Assemble spark
arrestor back, tighten it with screw.

MAINTENANCE
8
Spark arrestor 2-6
火花塞
Use incorrect model or caloricity of spark
arrestor could decrease engine performance
and damage it.
If keep engine running, spark plug and muffler
would very hot. Please be careful and don’t
touch them.
1) Remove the cover (refer to air cleaner
maintenance step 1), spark plug sleeve
and cap.
2) Put spark plug kit(provide with generator )
into spark plug, loosen it and take it down.
3) Check spark plug
TORCH-A5RTC
If electrode is damaged, insulator is broken,
please replace it. If spark plug could be
used, then clean the carbon deposition on it
with wire brush.
4) Adjusting the gap of spark plug, you can
bend the electrode slightly to keep the
gap between 0.60-0.80 (mm)。
5) Check the spark plug retainer. When
assemble spark plug, turn it in screw with
hand to avoid improper assembly.
6) After put spark plug on retainer, press it
tightly with spark plug wrench.
The torque of spark plug: 15 N*m
Spark plug should be
assembled properly and tightly, if not, it may
damage the engine.
Please use recommended or the
same standard spark plug. It is prohibited to
use improper spark plug with improper
caloricity.
Spark plug kit
Spark plug cap
0.6-0.8m
m
Side
electrode
Wire brush

MAINTENANCE
9
Valve clearance adjustment 2-7
气门间隙调整
There always be clearance between valve end and its transmitted parts, in case of contraction
which would affect engine work. If the clearance is in excess, it would result in higher
back-pressure and higher noise (abnormal noise from valve) and decrease engine
performance. If the clearance is insufficient, it would make the valve can’t be sealed totally,
which might result in abnormal performance or burning the working surface of relevant parts
of valve.
Generally, after 100h or 1 year using, you have to check the valve clearance and adjust it.
! Disassemble these parts in turn: spark plug cap, spark plug, cylinder head cover and
gasket.
!
! Pull the starter coil to make the piston on the top dead center.
! Measure the clearance of valve.
! If the clearance is beyond the standard, please adjust it.
Cylinder
Gasket
Spark plug cap
Flu gas hose
Cylinder head cover
Feeler gauge

MAINTENANCE
10
Please measure the clearance after engine cool-down.
! Adjust valve clearance.
Adjustment steps: loosen the tighten bolt, turn the adjustment nut to a proper position, and
tighten the adjustment nut.
Valve clearance
Intake
0.03~0.08mm
Exhaust
0.03~0.08mm
Adjust the bolt
Valve clearance
Tighten
Decrease
Loosen
Increase
Excess valve clearance: Both valves open behind, which will decrease the
time of air intake and exhaust, lower the opening height of valves, make engine has
insufficient air intake and can’t exhaust clearly, and result in power decrease. Besides,
it will increase the hit between relevant parts of valve and increase parts abrasion.
Insufficient valve clearance: In engine working, heat will expand parts which push
valves away, and result in incomplete sealing of valve, power decrease and valve surface
burning, even makes valves hit piston.
Valve
Valve tighten
Screwd
river
Wrench

第三部分 故障判定和修理
11
Part 3 Trouble determine and maintenance
3-1 Trouble determine
3-1-1 Start-up difficult
Phenomenon
Causes
Methods of elimination
Cylinder
compression
normal
Spark
plug
norm
al
Fuel
system
abnorm
al
Poor flow
of oil or
oil does
not flow
No fuel oil in the oil tank
Add fuel oil
The vent hole on the oil tank
is blocked
Evacuate the blocking
The main metering jet is
improperly adjusted or
blocked
Re-adjust or clean, blow open
The needle valve hole is
blocked
Dismantle the needle valve for repairing,
cleaning and blowing
The float is stuck or
damaged
Repair the float
oil blow
fluently
Fuel is dirty or deterioration
replace oil
oil mixed with water
replace oil
Too much fuel in the cylinder
Discharge of oil, and dry the spark plug
electrodes
The fuel marking No. is
wrong
use the correct label
Fuel
suppl
y is
norm
al
High
voltage
wire
spark is
normal
The spark
plug
bad
Electrode dirty,
carbon deposition
Clearing away the dirt and carbon deposit
Insulator damage, electrode
severe ablation
replace spark plug
The electrode gap is wrong
Adjust the electrode gap
High
voltage
wire
without
spark
The spark
plug
normal
High voltage wire is
damaged
Replace high voltage wire
Ignition coil is damaged
Replace the motor stator
Magnet demagnetization
replace the fly wheel
The trigger is damaged
replace trigger

第三部分 故障判定和修理
12
The clearance between the
ignition coil and the flywheel
is abnormal
adjust the gap
phenomenon
Causes
Methods of elimination
Cylinder
compression
is bad
Fuel
supply is
normal
ignition
system is
normal
Piston ring wearing limit
Replace with new piston ring
Piston ring break off
replace
Cementation of the piston
ring
Clear away the carbon deposit
Spark plug gasket not
installed or not tightened
Installed gasket and tighten it
The junction surface of the
cylinder body and cylinder
cover
Check the unevenness of the cylinder
cushion, cylinder body, and cylinder cover
junction surface
Tighten the bolts on the cylinder cover as
per the torque required and in a certain
sequence
Air leakage of the valve
Check the valve clearance and the valve
airtightness, and repair it when necessary
l If the generator still cannot be started, please send it to our authorized distributor for maintenance and
repair.
Spark plug inspection
warning
！
l Ensure that there is no overflowing fuel oil outside the
generator, and the sparkplug is not soaked by the fuel oil.
l To prevent fire, do not let the spark get close to the spark plug hole.
l When you test the spark plug, it is forbidden to use wet hands to hold the high voltage
power lines of the spark plug.
! Turn the fuel switch to "OFF" position and put away the carburetor petrol.
! Remove the spark plug cap and spark plugs.
! Pull the starter handle and let out of the unburned gas.
! Install the spark plug cap.
! Turn the switch to "ON" position

第三部分 故障判定和修理
13
! Let spark plugs of the negative electrode (the threaded portion) through the cylinder head connected
to ground, pull the starter handle spark and observed state.
3-1-2 Underpower
Phenomenon
Causes
Methods of elimination
The rotating
speed increases
slowly or even
the rotating
speed drops
down or there is
flameout when
the accelerator
is stepped on
Fuel oil
supply
system
There is air in the oil line or the oil line
is blocked
Drain the air, clearing the oil line
Improper adjustment of the main
metering jet
Re-adjust the main metering jet
The needle valve opening and the main
metering jet in the carburetor are
blocked
Cleaning, blowing open
The switch of oil tank is blocked
Clean and replace the bad parts
There is carbon deposit in the
combustion chamber
Clear away the carbon deposit
The air filter is blocked
Clean the filter element r
Improper
compression
The piston, cylinder and the piston ring
are worn.
Replace the wearing parts
There is air leakage in the junction
surface of the cylinder body and the
cylinder cover
Replace the cylinder cushion
The valve clearance is too big (too
small)
Re-adjust it
The valve is not sealed tightly
Repair it
Inspection of the cylinder pressure.
! Drain the oil in the oil tank.
! Loosen the oil draining bolt of the carburetor and drain the
gasoline.
● Dismantle the spark plug cap and the spark plug and install the
cylinder pressure gauge on the spark plug hole.
! Pull the starter for several times and measure the cylinder pressure.