Rato R2200 User manual

R2200·R2800·R3000
SERVICE MANUAL
CHONGQING RATO POWER.CO.,LTD

This manual contains information how to maintain and how to do troubleshooting.
Keep this owner’s manual handy, so you can refer to it at any 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 assume any responsibility
Copyright reserved, and no part of this publication may be reproduced
without our 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 reminds you to potential 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 don’t follow
instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be HURT if you don’t follow instructions.
Your generator or other property could be damaged if you don’t follow
instructions.

CONTENTS
CONTENTS
1. PREFACE.................................................................................................................................................. 1
1-1 Component Identification................................................................................................................ 1
1-2 Specifications.................................................................................................................................. 2
1-3 Maintenance Standard..................................................................................................................... 3
1-3-1 R2200................................................................................................................................... 3
1-3-2 R2800................................................................................................................................... 5
1-3-3 R3000................................................................................................................................... 7
2. MAINTENANCE.................................................................................................................................... 10
2-1 Maintenance Schedule................................................................................................................... 10
2-2 Engine Oil ..................................................................................................................................... 11
2-3 Air Cleaner Service....................................................................................................................... 11
2-4 Fuel Sediment Cup Cleaning......................................................................................................... 12
2-5 Spark Plug Service........................................................................................................................ 13
2-6 Valve Clearance Adjustment ......................................................................................................... 14
2-7 Governor ....................................................................................................................................... 17
3. TROUBLESHOOTING .......................................................................................................................... 20
3-1 Troubleshooting............................................................................................................................. 20
3-1-1 Starting Difficult ................................................................................................................ 20
3-1-2 Power Lack ........................................................................................................................ 22
3-1-3 Speed Unstable .................................................................................................................. 23
3-1-4 Unable Igniting .................................................................................................................. 23
3-1-5 Gasoline Engine is Overheat.............................................................................................. 24
3-1-6 Abnormal Sound ................................................................................................................ 24
3-1-7 Unable Generating Electricity............................................................................................ 25
3-1-8 Voltage Too Low................................................................................................................ 25
3-1-9 No AC Output Voltage....................................................................................................... 26
3-1-10 No DC Output Voltage..................................................................................................... 26
3-1-11 Stator Iron Core Overheat................................................................................................ 26
3-1-12 Stator Winding Overheat.................................................................................................. 27
3-1-13 Rotor Winding Overheat.................................................................................................. 27
3-2 Safety Precautions......................................................................................................................... 28
3-2-1 Safety................................................................................................................................. 28

CONTENTS
3-2-2 Special Tools...................................................................................................................... 30
3-3 Dismounting Chart........................................................................................................................ 31
3-4 Engines.......................................................................................................................................... 32
3-4-1 Recoil Starter ..................................................................................................................... 32
3-4-2 Flywheel............................................................................................................................. 35
3-4-3 Air Cleaner......................................................................................................................... 38
3-4-4 Carburetor.......................................................................................................................... 38
3-4-5 Cylinder Head/Valve.......................................................................................................... 44
3-4-6 Crankshaft/Piston............................................................................................................... 51
3-5 Generators..................................................................................................................................... 58
3-5-1 Fuel Tank ........................................................................................................................... 58
3-5-2 Muffler............................................................................................................................... 60
3-5-3 Generators.......................................................................................................................... 62
3-5-4 Control Panel ..................................................................................................................... 70
4. WIRING DIAGRAM.............................................................................................................................. 73
4-1 Electric Diagram ........................................................................................................................... 73
APPENDIX................................................................................................................................................. 75

1. PREFACE
1
1. PREFACE
1-1 Component Identification
1)
FUEL METER
FUEL TANK CAP
SPARK PLUG CAP
MUFFLER
ENGINE SWITCH
RECOIL STARTER GRIP
CHOCKER LEVER
AC CIRCUIT BREAKER
DC PROTECTOR
FUEL VALVE
GROUND TERMINAL
AC RECEPTACLES
AIR CLEANER
DC RECEPTACLES
VOLTMETER

1. PREFACE
2
1-2 Specifications
Item
R2200
R2800
R3000
Engine
Engine Style
R200
R200
R210
Engine Type
Single Cylinder, 4-Stroke, Forced Air Cooling, OHV
Displacement (cc)
196
196
212
Igniting System
Transistorized Magneto
Fuel Volume (L)
15
15
15
Fuel Consumption(L/hr)
1.25
1.35
1.5
Continuing Time (hr)
12
11
10
Oil Capacity (L)
0.6
0.6
0.6
Generator
Charging Voltage (DC) (V)
12
Charging Current (DC) (A)
8.3
Rated Frequency (Hz)
50
Rated Voltage (V)
220/230
Rated Output Power (kW)
2
2.5
2.7
Maximum Output Power (kW)
2.2
2.8
3
Generator
Set
Length (mm)
593
593
593
Width (mm)
440
440
440
Height (mm)
432
432
432
Net Weight (kg)
46
49.5
50
Phase
Single
General
Purpose
Accessory
Large Air Cleaner
●
●
●
Large Muffler
●
●
●
Large Fuel Tank
●
●
●
Fuel Gauge
●
●
●
Voltmeter
●
●
●
Automatic Voltage Regulator
●
●
●
Oil Alert System
●
●
●
Non-fuse Breaker
●
●
●
Electric Starting Accessory
-
-
-
Remarks: ● means available, - means unavailable

1. PREFACE
3
1-3 Maintenance Standard
1-3-1 R2200
Engine
Parts
Item
Standard
Service Limit
Engine
Maximum Speed (No load)
Cylinder Compression
3150-3180rpm
>1.17Mpa/1400rpm
--
--
Cylinder
Head
Sleeve I.D
68.0mm
68.165mm
Cylinder
Head
Warpage
--
0.10mm
Piston
Skirt O.D.
Piston-to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D
Piston Pin-to-Piston Pin Bore
Clearance
67.985mm
0.015-0.05mm
18 .002mm
18.0mm
0.002-0.014mm
67.845mm
0.12mm
18.048mm
17.954mm
0.06mm
Piston
Rings
Ring Side Clearance：
Second
Ring Enc Gap:
Second
Ring Width：
Second
0.015-0.045mm
0.2-0.4mm
0.15-0.35mm
1.5mm
2.5mm
0.15mm
--
1.0mm
1.0mm
1.37mm
2.37mm
Connecting
Rod
Small End I.D
Big End I.D
Big Oil Clearance
Big End Side Clearance
18.002mm
30.02mm
0.040-0.063mm
0.1-0.7mm
18.07mm
30.066mm
0.12mm
1.1mm
Crankshaft
Crankshaft Pin O.D
29.98mm
29.92mm

1. PREFACE
4
Valve
Valve Clearance
Stem O.D
Guide I.D
Stem Clearance
Seat Width
Spring Free Length
IN
EX
IN
EX
IN/EX
IN
EX
0.15±0.02mm
0.20±0.02mm
5.48mm
5.44mm
5.50mm
0.02-0.044mm
0.06-0.087mm
0.8mm
34mm
--
--
5.318mm
5.275mm
5.572mm
0.1mm
0.12mm
2.0mm
32.5mm
Camshaft
Cam Height
Cam Heignt
Journal O.D
IN
EX
27.7mm
27.75mm
13.984mm
27.45mm
27.50mm
13.916mm
Crankcase
Cover
Camshaft Bracket I.D
14.0mm
14.048mm
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#68
13.7mm±1.5
3 turns 2-1/8 turns
--
--
--
Spark Plug
Gap
0.7-0.8mm
--
Spark Plug
Cap
Resistance
5kΩ
--
Ignition
Coil
Resistance
Air Gap
Primary Coil
Secondary Coil
（at flywheel）
0.8-1.0Ω
5.9-7.1 kΩ
0.4-0.6mm
--
--
--

1. PREFACE
5
Generator
Parts
Item
Standard
Service Limit
Stator Winding
Resistance
Stator Winding
2.2±5%Ω at 20℃
--
Stator Auxiliary
Winding
3.2±5%Ω at 20℃
--
Rotor Excitation
Winding
Resistance
Excitation
Winding
45.6±5%Ω at 20℃
--
Carbon Brush
Carbon Brush Length
10mm
6mm
1-3-2 R2800
Engine
Parts
Item
Standard
Service limit
Engine
Maximum Speed (No Load)
Cylinder Compression
3150~3180rpm
>1.17Mpa/1400rpm
--
--
Cylinder
Head
Sleeve I.D
68.0mm
68.165mm
Cylinder
Head
Warpage
--
0.10mm
Piston
Skirt O.D.
Piston-to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D
Piston Pin-to-Piston Pin Bore
Clearance
67.985mm
0.015-0.05mm
18 .002mm
18.0mm
0.002-0.014mm
67.845mm
0.12mm
18.048mm
17.954mm
0.06mm
Piston
Rings
Ring Side Clearance：
Second
Ring Enc Gap:
Second
Ring Width
Second
0.015-0.045mm
0.2-0.4mm
0.15-0.35mm
1.5mm
2.5mm
0.15mm
--
1.0mm
1.0mm
1.37mm
2.37mm

1. PREFACE
6
Connecting
Rod
Small End I.D
Big End I.D
Big Oil Clearance
Big End Side Clearance
18.002mm
30.02mm
0.040-0.063mm
0.1-0.7mm
18.07mm
30.066mm
0.12mm
1.1mm
Crankshaft
Crankshaft pin O.D
29.98mm
29.92mm
Valve
Valve Clearance
Stem O.D
Guide I.D
Stem Clearance
Seat Width
Spring Free Length
IN
EX
IN
EX
IN/EX
IN
EX
0.15±0.02mm
0.20±0.02mm
5.48mm
5.44mm
5.50mm
0.02-0.044mm
0.06-0.087mm
0.8mm
34mm
--
--
5.318mm
5.275mm
5.572mm
0.1mm
0.12mm
2.0mm
32.5mm
Camshaft
Cam Height
Cam Heignt
Journal O.D
IN
EX
27.7mm
27.75mm
13.984mm
27.45mm
27.50mm
13.916mm
Crankcase
Cover
Camshaft Bracket I.D
14.0mm
14.048mm
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#68
13.7mm±1.5
3 turns 2-1/8 turns
--
--
--
Spark Plug
Gap
0.7-0.8mm
--
Spark Plug
Cap
Resistance
5kΩ
--
Ignition
Coil
Resistance
Air gap
Primary Coil
Secondary Coil
（at flywheel）
0.8-1.0Ω
5.9-7.1 kΩ
0.4-0.6mm
--
--
--

1. PREFACE
7
Generator
1-3-3 R3000
Engine
Parts
Item
Standard
Service limit
Stator Winding
Resistance
Stator Winding
1.8±5%Ω at 20℃
--
Stator auxiliary
Winding
3.5±5%Ω at 20℃
--
Rotor Excitation
Winding
Resistance
Excitation
Winding
51.3±5%Ω at 20℃
--
Carbon Brush
Carbon Brush Length
10mm
6mm
Parts
Item
Standard
Service
limit
Engine
Maximum Speed (No Load)
Cylinder Compression
3150~3180rpm
>1.17kpa/1400rpm
--
--
Cylinder
head
Sleeve I.D
69.985mm
70.025mm
Cylinder
head
Warpage
--
0.10mm
Piston
Skirt O.D.
Piston-to-Cylinder Clearance
Piston Pin Bore I.D
Piston Pin O.D
Piston Pin-to-Piston Pin Bore
Clearance
69.985mm
0.015-0.05mm
18.002mm
18.0mm
0.002-0.014mm
69.975mm
0.12mm
18.048mm
17.954mm
0.06mm

1. PREFACE
8
Piston
Rings
Ring Side Clearance：
Second
Ring Enc Gap:
Second
Ring Width:
Second
0.015-0.045mm
0.2-0.4mm
0.15-0.35mm
1.5mm
2.5mm
0.15mm
--
1.0mm
1.0mm
1.37mm
2.37mm
Connecting
Rod
Small End I.D
Big End I.D
Big Oil Clearance
Big End Side Clearance
18.006mm
30.215mm
0.04-0.063mm
0.1-0.7mm
18.017mm
30.225mm
0.12mm
1.1mm
Crankshaft
Crankshaft Pin O.D
30.190mm
30.175mm
Valve
Valve Clearance
Stem O.D
Guide I.D
Stem Clearance
Seat Width
Spring Free Length
IN
EX
IN
EX
IN/EX
IN
EX
0.15±0.02mm
0.20±0.02mm
5.48mm
5.44mm
5.50mm
0.02-0.044mm
0.06-0.087mm
0.8mm
34.0mm
--
--
5.318mm
5.275mm
5.572mm
0.10mm
0.12mm
2.0mm
32.5mm
Camshaft
Cam Height
Cam Height
Journal O.D
IN
EX
27.7mm
27.75mm
13.984mm
27.45mm
27.50mm
13.916mm
Crankcase
cover
Camshaft Bracket I.D
14.0mm
14.048mm
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#72
13.7mm±1.5
3 turns 2-1/8 turns
--
--
--
Spark plug
Gap
0.7-0.8mm
--

1. PREFACE
9
Generator
Parts
Item
Standard
Service limit
Stator Winding
Resistance
Stator Winding
1.4±5%Ω at 20℃
--
Stator Auxiliary
Winding
3.9±5%Ω at 20℃
--
Rotor Excitation
Winding
Resistance
Excitation Winding
59.0±5%Ω at 20℃
--
Carbon Brush
Carbon Brush Length
10mm
6mm
Spark Plug
Cap
Resistance
5kΩ
--
Ignition
Coil
Resistance
Air gap
Primary Coil
Secondary Coil
（at flywheel）
0.8-1.0Ω
5.9-7.1kΩ
0.4-0.6mm
--
--
--

2. MAINTENANCE
10
2. MAINTENANCE
2-1 Maintenance Schedule
Good maintenance is essential for safe, economical, and trouble-free operation. It will also
help reduce air pollution.
Exhaust gas contains poisonous carbon monoxide. Shut off the engine
before performing any maintenance. If the engine must be run, make
sure the area is well ventilated.
Periodic maintenance and adjustment is necessary to keep the generator in good operating
condition. Perform the service and inspection at the intervals 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 level
○
Change
○
○
Air Cleaner
Check
○
Clean
○(1)
Sediment Cup
Clean
○
Electrolyte Level
Check
○
Spark Plug
Clean
○
renew
Valve Clearance
Check-Adjus
t
○(2)
Cylinder Head
Clean
Every 300 hours (2)
Fuel Tank And
Strainer
Clean
Every 2 years (2
Fuel Line
Replace
Every 2 years (2)
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by an authorized generator dealer.
(3) When more often use, only servicing according to above correct intervals can insure the
generator set long-term use.

3. TROUBLESHOOTING
11
2-2 Engine Oil
Draining can be performed rapidly and
completely while the engine is still
warm.
1) Remove the oil dipstick and drain
plug to drain the oil.
2) Reinstall the drain plug, then tighten
the plug securely.
3) Refill oil and check the oil level.
Oil capacity：
R200：0.6 L
R210：0.6 L
Using engine oil may cause skin cancer if repeatedly let it contact with
the skin for prolonged periods. Although this is unlikely that you hardly
used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as 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 station or recycling center for
reclamation. Do not throw it in the dust heap or pour it on the ground.
2-3 Air Cleaner Service
A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction,
service the air cleaner regularly. Service more frequently when operating the generator in
extremely dusty areas.
Using gasoline or flammable solvent to clean the filter element can cause a
fire or explosion. Only use soapy water or nonflammable solvent.
Never run the generator without the air cleaner. Rapid engine wear will
result.
1) Remove the air cleaner clip or butterfly nut and open the air cover. Check the air cleaner
DRAIN PLUG
LOWER LEVEL
UPPER LEVEL
OIL DIPSTICK

2. MAINTENANCE
12
element for complete and clean.
2) If the air cleaner element is dirty, please clean the air cleaner element:
Wash the air cleaner element in a solution of household detergent and warm water, then
rinse thoroughly or wash in nonflammable or high flash point 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 sediment cup, o-ring and strainer.
2) Clean the sediment cup, and o-ring, and strainer
in nonflammable or high flash point solvent.
3) Reinstall o-ring, and strainer and screw down
the sediment cup.
4) Turn the fuel valve to the ON and check for
leaks.
ELEMENT
AIR CLEANER COVER
CLIP
AIR CLEANER
STRAINE
R
0-RING
SEDIMENT
CUP
FUEL VALVE
SEDIMENT
CUP

3. TROUBLESHOOTING
13
2-5 Spark Plug Service
Recommended spark plugs: F7RTC or other equivalents
1) Remove the spark plug cap.
2) Clean any dirt around the spark plug base.
3) Use the plug wrench to remove the spark plug.
4) Visually inspect the spark plug if the insulator is cracked, if
cracked, replace with a new spark plug.
5) Measure the plug gap with a feeler gauge. Correct as
necessary by carefully bending the side electrode.
6) The gap should be: 0.70-0.80 mm
7) Check that the spark plug washer is in good condition.
8) Install the spark plug on and screw down it with
plug wrench, compress the plug washer. Cover the
spark plug cap on.
To avoid cross-threading, first, screw in spark
plug by hand, then tighten with a spark plug
wrench to compress the gasket.
If a new spark plug is used, more twist 1/2 turns
after compressing the gasket
If reinstalling the used spark plug, just more twist 1/8-1/4 turns.
Spark plug torque value：22±2N·m.
SPARK PLUG CAP
PLUG WRENCH

2. MAINTENANCE
14
2-6 Valve Clearance Adjustment
Keep the clearance between engine valve rod end and driving parts for avoiding heat
expanding and cold shrinking to effect engine performance. If the valve is too big, it can
result in exhausting unsmooth, effecting engine performance and increasing engine
noise(valve abnormal), if the valve 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
1000h, check and adjust the valve.
Dismount the cylinder head cover, gasket, spark plug, and spark plug cap in order.
Light pull the recoil starter rope until the piston compressed to dead point of the stroke.
Measure the valve clearance
Adjust if the valve clearance is out of the service limit.
FEELER
SPARK
PLUG
SPRAK
PLUG CAP
BREATHE TUBE
CYLINDER
HEAD COVER
CYLINDER
HEAD COVER
GASKET

3. TROUBLESHOOTING
15
Measure the valve clearance in the cold the engine state.
SPARK PLUG
SPARK PLUG CAP
VALVE ADJUSTING NUT
VALVE LOCKED NUT