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EN

20

6.6. Maintenance intervals

before 

each 

start

after 

50

 hours

(Initial)

all

200

 hours

(

6

 month

)

all

400

 hours

(

12

 month

)

all

800

 hours

(

24

 month

)

all

1600

 hours

(

36

 month

)

Fuel

Refuel

Check the fuel tube for leaks

Change the fuel filter

Oil

Check oil level

Check whether any oil is leaking

Change the Oil, Clean the oil filter

Cooling

Clean cooling lamellars

Air

Clean the air filter and the filter housing

 1)

Change the air filter

 1)

Tubes

Replace fuel tube and (including overflow tube of the 
injection nozzle)

Elektrics

only Version
"E"

Check the electric connections whether they are well 
attached and in good state

Check the electric cables for scrub marks or burn 
marks

Check loading state of the battery

Muffler

Check muffler and exhaust manifold for leaks

Check muffler and exhaust manifold for clogs

Check Bosch count on rated power

Screws

Check all screws (including coupled device and the 
screws of the pedestal)

Check all screws which are easily accessible

Refasten cylinder head- and flywheel screws

Governing

Check easy moving of the governing lever

Readjust maximum speed

Cylinder 
head

Check valve clearance

/

/

Check valve sunk deep

Change cylinder head gasket and tunnel gasket of 
push-rod (beside cylinder head gasket)

/

Check compression

Change piston rings

Injection 
pump

Clean injection nozzle

Check injection pressure

Check injection timing

Clean injection pump

Other

Check for abnormal noise during operation

to be done by the user

to be done by a professional

If the surrounding air is not suited due to dust, pollution or heat, an other air filter type must be installed. The standard air filter type (paper filter) is inapprop-

riate! Other air filter types are: oiled filters, cyclone separator filters. In rare or accidental cases of use the air filter must be checked and maintained straight 

after usage - max. operation time between checkings is 25 working hours!

Summary of Contents for ED4-0474-5

Page 1: ...Air cooled single cylinder diesel engine ED4 5 series User and maintenance manual EN L1812 version March 2019 ED4 0474 5...

Page 2: ...en necessary Corrected versions are available on our website Should questions come up about the device or its proper handling please contact us before installing or using it All pictures are used as s...

Page 3: ...5 1 Components 13 5 2 Information about engine performance 13 5 3 Information about starter battery optional 13 5 4 Check ups before every start up 13 5 4 1 Engine oil 13 5 4 2 Fuel 14 5 4 3 Fuel sys...

Page 4: ...ediate medical attention is required Do not attempt to vomit after swallowing Should fuel spill over your skin or clothes immediately rinse with soap and water and change your clothes Always keep the...

Page 5: ...ructions Start the motor and let it get to operating temperature about 5 minutes of running the engine Stop the motor and drain the lubricating oil using the drain plug Fill motor protection oil into...

Page 6: ...223 mm Height H 494 mm Shaft height W 155 mm Baseplate G1 G2 G3 95 mm 272 mm 117 mm Net weight 53 kg Sound level 89 dB A 4m 1 Rated maximal power All given information applies to the engine at 0m sea...

Page 7: ...63 0 57 0 50 3500 0 70 0 70 0 70 0 69 0 66 0 64 0 64 0 64 0 63 0 63 0 61 0 55 0 48 4000 0 66 0 65 0 65 0 64 0 61 0 59 0 59 0 58 0 58 0 58 0 55 0 52 0 46 4500 0 60 0 60 0 60 0 58 0 56 0 54 0 54 0 53 0...

Page 8: ...KW25x88 F2 MOTORWELLE TP26x77 FG2 35 35 86 35 18 8 65 0 2 30 30 65 0 2 14 M8 6H Tiefe 15 1 2 7 165 1 1 4 6 0 8 h 7 0 0 0 4 28 15 8 88 25 0 020 0 041 62 20 15 8 88 25 4 0 0 025 62 28 4 35 77 1 5 26 0...

Page 9: ...ndation must be adequately dimensioned and tor sion resistant It has to be robust enough to absorb vibrations and to maintain alignment The foundation must be chosen so that all mounting feet are laid...

Page 10: ...with the tolerance of the manufacturer Sloppy balancing can lead to vibrations bearing failure or to the shaft breaking Instructions Attach both coupling halves so that a movement is possible with bo...

Page 11: ...are also necessary 4 8 2 Type C for constant speed This speed controller is made for fixed speed and is usually used as a speed controller for generators At delivery the engine is set up as follows Ra...

Page 12: ...en there is too little oil A sudden fall in oil pressure cannot be measured Oil pressure sensor Thread 1 8 Closed 0 9bar Open 1 1bar GND over sensor thread on crankcase cover 12V 12V Lamp 4 9 4 2 Oil...

Page 13: ...car battery to jump start the engine first disconnect the starter battery of the motor If the built in battery is completely drained the car battery could load an extremely large current into the star...

Page 14: ...bottom nut During operation no diesel should escape Check this during a test run Reconnect the injection pipe and switch the governor to full speed The motor should start after a few tries The engine...

Page 15: ...y be repeated for a maximum of 3 times then the electric starter has to be left to cool down for at least 15 minutes Contravening can result in damaging the starter and or motor Never start into the r...

Page 16: ...as thoroughly servicing and maintaining the device significantly prolongs the life span of your device Small mistakes can cause huge problems even break the device entirely Here you will find instruct...

Page 17: ...k cap and take out the fuel filter You can use a needle nose pliers to pull the fuel filter Make sure the gasket and the o ring of the fuel cock are securely set when reassembling After reassembling c...

Page 18: ...ideal speed are important These two characteristics disagree with each other Optimal balance is reached when the speed changing causes a 1 time low oscillation This means set up the speed without loa...

Page 19: ...Measure the battery voltage at the starter M8 screw If there is no voltage the battery pole cable is broken Check the voltage at the faston connector of the starter When the start key is set to posit...

Page 20: ...Screws Check all screws including coupled device and the screws of the pedestal Check all screws which are easily accessible Refasten cylinder head and flywheel screws Governing Check easy moving of...

Page 21: ...logged and the motor is getting too little air and therefor has low performance air filter clogged Clean or replace the air filter Clean air filter housing and intake manifold Wrong fuel Remove all fu...

Page 22: ...ogged Clean and check injection nozzle Injection pump not proper mounted or broken Check injection pump position mounting If this is not the solution change the injection pump Governor blocked Speed a...

Page 23: ...104 126 Crankcase gasket 1 ZSPMOT 00443 ZSPMOT 00444 ZSPMOT 00019 127 Main bearing 1 ZSPMOT 00105 ZSPMOT 00106 ZSPMOT 00107 129 Crankcase cover 1 130 Seal ring front 1 standard part 131 Screw 16 stand...

Page 24: ...0128 222 Plate 1 ZSPMOT00709 223 Nut 2 standard part 224 Washer 2 standard part 230 Valve gasket 2 ZSPMOT 00129 ZSPMOT 00130 ZSPMOT 00131 301 Bonnet assy 1 ZSPMOT 00143 ZSPMOT 00143 ZSPMOT 00145 315 W...

Page 25: ...5 504 503 502 510 507 508 508 511 512 505 401 405 407 407 406 408 602 602 601 601 605 603 413 412 Rotek order nr Nr Description pcs ED4 0219 ED4 0306 ED4 0474 118 Needle bearing camshaft 1 standard pa...

Page 26: ...Washer 4 standard part 1411 Recoil starter assy 1 ZSPMOT 00065 ZSPMOT 00006 ZSPMOT 00017 1412 Screw 4 standard part 1501 Gasket 1 1502 Flywheel cover 1 1503 Rubber element 4 1505 Washer 4 standard pa...

Page 27: ...uded from warranty Rotek can not be hold responsible for costs damage direct or indi rect losses including possible loss of profit loss of contract or loss of production which are a result of using th...

Page 28: ...Rotek Handels GmbH Handelsstrasse 4 2201 Hagenbrunn Austria T 43 2246 20791 0 F 43 2246 20791 50 http www rotek at...

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