Rotek Ed4-0418-5 Operating instructions

Air-cooled single cylinder diesel engine

ED4-5 series

User and maintenance manual

EN L1812 version October 2020

ED4-0418-5

ED4-0474-5

EN2

Introduction

Dear Customer,

Please take time to read this manual carefully and thoroughly. It is

important to know about the instructions for correct installation of

your device, its components as well as proper and safe handling,

before putting it into operation.

This manual should be kept close to your device, to use it as a re-

ference if necessary and, if the device is sold on, to hand it on to

subsequent owners.

Operation and maintenance of this device involves dangers, which

are explained via symbols in this manual. The following symbols are

used in this text. Please read these instructions very carefully.

Security precaution

Dangers are marked by this symbol.

General advice

User advice is marked by this symbol.

We worked on the contents of this handbook to make sure your

device ﬁts the described device. However, differences cannot be

ruled out so that we do not guarantee entire congruence of device

and manual. The information in this handbook is constantly revie-

wed and updated when 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 symbols and may not look exactly the same

as your device. Technical changes, errors and misprints reserved.

Damage done to the device due to ignorance of the instructions in this

manual will not be covered by its warranty. We assume no liability over

damage caused by wrong handling.

This manual may not be reproduced in any form, neither partially nor

completely, using any electronic or mechanical means whatsoever,

without permission in written form by Rotek. Ignoring this is a viola-

tion of copyright laws and will be prosecuted. All rights, particularly

the right of reproduction, reserved.

Inspection of delivered products

After receiving the device, it is recommended to check whether the

goods correspond to the components mentioned in the order, waybill or

delivery note. Remove the packaging carefully to make sure no dama-

ge is done to the device. Furthermore, make sure to check the device

for any transport damage. If the delivery is incomplete or ﬂawed, do not

hesitate to contact your retailer.

3EN

Index

1. Safety Instructions 4

1.1. Equipment 4

1.2. Risks from noise development 4

1.3. Risks posed by moving parts 4

1.4. Risks posed by gas emissions 4

1.5. Risks posed by fuel 4

1.6. Risks posed by high temperatures 4

1.7. Risks posed by exhaust gas 4

1.8. Maintenance intervals 4

1.9. Disposal of toxic waste 4

2. Transportation and storage 5

2.1 Transportation for assembly 5

2.2. Storage as newdrive 5

2.3. Prolonged downtime/Storage 5

2.3.1. From 30 days to 6 months 5

2.3.2. Longer than 6 months 5

3. Speciﬁcation 6

3.1. Technical data 6

3.2. Derating chart for operation under different conditions 7

3.3. Performance Curve 7

3.4. Flange and shaft dimensions 8

4. Installation 9

4.1. Preparation 9

4.2. State of installation site 9

4.2.1. In- and outtake Ventilation 9

4.3. Motor mounting 9

4.4. Exhaust gas system 9

4.4.1. Mounting the mufﬂer 9

4.4.2. Information about other exhaust gas systems 9

4.5. Fuel System 9

4.6. Coupling 10

4.6.1. Maximum axial and radial load 10

4.6.2. Balancing 10

4.6.3. Direct coupling 10

4.6.4. Operating with a pulley 10

4.7. Concluding mechanical installation instructions 11

4.8. Speed controller 11

4.8.1. Type “A” – for variable speed 11

4.8.2. Type “C” – for constant speed 11

4.9. Electrical installation 11

4.9.1. Electrical connection (chords) 11

4.9.2. Starter battery 11

4.9.3. Circuit diagram of starter-dynamo 12

4.9.4. Oil-pressure sensor 12

4.9.4.1. Schematics of oil-pressure sensor-lamp 12

4.9.4.2. Oil-pressure sensor with magnetic valve 12

5. Usage 13

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 system ventilation 14

5.4.4. Other check-ups 14

5.5. Start-up 14

5.5.1 Special information about initial start-up 14

5.5.2. Starting the engine 14

5.5.2.1. Hand start (all versions) 15

5.5.2.2. Electric start (only motor version “E”) 15

5.5.3 Stopping the engine 15

6. Maintenance 16

6.1. Instructions about maintenance 16

6.2. Precautions 16

6.3. Starter battery 16

6.4. Cleaning the crankcase 16

6.5 Upkeep 16

6.5.1 Changing the engine oil 16

6.5.2 Cleaning and exchanging the air ﬁlter 17

6.5.3. Fuel Supply 17

6.5.3.1. Changing the fuel ﬁlter 17

6.5.3.2. Ventilating the injection system 17

6.5.3.3. Examining, cleaning the injection nozzle 17

6.5.4. Proper timing/adjusting the valves 18

6.5.5. Governing behaviour 18

6.5.6. Mufﬂer and colours of exhaust fumes 18

6.5.7. Other 18

6.5.8. General tightening torque 19

6.5.9. Engine torque and measured values 19

6.5.10. Solving electric issues 19

6.5.10.1 Starter malfunction 19

6.5.10.2. Battery does not charge 19

6.6. Maintenance intervals 20

6.7. Possible errors and their solutions 21

6.7.1. Engine does not start 21

6.7.2. Abnormal colour of exhaust gas 21

6.7.3. Low engine performance 22

6.7.4. Rough engine run 22

6.7.5. Engine overheating 22

6.7.6. Engine suddenly stopps 22

6.7.7. Abnormal running noise 22

6.8. List of parts/exploded assembly drawing 23

6.8.1. Crankcase 23

6.8.2. Cylinder head 24

6.8.3. Shafts 25

6.8.4. Fuel 25

6.8.5. Flywheel 26

6.8.6. Electrics 26

7. Appendix 27

7.1. Warranty conditions 27

7.2. Declaration of conformity 27

EN4

1. Safety Instructions

The guidelines in this manual have to be added to the valid local legal

requirements and technical standards. They do not replace any plant

standards or additional (also legal) regulations, which were adopted as

safety measures.

1.1. Equipment

Always wear tight-ﬁtting clothes during maintenance and make sure

their ends are closed with elastic bands.

When working on the device always wear safety shoes, gloves, a hel-

met and hearing protection in accordance with the applicable regulati-

ons to avoid accidents at work.

Make sure that a ﬁrst aid kit and a working ﬁre extinguisher are close

by before starting to work on the device.

1.2. Risks from noise development

The operating noise of the motor can cause damage to your hearing.

Do not linger around a running engine and always wear ear protection.

The engine must never be operated without a mufﬂer/exhaust system.

Make sure that all legal regulations relating to the local noise level are

obeyed before starting up the device.

1.3. Risks posed by moving parts

Never perform work on moving parts.

The engine must never be put into operation when the protective co-

vers are open or loose.

Never approach the machine in operation wearing ties, scarves, bra-

celets etc. These could get caught on moving parts and cause serious

injuries.

1.4. Risks posed by gas emissions

To avoid the risks posed by dangerous gases:

Make sure that the location of the unit is well ventilated (in emergenci-

es using a forced ventilation system). Avoid inhaling dangerous gases

(by wearing breathing protection). Verify that there are no hazardous

gases present at the installation site.

1.5. Risks posed by fuel

It is necessary to shut down the engine during refuelling. Let the device

cool down for at least 5 minutes before refuelling.

Do not smoke in close proximity to the device, keep it away from ﬁre

and ignition sources. Diesel is ﬂammable and poisonous! Moreover,

lead acid batteries develop explosive gases when charging and di-

scharging.

Never spill fuel onto the engine or the mufﬂer when refuelling.

Never put the engine in operation when there are apparent leaks in the

lines supplying oil or diesel.

Never spill diesel or oil. Do not inhale fumes, do not swallow and avoid

skin contact. After swallowing any amount of diesel or oil, immediate

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 ﬂoor on the site of the device clean – spilt oil or diesel

should be removed as soon as possible.

When using an additional external tank make sure it is installed and

connected in accordance with the valid standards and regulations.

1.6. Risks posed by high temperatures

The engine must only be used in places where no untrained people,

passers-by or children are at risk.

Children are not allowed to stay in close proximity to the engine.

Never store combustible or ﬂammable substances (diesel, oil, paper,

woodchips etc.) in the vicinity of the device. Note that diesel, oil, engine

and exhaust pipe are hot after operation – avoid skin contact – there is

a risk of burning or scalding.

Always keep a minimum safety distance of 1 meter to walls or similar

structures to avoid overheating the engine.

Never cover the engine during operation – there is a risk of overhe-

ating!

1.7. Risks posed by exhaust gas

The engine must not be used in poorly ventilated areas (such as en-

closed spaces, tunnels, containers), unless those installations were

expressly approved by ROTEK.

Exhaust gases are toxic. They can cause loss of consciousness or even

death. When using the device in closed or partially closed spaces,

make sure that the exhaust gases are lead outside by means of a leak-

free line. Regard the maximum permitted exhaust back pressure in or-

der to prevent the motor from overheating. Make sure that the exhaust

adaption (mufﬂer, pipe) is free from combustible materials and that the

escaping gases do not pose a threat. Observe the pertinent standards

and regulations at all times.

1.8. Maintenance intervals

If the mandatory maintenance intervals were not complied with it is

forbidden to start the engine – vapours of unspent fuel (developed by

incorrectly adjusted valves for example) are explosive!

Never start the engine without an air ﬁlter – the engine could be da-

maged.

Only original spare parts may be used in the course of maintenance.

The only exception are standardised parts (such as ball bearing,

screws, nuts, etc.) which match the speciﬁcs of the original part.

1.9. Disposal of toxic waste

The incorrect disposal of toxic waste poses a threat to the environment

and is prohibited by law. Hazardous wastes include: lubricants, fuels,

ﬁlters and batteries.

Collect poisonous liquids in suitable sealed containers.

5EN

2. Transportation and storage

2.1 Transportation for assembly

Incorrect handling can cause serious damage to the device.

You can pick up the device using the motor base plate (using noo-

ses) and move it.

Pay attention that the lifting point is not located in the centre of the

device.

Persons have to keep a safety distance during lifting operation.

Make sure that the lifting gear and the supporting construction is sui-

ted to carry the weight of the device.

Please also consider following points:

• All used lifting means must be in good order.

• The loading capacity must be suited to the weight of the load.

• Wrong movements can cause personal injury or serious damage to the device.

• Make sure nobody is in the vicinity of the hanging motor.

• When picking up the device vertically it is important to position the lifting point

exactly into the focal point. Additionally, guide rope should be used.

• It is forbidden to pick up the device outside in unsafe weather conditions (i.e.

strong wind, storms).

• Always put down the engine carefully onto an even surface that suits the

weight of the device.

2.2. Storage as newdrive

• If the device is not used instantly, the engine has to be stored at a safe, clean,

dry and vibration free location (only if no fuel and/or oil were filled into the

device).

• Should there be a starter battery included in your order (which is not the de-

fault), please consider following points:

Make sure to disconnect the minus (-) pole ﬁrst and the plus (+) pole

second. During assembly the plus (+) pole is connected ﬁrst, the minus

(-) pole second.

When storing batteries without battery loader make sure the tempe-

rature of your storage room is at 20°c. Do not forget to charge the

battery every 3 months. The self-drain can signiﬁcantly shorten your

batteries lifespan.

• The ball bearing does not have to be cared for when the device is in storage.

2.3. Prolonged downtime/Storage

2.3.1. From 30 days to 6 months

If a previously used device is to be stored for longer than 30 days

follow these instructions:

• 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 the device and let it run for 5 minutes.

• Drain the motor protection oil when the engine is still warm and replace it with

normal motor oil.

• Drain the fuel, clean the diesel tank if necessary, and maybe change the filter.

• Clean the device and conserve it with oil mist.

• Close up all suction intakes with masking tape (recoil starter, air filter)

• Remove the injection nozzle, add a few splashes of motor oil into the cylinder

and turn the motor with your hand to distribute the oil. Reinstall the injection

nozzle.

• Add splashes of oil into intake- und exhaust-manifold, Rocker-arm, valves,

valve-rod etc. and protect non painted parts with fat.

• Disconnect the battery and remove it from the device and, if available, connect

it to a battery loader.

Consider during disassembly the minus (-) pole is disconnected ﬁrst

and the plus (+) pole second. During assembly the plus (+) pole is

connected ﬁrst, the minus (-) pole second.

When storing batteries without battery loader make sure the tempe-

rature of your storage room is at 20°c. Do not forget to charge the

battery every 3 months. The self-drain can signiﬁcantly shorten your

batteries lifespan.

• Wrap the engine in plastic foil.

• Only store at dry locations.

• Preparation for reactivation:

• Remove all cladding and protective foil.

• Put the engine in operation following the instructions for first start-up.

2.3.2. Longer than 6 months

Additionally to the instructions in 2.3.1.:

• lube-system, fuel-system, and all moving parts are to be protected with slus-

hing oil SAE 30 (ex. ESSO RUST, AGIP RUSTIA). Turn the motor to distribute the

oil and drain the excess.

• Every so often turn the motor by hand.

Preparations for reactivation:

• Remove the intake-manifold, pour motor oil close to the valves, turn the motor

shaft a few times and change the oil without starting up the engine.

• Check the valve-clearance and oil- and air filtration.

• Do the earlier service instructed by the motor operation hour maintenance

chart (i.e. after 120 operation hours the 200 hour service should be executed).

EN6

3. Speciﬁcation

3.1. Technical data

BB3

B1 B2

T1 T2

Model ED4-0418-5 ED4-0474-5

Design 1-cylinder four-cycle engine with direct injection

Displacement 418 ccm 474 ccm

Bore x Stroke 86 x 72 mm 88 x 78 mm

Compression 19 : 1

Maximum power 1) 6,3 kW @ 3.600 min-1 7,2 kW @ 3.600 min-1

Maximum torque 1) 18,8 Nm @ 2.800 min-1 23,4 Nm @ 2.700 min-1

Idle speed 1.100 min-1 (±100)

Type of output using crankshaft

Rotation direction anticlockwise (see schematic picture)

Fuel 2) Diesel (Premium Diesel)

Tank capacity 5,5 l

Fuel consumption

283 g/kWh @ 3.600 min-1

(2,1 l/h under full load)

287 g/kWh @ 3.600 min-1

(2,4 l/h under full load)

Speed regulation integrated centrifugal governor acting directly onto the injection pump

Cooling system Forced air cooling system using a fan wheel and air vents

Lubrication system combined splash- and pump-forced lubrication system

Oil volume ca. 1,65 l (allways determine correct oil level by measuring with oil-dip-stick)

Max. allowed inlet underpressure 1,2 kPa @ maximum power, 3.600 min-1

Max. allowed outlet backpressure 2,0 kPa @ maximum power, 3.600 min-1

Fullﬁll emission class EU Stage-V, Category: NRE-v-1 (non road engine)

Start system combined recoil- and electric starter

Electric starter 12 V / 0,8 kW

Dynamo integrated parmanent magnetic generator behind ﬂywheel

12 V / max. 8A

Battery 12 V / min. 20 Ah, recommended 36 Ah (not included in delivery)

Net weight 52 kg 53 kg

Sound level 88 dB(A) @ 4m 89 dB(A) @ 4m

Model ED4-04xx-5

Width B B1 B2 B3 441 mm 218 mm 223 mm 29 mm

Deep T T1 T2 328 mm 105 mm 223 mm

Height H 494 mm

Shaft height W 155 mm

Baseplate G1 G2 G3 95 mm 272 mm 117 mm

1) Rated / maximal power

All given information applies to the engine at 0m sea level and a surrounding temperature of +20c°. The total capacity of the device must be reduced because of cooling issues when using the device

in higher temperatures or in greater heights (see 3.2. Derating chart).

2) Fuel

You cannot use fuels other than regular diesel such as biodiesel, plant oil or heating oil without changing the engine! Never use fuels other than standard diesel without clearing with ROTEK

ﬁrst. Your engine could be damaged! We would like to point out that in Western Europe it is mandatory to mix biodiesel into available diesel fuels. Because of this mix, the “normal” diesel

only keeps about 6 months in storage! After about 6 months microbial growth increases considerably in the diesel.These organisms further on corrosion in tank and motor, and they produce

biomass which clogs the injection nozzle, the injection pump and damages the motor over time. This is a particular problem if the engine is only used rarely. Pay attention to the date you last

refuelled and drain the tank in appropriate time intervals. Also available are types of so called "premium diesel" (SHELL© V-Power, ARAL© Ultimate, OMV© MaxxMotion, ...) which either

do not contain biodiesel at all (ex. BP© Ultimate) or contain special biodiesel made from hydrated plant oils (ex. OMV© Maxxmotion) and can therefor be stored for 2 years without worries.

7EN

3.2. Derating chart for operation under different conditions

Operate at sea-

height (m)

Ambient temperature (°C)

0 5 10 15 20 25 30 35 40 45 50 55 60

0 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.94 0.85 0.76 0.67

500 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.91 0.82 0.73 0.64

1000 0.96 0.95 0.93 0.93 0.92 0.91 0.91 0.91 0.88 0.84 0.76 0.67 0.59

1500 0.90 0.89 0.89 0.88 0.87 0.87 0.87 0.86 0.84 0.80 0.73 0.65 0.57

2000 0.84 0.84 0.83 0.82 0.82 0.80 0.80 0.80 0.79 0.76 0.68 0.62 0.55

2500 0.79 0.78 0.78 0.77 0.76 0.75 0.75 0.74 0.74 0.71 0.66 0.60 0.52

3000 0.74 0.73 0.73 0.73 0.71 0.70 0.69 0.69 0.68 0.68 0.63 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 0.53 0.52 0.50 0.49 0.44

5000 0.55 0.55 0.55 0.53 0.52 0.50 0.50 0.49 0.49 0.47 0.45 0.44 0.40

Multiply the given factor with the relative nominal capacity – ex. ED4-0474 engine: operation with 3.600 min-1 in 2.000m operational height, at +40 C° ambient tem-

perature. The continuous rating must be around 5,69kW (7,20 kW * 0,79 factor = 5,69 kW).

3.3. Performance Curve

Drehmoment in Nm | Torque in Nm

ED4-0418-5

ED4-0474-5

Leistung in kW | Power in kW

ED4-0418-5

ED4-0474-5

Einspritzmenge je Hub in mm³ |

Injection quantity each stroke in mm³

ED4-0418-5

ED4-0474-5

P [kW ]

Me [Nm ]

Q [mm³]

min-1

2.400 2.600 2.800 3.000 3.200 3.400 3.600

min-1

2.400 2.600 2.800 3.000 3.200 3.400 3.600

EN8

3.4. Flange and shaft dimensions

ED4-0418-5 / ED4-0474-5

WELLE (SHAFT) KW1“x88 (F1) WELLE (SHAFT) KW25x88 (F2)

3586

18,8

±0,2

30°

±0,2

14-M8-6H

Tiefe (Deep) 15

Ø127

Ø165,1

Ø146,08h7

0,04

28 15,8

Ø25

- 0,020

0,041

20 15,8

Ø25.4

0,025

WELLE (SHAFT) TP26x77 (FG2)

MOTORFLANSCH (FLANGE):

1:5

Ø26

0,025

WELLE (SHAFT) TP1“x105 (FG1)

5/16“-24UNF

48,7 31,3

105,3

3:16

Ø25,4 0

0,025

WELLE (SHAFT) G3/4“x61 (P4)

22,5

3/4“-16UNF

Ø19,05 0

0,025

M10x1.25

7/16“-20UNF

9EN

4. Installation

The installation has to be done by professionals. Poor installation can

damage the device (ex. bearing failure because of inadequate paralle-

lism). The professionals present are responsible for the observance of

appropriate regulations and standards.

All operations on the device including maintenance and start-up must

be done on a resting engine.

4.1. Preparation

• All devices are packed in a different way, depending on sales channel and

method of transportation. Remove all packaging carefully, to avoid damaging

the device.

Before installation, make sure that any protective coats, covers for

transport (ex. shaft cover) or other protective means were removed.

4.2. State of installation site

• The installation site must be well ventilated with dry, clean, conditioned or

ambient air, because the motor radiates heat that would raise the room tem-

perature so high, it would have negative effects on the motor capacity.

• The installation site should be chosen so that normal maintenance is easily

possible.

• The ground underneath the must be able to take the weight of the device. It

should also be even and nonslip.

• The installation site must be designed so that accidental touching with the

engine case, rotating or otherwise dangerous parts is impossible.

• The installation site must be protected from any natural forces (such as rain,

snow, hail, storms, flooding, direct sun radiation, frost or heat) as well as air

pollutants (such as abrasive dust, electric smog, fluff, smoke, oil, mist, exhaust

gases or other pollutants).

• Consider the noise limits at the installation site.

4.2.1. In- and outtake Ventilation

Normally, the engine can draw enough air from its surroundings.

However, the motor radiates heat that in closed spaces would raise

the room temperature so high it would have negative effects on the

motor capacity.

The ventilation plan must consider following aspects:

• diverting heat produced by the engine

• necessary air rate:

for the engine to consume properly

to cool any other devices

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 inappropriate! 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!

If the engine is to be built into an enclosed space, the air vents must

be large enough to make free air circulation possible. A guide value for

non-forced air ventilation is 0.4m².

When installing for continuous operation or in places where the instal-

lation site is very hot, it is recommended to install an exhaust fan with

appropriate volume.

To reach the highest capacity possible, the surrounding air must not

rise above +25°C. In case of higher temperatures it is necessary to

derate the power of the engine capacity.

Make sure that hot exhaust gas is not sucked in again by the engine

4.3. Motor mounting

The motor assembly must be done through four montage holes in the

base plate. A mechanical assembly using the motor ﬂange is not al-

lowed.

Please also consider following points:

• The installation frame or foundation 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 out evenly on

the ground to avoid tension (possibly use underpinning).

• Make sure the dimensions of the attachment screws are appropriate.

In order to achieve a large enough surface area, use a large washer

between the base plate and the mounting nut.

The engine plus any add-on device should be well balanced and

attached onto a hard metal structure with vibration damper in bet-

ween. This reduces vibration.

4.4. Exhaust gas system

4.4.1. Mounting the mufﬂer

The mufﬂer contained in the order is made to be used in industrial are-

as. If the engine is to be used uptown it might be necessary to replace

it with a better one.

4.4.2. Information about other exhaust gas systems

When installing a different exhaust gas system please consider fol-

lowing points:

The exhaust back pressure has a signiﬁcant effect on the engines pow-

er. Too high exhaust back pressure causes lower power, hotter exhaust

gas and a hotter motor, and high consumption of fuel. The exhaust

back pressure can be held to a minimum when the exhaust system is

well dimensioned.

• Make sure that during the installation of the exhaust pipes the radiated heat

cannot be sucked in by the motor. The pipes should be insulated. If the exhaust

pipe go through walls, insulation is mandatory.

• The exhaust pipe should be kept as short as possible and have no bends. If this

is not possible the radius of the curvature should be held as wide as possible.

• When using exhaust pipes up to 10 meters in length the radius of the pipes

has to be about 30% higher than the diameter of the exhaust manifold or the

muffler exhaust pipe. The diameter must not be smaller than that.

• If the exhaust pipe has a significantly larger radius than the device connection,

a cone-shaped connector with an angle less than 30° should be installed ad-

ditionally in order to avoid exhaust back pressure.

• The installed exhaust pipe has to be complete and 100% leak-proof in order to

avoid heat, poisonous gases and power lost.

• It is recommended to install a screw at the lowest point of the exhaust pipe to

drain the condensate.

• Between the outtake manifold of the motor/muffler and the exhaust pipe a fle-

xible pipe should be installed in order to avoid vibration transmit and to enable

thermal expansion of the pipes.

• Make sure that muffler and any exhaust pipes are free from flammable mate-

rial (fire hazard).

4.5. Fuel System

The fuel system of the motor must provide a clean and continuous

diesel supply. Pay attention to the following points during the instal-

lation of an additional fuel tank:

• Only use diesel durable tubes with wire netting for diesel fuel.

• Tank ventilation is necessary in order to avoid too high or too low pressure in

the tank.

• Avoid too high pressure in the integrated tank. This can happen when the tank

ventilation is clogged up or the overrun is connected to another external tank.

• It is recommended to choose a tank that has a cone-shaped bottom, in order

to collect condensed water, and has an integrated drain valve.

• Fuel tubes to and from the tank must have at least the same diameter as their

counterparts on the motor. When the pipes are very long or the surrounding air

cool, the diameter of the pipes has to be wider to let through enough fuel.

EN10

4.6. Coupling

Before the motor can be connected to a load their compatibility

needs to be checked!

It is important to check

• whether motor and load are compatible in oscillation

• whether the measurements of shaft and flange of the motor are

compatible with the measurements of the coupling.

Motor and load have to be levelled carefully! An incorrect levelling can

lead to vibrations and bearing failure.

When starting up the motor BEFORE the montage of a coupling or a

pulley the key has to be ﬁxed to the nut very tightly!

Make sure that while assembling a coupling or a pulley all safety mea-

sures concerning touching rotational parts are obeyed. Consider the

appropriate installation instructions from the manufacturer.

In no case whatsoever should pressure, hits or blows hit the shaft (for

example with a hammer). This could damage the bearings.

Assembly and disassembly has to be done with suitable attachment

and detachment tools!

4.6.1. Maximum axial and radial load

Make sure that the maximum axial and radial load of the motor main

bearing aren’t exceeded before operating. If you’re using pulleys it

is necessary to recalculate the life-span of both shaft bearings and

to adjust maintenance intervals accordingly.!

4.6.2. Balancing

The crankshaft of the engine is dynamically balanced with half the

key. Each element of the coupling also has to be balanced out ac-

cordingly.

When the coupling is too short the overhanging key part has to be

worked off until it is the diameter of the shaft or covered up with

rings using the key nut in the according size. If the coupling is too long

the missing key part has to be ﬁlled out in the overhanging coupling.



4.6.3. Direct coupling

When directly attaching a moving element (ex. pump, ventilator) to the

motor shaft, balance is extremely important!

The coupling has to be chosen so that the transferred torque, the run-

ning characteristics of the engine and the necessary safety characte-

ristics are considered.

The motor plus the load should be balanced out so that out-of-rounds

and deviations in balance of the two coupling halves comply 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 both halves.

• Set up the parallelism of both shafts with a comparator or a thickness gauge at

four points which are located 90° from each other (the distance set up equals

the value A).

• Measure the distance between the two contact-areas of the coupling at four

different points which are also set 90° from each other.

• The difference between the two values may not be greater than 0.05mm.

A A

You can use two measure-devices to set up parallelism and coaxal at

the same time. While turning the shaft slowly deviations can be mea-

sured precisely.

Alignment errors are corrected by using washers between the base

and the foundation. After refastening the nuts the alignment has to be

checked again.

If you are using 2-part couplings you have to make sure to leave a

distance of 1-2mm to the shaft in order to allow thermal expansion

of both shafts.

4.6.4. Operating with a pulley

The axis of the motor shaft must be parallel to the axis of the moving

device, in order to minimize the axial force on the bearing. Make sure

the pulleys are set up in one line (see diagram below).

Assembly with a ﬁxed axle distance:

• Attach an additional tension roller to the belt. The tension roller should be

placed on the inside of the V-belt. In case a flat belt is used - the roller can also

be placed on the outside of the belt.

Assembly with variable axle distance:

• Attach two clamping rails to the base. They must be parallel to the belt.

• Attach the load (not the motor) as shown in the diagram below. This way eve-

rything can be balanced out as precisely as possible.

Tension screw

The tension of the belt has to be set up very precisely. If the tension

is too high the shaft bearing wears out very fast and the crankcase

or the shaft might break. If the tension is too low, vibration can oc-

cur, which can also damage the device.

Starting at a pulley diameter of 315mm and a rotational speed of

3.000min-1 we do not recommend using pulleys made from gray cast

iron or using ﬂat belts.

Please note that all moving (rotating) parts must be protected from

touching anything before starting up the device!

11EN

4.7. Concluding mechanical installation instructions

After the ﬁrst start-up the correct alignment is to be checked while the

motor is as warm as it usually is while operating..

• All screws, nuts and other clamped or bolted connections must be correctly

assembled and fastened.

• The cooling air must be able to circulate without a problem.

The engines are equipped with a mechanical, adjustable speed regu-

lator. Make sure the injection pipe cannot vibrate with the engine at

any time, particularly when using the device at different speeds. This

could severely damage the injection pipes already after a short period

of time. If necessary support the injection pipes at appropriate spots..

4.8. Speed controller

4.8.1. Type “A” – for variable speed

At delivery the engine is set up as follows:

➽Maximal speed: 3.000 min-1

➽Idle speed: 1.300 min-1

less

oscillate

faster

regulation

higher

speed

lower

speed

for wire rope Adjusting screw max. speed

Adjusting screw

max. Injection qty.

Speed adjusting knob

Fasten to hold speed

Idle

Full speed

• If necessary attach a appropriate wire rope for speed regulation. There is a

clamp located at the left end of the governor. Here the rope should be attached.

• If an outher maximum speed than 3.000 min-1 is necessary in your applica-

tion, you can adjust the regulation-spring in different positions. Highest allo-

wed speed is 3.700 min-1

If you change the set-up for the maximum speed, you also have to

readjust the adjusting screw for the maximum injection quantity.

Open the check-nut and adjust the screw as follows:

Load the engine with the nominal load according to the perfor-

mance curve and adjust the screw so that the engine achieves a

Bosch count below 4. Make sure to refasten the check-nut after

the adjustments.

If the engine is used above 1.000m sea level, readjustments of the

maximum injection quantity 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:

➽Rated speed: 3.000 min-1

If you want to change the engine speed, the regulating-spring must

be exchanged.

wire rope slot for

cut-off solenoid

Regulating

spring

Adjusting screw

max. Injection quantity

Bring lever in right position

„click“

cut-off lever

press to stop engine

Engine off Rated speed

less

oscillate

faster

regulation

higher

speed

lower

speed

4.9. Electrical installation

Depending on the version the engine is equipped with following

electrical components:

➽Version "H":

No electrical components

➽Version "E":

Dynamo, Battery loading regulator and electric starter

➽Special components (not included, additionally available):

- Starting battery

- Key box

- Oil pressure sensor

- Injection pump with mounted 12V magnetic valve

4.9.1. Electrical connection (chords)

Only use stranded wire cable as a connection.

Battery(+) as well as battery(-) chords are to be held as short as

because the current of the starter is very high.

Note that the motor and add-on-parts get hot when used. Always

protect the cable from touching hot parts by using a protective hose.

Caused by motor vibration during operation all screw connections

must be secured with spring washers or lock-nuts.

4.9.2. Starter battery

A starter battery and a battery cable are not included in the delivery,

they can however be ordered separately as add-ons. Make note of

following points:

Lead acid batteries contain sulfuric acid. If there are liquids

escaping from the battery, do not touch or swallow them.

Carefully dilate the acid with water and neutralize it with soda

(sodium carbonate).

Always wear protective gloves and safety goggles when wor-

king with the starter battery.

• You can find the necessary capacities in the chart in chapter 3.1.

The usage of valve-regulated (maintenance free) batteries is re-

commended..

• Always connect the plus(+) pole first, then the minus(-) pole. Fas-

ten the connections properly.

EN12

4.9.3. Circuit diagram of starter-dynamo

Motors in versions "E" are delivered with preassembled dynamo,

loading regulator and electric starter.

Dynamo

(mounted behind ﬂywheel)

Electric starter

Battery (+) cable ≥16mm²

RED

BROWN

BLACK

RED

Battery (-) cable ≥16mm²

Ground connection

on motor case

(crankcase)

Start key

OFF

START

Schematics of start key:

Loading output +12V ≥2,5mm²

Battery(+) ≥2,5mm²

WHITE

Starter relais ≥2,5mm²

Battery

regulator

4.9.4. Oil-pressure sensor

The optionally available oil pressure sensor (order: ZSPMOT00003)

is attached to the crankcase cover. To attach it, remove the blind

screw ﬁrst (see diagram).

Remove blind screw

Attach pressure

sensor

Thread: 1/8“

use teﬂon tape

The sensor is equipped with a switch, which opens at 1,1bar oil

pressure (and is closed below 0,9bar).

4.9.4.1. Schematics of oil-pressure sensor-lamp

The easiest wiring of the oil-pressure sensor is by using a 12V lamp.

Disadvantage:

The lamp only lights up when 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-pressure sensor with magnetic valve

Optionally, you can use an injection pump with an integrated mag-

netic valve in the series ED4-04xx.

This magnetic valve can be connected to the oil-pressure-sensor in

such fashion, that the motor stops automatically when there is too

little oil. In order to ensure that the engine always stops, even if there

is just a short disruption in oil pressure, a small circuit-board must

be integrated. You can ﬁnd the up-to-date wiring schematics on our

website. We offer all the necessary parts, including the board.

START

KEY

Loading regulator +12V

Battery +12V

Starter relais

GND

Electric circuit board GEN4R-D-REV3

available in the following versions:

Order.Nr.: MOT140 - Building kit (board, part, not assembled)

Order.Nr.: MOT141 - Ready for use in plastic case

Further details see homepage.

START

Oil sensor

Thread: 1/8“

Closed <0,9bar

Open >1,1bar

GND over sensor thread

GND over valve thread

Magnetic valve

13EN

5. Usage

5.1. Components

Tank cover

Tank

Tank cock

OFF Injection-

pump

Recoil-

starter

Recoil-

starter

Governor

Oil dipstick

Oil drain screw

Mufﬂer

Air ﬁlter

Elektric starter

(only E version)

Loading regulator

(only E version)

Oil ﬁlter

Flange

Base plate

Crankshaft STOP

MAX.

SPEED

Tank cover

Valve cover

Decompressor

Injection nozzle

Diesel return tube

5.2. Information about engine performance

The performance refer to standard conditions (0m sea level, +25°C

ambient temperature). For higher temperature or usage at higher sea

level it is necessary to calculate a derating of the maximum perfor-

mance (see 3.3).

5.3. Information about starter battery (optional)

Please consider following points:

Lead acid batteries contain sulfuric acid. If there are liquids escaping

from the battery do not touch or swallow them. Carefully dilate the acid

with water and neutralize it with soda (sodium carbonate).

Always wear protective gloves and safety goggles when working with

the starter battery.

When correctly set up, the battery will be charged via the built in dy-

namo.

If the motor is operated without a battery (ex. when using an external

battery to start up), the plus cable from loading regulator has to be

isolated against the crankcase. A shortcut could damage the dynamo

or loading regulator.

When using a 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 starter

battery. This seriously damages the battery, in extreme cases the bat-

tery might even explode.

Be very attentive when handling starter cables, if it comes to an elec-

trical shortcut very large currents can be transmitted. Therefore re-

member: always connect the plus(+) pole ﬁrst, then the minus(-) pole.

5.4. Check-ups before every start-up

5.4.1. Engine oil

Oil is the most important resource of the motor. Only use high qua-

lity motor oil for diesel engines.

Check the oil level bevor every start up! ATTENTION – when delivered

the engine is NOT supplied with oil and must not be started up under

any circumstance!!

Remove the oil dipstick ❶and wipe it

with a clean piece of cloth. Reinsert the

clean dipstick ❶completely, then re-

move it again. The correct oil level ❸is

now marked by the oil ﬁlm covering the

dipstick. The line has to be close to the

maximum mark ❹. If necessary add more

oil, in order to achieve the correct oil level

❷(lower edge of the thread in the crank-

case).

Do not add too much oil – too much oil is damaging and must be drai-

ned! Different types of oils and brands may not be mixed together!

Note the maintenance intervals of the oil change.

Fill the oil in

Oil dipstick

Drain the oil

Ambient temperature Oil viscocity

+20 up to +40°C SAE 40

0 up to +30°C SAE 30

-20 up to +10°C SAE 20

-20 up to +20°C SAE 10W 30

-10 up to +40°C SAE 15W 40

EN14

5.4.2. Fuel

• Fill up the tank completely with diesel.

You cannot use fuels other than regular diesel such as biodiesel, plant

oil or heating oil without changing the engine! Never use fuels other

than standard diesel without clearing with ROTEK ﬁrst. Your engine

could be damaged!

We would like to point out that in Western Europe it is mandatory to mix

biodiesel into available diesel fuels. Because of this mix, the “normal”

diesel only keeps about 6 months in storage! After about 6 months mi-

crobial growth increases considerably in the diesel. These organisms

further on corrosion in tank and motor, and they produce biomass

which clogs the injection nozzle, the injection pump and damages the

motor over time. This is a particular problem if the engine is only used

rarely. Pay attention to the date you last refuelled and drain the tank in

appropriate time intervals. Also available are types of premium diesel

(SHELL© V-Power, ARAL© Ultimate, OMV© MaxxMotion, ...) which eit-

her do not contain biodiesel at all (ex. BP© Ultimate) or contain special

biodiesel made from hydrated plant oils (ex. OMV© Maxxmotion) and

can be stored for 2 years without worries.

5.4.3. Fuel system ventilation

If air got into the injection system (ﬁrst time start-up, completely

empty tank, storage over a very long time, etc.) it is possible that the

motor can’t start.

If that is the case, follow these instructions:

• Fill up the diesel tank completely, remove the fuel-pipe ➊from

the injection pump ➋. Open the fuel cock and drain diesel until

the diesel flowing is not foaming.

• Reconnect the tube to the injection pump.

• Switch the governor ➌to position “motor OFF”.

• Disconnect the injection pipe ➍from the injection pump ➋– loo-

se only the top nut ➎.

• Loose the bottom nut ➏of the injection pump ➋carefully until

diesel drains out of it.

Careful - do not unscrew the nuts completely. Behind them is a spring

that could be lost.

• After some diesel drained out, refasten the bottom nut ➏.

During operation no diesel should escape! Check this during a test run!

• Reconnect the injection pipe ➍and switch the governor ➌to full

speed.

• The motor should start after a few tries. The engine will be a little

restless for the first 30s after the start up until all air has escaped

the system.

5.4.4. Other check-ups

• Remove any dirt or dust, so that the engine cooling cannot suck in any foreign

matter.

Note that the motor must NOT be started up if the protective covers are

not attached properly.

• Check that the device does not have any leaks (fuel, oil, battery acid). Fasten

leaking sealing caps appropriately.

• Make sure the device is well ventilated. The exhaust gas of the motor can be

damage your personal health.

• Check whether the governor (as well as a possible pulley) moves easily and

whether it is possible to set it to idle-speed (=engine off) and rated speed/max.

speed.

5.5. Start-up

5.5.1 Special information about initial start-up

The motor must only be started up when the device was installed fol-

lowing the rules and instructions of this manual and the engine base is

ﬁxed properly to a stable mounting frame.

• Vent the injection nozzle, as explained in 5.4.3.

• Let the motor run on half rated rotational speed (aprox. 1.500-

1.800 min-1) for 1 hour after starting up for the first time.

• Turn off the engine after initial start-up and check the oil level.

• Check all screws, nuts and clamp connections after initial start-

up. Refasten if necessary.

If the engine behaves abnormally (noise, smoke) turn off the motor

immediately and solve the cause of error before putting the engine

into operation again.

To ensure a maximum life-span of the motor it is recommended not

to operate above 3.000 min-1 in the ﬁrst 50 hours of operation. Only

change the speed slowly during this 50 hours (change governor po-

sition slowely)!

5.5.2. Starting the engine

It is forbidden to start up the motor without properly assembled air

ﬁlter and mufﬂer!

• Open the fuel cock

OPEN / RUN

CLOSED

OFF

• Governor in position START / FULL SPEED

START

„click“

Fasten the knob

Governor version „A“ Governor version „C“

• Press decompressor lever

15EN

5.5.2.1. Hand start (all versions)

• Pull the recoil-starter slowly until you feel some resistance. Bring

the recoil handle slowly back.

• Press the decompressor lever.

• Pull the recoil handle hard and fast.

• Repeat until the motor starts up..

5.5.2.2. Electric start (only motor version “E”)

When operating at temperatures below +5°C, it is recommended to

hold decompressor lever for 2-3s during starter activity. Afterr this pe-

riod release the decompressor lever.

• Turn the start key to “START”. Let go of the key as soon as the

motor starts up.

Only start up for a maximum of 10 seconds! If the engine doesn’t start,

wait one minute until trying to start-up again. This process may only

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 running engine!

If the motor does not start, try to vent the injection system as described

in 5.4.3.

Generally you should not connect a load higher than 50% of the nomi-

nal load when the engine is cold.

• Observe the engine run and the colour of the exhaust gas after

starting up. The engine should run smoothly after a few seconds.

5.5.3 Stopping the engine

• Let the engine run without load for about five minutes after being

used for heavy load – this way the motor can cool down.

• Turn off the motor via the governor.

STOP

Press

Governor version „A“ Governor version „C“

• When using devices of version “E” turn the start-key to position

“OFF” – otherwise the battery will discharge.

EN16

6. Maintenance

Regular service and maintenance prolongs the life-span of your de-

vice and enables an undisturbed user experience.

The staff responsible for maintaining and cleaning the device must

be trained to do so. Never let unable people handle the device in any

way at all.

6.1. Instructions about maintenance

If you hire a specialised company to maintain the device, please get

a conformation from them.

Any damage done to the device due to inappropriate maintenance or

not maintaining the device at all do not carry warranty.

Fixing issues that can be ﬁxed by the user himself do not carry war-

ranty either but fall into the normal maintenance of this device.

6.2. Precautions

Before cleaning, oiling or servicing the device follow these instruc-

tions:

• Turn off the motor. The motor must be at rest.

• Use appropriate measures to keep the motor from starting up again.

• The motor and all of its add-on parts must have cooled down to the surround-

ing temperature.

Pay attention while working in close proximity to moving parts and

parts that might be hot.

6.3. Starter battery

If you are using a battery that needs to be maintained, make sure

to regularly check the state of the connectors and the water level. If

necessary ﬁll distilled water up to the maximum mark.

After a long storage period the loading condition of the battery must

be checked before putting the device into operation. Weak batteries

must not be used.

6.4. Cleaning the crankcase

Clean the engine block from the outside with compressed-air or with

suitable detergents.

Electric parts (clamps, electric starter, etc.) must not be cleaned with

compressed-air or any liquid cleaners. This could lead to a short or

other disruptions.

It is extremely important to have free air ventilation in order to cool

the motor down. Therefore you must clean the bars and ribs of the air

vents immediately, even if they’re only slightly dirty.

6.5 Upkeep

Engines are technologically complex mechanisms with many mo-

ving parts. There parts are subjected to strong mechanical, thermal

and chemical forces because of the environment and the combusti-

on process. Choosing the correct fuel and oil as well 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 instructions how to properly identify and maybe

even correct some disruptions. However, some difﬁculties can only

be handled by trained staff or professionals. If you have a problem

go over this list point by point – often the problem is small and easily

solved.

A diesel engine needs 4 things to work:

➽OIL ➽AIR ➽DIESEL ➽CORRECT TIMING

You should check in this order to ﬁnd the cause of a possible pro-

blem.

6.5.1 Changing the engine oil

Always check the oil level before starting up! There are marks on the

dipstick marking the minimum and maximum – when the device is

set up on an even surface the oil level should be between these two

marks.

Do not overﬁll! Too much oil can cause damage and must be drained.

Oil is the most important resource of the motor. Stick to the mainte-

nance intervals and its schedule!

Put a suitable container under the drain screw, open the drain-screw

and drain the motor oil. Always change the motor oil while it is warm!

drain screw

drain channel

container

Normally, the oil should be black because of the combustion residue

of the motor. There should be no foreign substances, white colouring

(water in the oil) or foaming visible.

The spent oil taken from the motor has to be brought to a collecting

point for toxic waste!

Close the drain screw after draining.

Remove the oil ﬁlter (loosen the screw and pull it out). Wash it in

petroleum ether (=benzine). After drying it, reattach it.

Fill new oil into the motor, make sure to use the correct one (see

5.4.1.).

After changing the oil, start up the engine and let it run for 5 minutes.

Then check the oil ﬁlter and the drain-screw for any leaks. Check the

oil level again and reﬁll oil if necessary.

If the oil level increased from one check to the other do NOT start the

machine. Fuel or water might have gotten into the motor oil – this can

damage your device. In those cases drain the oil completely and try to

identify pollutants such as water or fuel (check the smell, maybe try

to set small amounts on ﬁre, see whether water separates from the

oil). Find out why there is leakage into your oil and ﬁx it. Wash out the

crankcase with fresh oil and change the oil. (Also clean/change the

oil ﬁlter).

17EN

6.5.2 Cleaning and exchanging the air ﬁlter

If the air ﬁlter is lose or dirty the engine performance will be low (ex.

motor produces black gas under load). Therefor you must always

change the ﬁlter according to the maintenance intervals.

Open the nut of the air-ﬁlter-cover and take it off. The air ﬁlter can

now be taken out of its case. There are two ﬁlters: the coarse ﬁlter

and the ﬁne ﬁlter. Carefully take the coarse ﬁlter off the ﬁne ﬁlter.

The ﬁlter can be cleaned with compressed air. Check for any tears

or other damage. If the ﬁlter is damaged in any way it must be re-

placed.

➽Cleaning interval: 100 working hours

➽Changing interval: 6 month / 300 working hours

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 inappropriate! 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!

Clean the inside of the air-ﬁlter-housing with a dust cloth, then repla-

ce either a new or the cleaned air ﬁlter. Close the lid.

6.5.3. Fuel Supply

Check whether there is enough fuel in the tank. Look into the tank to

check for dirt, rust or, during winter, small ice crystals. If you ﬁnd any

of the above drain the tank completely and ﬁll it up with new diesel.

• Close the fuel cock and remove the fuel tube from it.

• If you carefully open the cock fuel should leak out. If this is not

the case clean or replace the fuel filter.

• If the above point is ensured, check the injection system.

6.5.3.1. Changing the fuel ﬁlter

• Completely empty the tank (J1). Note that there still might be diesel in the tube

(J2).

• Open the two nuts (J3) of the fuel cock (J4).

• Check the fuel cock (J4) for any pollution as well as the o-ring (J7) for wearing.

• Open the tank 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 check for any leakage.

6.5.3.2. Ventilating the injection system

see 5.4.3.

After the device stood still for a long time it is possible that the piston

of the injection pump is stuck. In this case remove the injection pump,

put it into petroleum ether (=benzine) and actuate it a few times while

it is lying in the benzine. Then check whether you can move the piston

and the adjusting-knob easily. When reassembling be careful to place

the adjusting-knob of the injection pump into the regulation-arm (fork

shaped) of the governor!

6.5.3.3. Examining and cleaning the injection nozzle

If the injection nozzle is dirty it can be cleaned the following way:

• Remove the injection pipe (M1) by loosening the golden nut (M2).

• Open the clamp (M3) and pull down the overflow-tube (M4) of the injection

nozzle.

• Open the screws (M5) and remove the plate (M6).

• The injection nozzle can now be removed. If necessary push it out with the

leaver.

The injection nozzle (M7) has 4 openings on its bottom out of which

diesel is pumped into the combustion chamber. If one or more

nozzles are clogged up, the diesel won’t be distributed evenly in the

chamber. Clean the injection nozzle with a piece of cloth.

• Attach the injection nozzle to a injection-tester and check the distributed fuel

spray.

• During the spray test the nozzle as well as the screwing should also be che-

cked for leaks. Attach the nozzle including the high-pressure-pipe to the che-

cker for 10s at a pressure of 12,7 MPa (127 bar). The system must be leak

proof.

You can also check the fuel-spray without injection-checker. Connect

the injection-pipe (M1) in dissembled state to the nozzle. Put down a

piece of paper so that the nozzle is pointing at it vertically (at a dis-

tance of about 5mm). Press the decompressor and shortly use the star-

ter of the motor. The nozzle should be producing fuel. You can see the

fuel-spray on the piece of paper – the fuel should be distributed evenly.

GOOD BAD

EN18

6.5.4. Proper timing/adjusting the valves

Improper valve clearance is noticeable by restless engine run, back-

ﬁre or low performance.

In order to set up the valves follow these instructions:

• Remove the valve bonnet by unscrewing 2 screws (N1).

• Press the Outtake-valve (N4) and turn the shaft manually by hand

(pull the recoil starter) until both valves are closed (valves are

completely closed - push rods N3 on lowest position).

• The push-rods (N3) should be easily to move. Check the valve

clearance with a feeler gauge. The valve clearance should be ap-

prox. 0,15mm for both valves (N2) and (N4).

Should there be no feeler gauge available, normal typewriter paper is

ﬁne (meaning two layers of paper is approx. 0,15mm also).

• Unscrew the check nut (N5) in order to set up the valves. Set up

the valves with the screw (N6) so that if the feeler gauge is moved

through the gap, there is a noticeable resistance. Then hold the

screw until the check nut is refastened.

• Check the valve clearance again and repeat the process if neces-

sary. Set up both the intake valve (N4) and the outtake valve (N2).

It has to be easy to move or turn the push rods. The valve springs must

not be broken and the push rod guides must not be worn. The position

(how deep is the nut) of the check nuts should be nearly the same.

Signiﬁcant differences of nut deeps are a sign of incorrect assembly

or a damaged rocker arm, push rod or valve. In that case remove the

rocker arm entirely and pull out the push rod. Always replace damaged

or deformed parts..

When reassembling the push rods they have to lay on the appropriate

tapers of the camshaft (in the engine). Check whether the valves are

working properly by turning the camshaft.

The timing of this device is ﬁxed and cannot be changed..

• After setting up the valves, reassemble the bonnet assembly.

Check whether the bonnet gasket is properly mounted.

6.5.5. Governing behaviour

The mechanical governer can be inﬂuenced in its regulation in diffe-

rent ways. The governing (how much the actual speed deviates from

the ideal speed) and the oscillating (engine speed oscillates arround

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 load. Then burden the motor

up with maximum load. Now the speed must ﬁrst sink, then become

higher than the rated speed and then ﬁnal go back to rated speed.

Engine speed should not oscillate around the rated speed.

To improve the governing, the regulating spring can be hung closer to

the middle of the regulation-arm. To decrease the oscillation the regu-

lating spring can be hung closer to the outside of the regulation-arm.

Normally a allready marked rated speed has to be reset after changing

the spring position – see the diagrams of the governor in 4.8.

Normally it is not necessary to change the speed or the behaviour. At

too low engine speed ﬁrst check for any other causes of error (air ﬁlter,

diesel, valves, etc.)!

6.5.6. Mufﬂer and colours of exhaust fumes

Backﬁre can be a result of loose screws on the outtake-manifold or

the mufﬂer. In that case the ﬁt of the screws as well as the state of

the gaskets should be checked. The exhaust pipe should be leak

and damage free

Residue must be removed from the exhaust pipe and the mufﬂer. How-

ever, such residue indicates that either the wrong fuel is being used or

that oil is being burnt.

Too much exhaust back pressure can overheat the engine.

The colour of the exhaust gas can be an indication of the current

operation state of the motor:

motor is smoking

white or grey

water in the

fuel drain the fuel tank

motor is smoking blue motor oil is

being burned

check the oil level, valve guides

and compression

motor is smoking

black too heavy load

check the air ﬁlter as well as the

injection nozzle. Maybe reduce

the load

6.5.7. Other

Unusual noises might be caused by worn piston, piston-rings, cylin-

der, piston bolt, bearings, etc..

Too little compression might be caused by worn piston, broken cy-

linder, incorrect set up or leaking valves.

If the motor gets too hot, the cause is either a too heavy load or a

clogged up ventilation system (air housing, ventilator).

If there is water in the fuel the engine does not start up, it smokes

white or it runs very restlessly. In this case drain the fuel.

Measure clearance

on this point

19EN

6.5.8. General tightening torque

Torque [ Nm ±5% ]

Electric Low

Strength 1)

High

Strength 1) Tension rod

M4 1,2 1 1,5 2,5

M5 2,5 2 3 4

M6 4 2,7 5 6

M8 8 5,5 18 22

M10 12 13 20 25

M12 20 20 35 44

M16 40 35 80 100

1) screws which don’t have to be so hard (screws in alluminium,

mounting screws external parts, flywheel cover, etc.)

2) screws in parts which have to be very hard (base plate, flange

etc.)

6.5.9. Engine torque and measured values

ED4-0418/ED4-0474

cylinder head 54-58 Nm

connection rod 40-45 Nm

plate of injection

nozzle 10-12 Nm

ﬂywheel 120-135 Nm

exhaust

temperature ≤ 500 °C

oil temperature ≤ 110 °C

injection pressure 19,6 ± 0,49 MPa

injection timing @ 3.000min-1: 17° ±1° bTDC 1)

@ 3.600min-1: 18° ±1° bTDC 1)

valve clearance

intake valve 0,10-0,15 mm cold

valve clearance

outtake valve 0,10-0,15 mm cold

1) bTDC means "before Top Dead Center"

6.5.10. Solving electric issues

This chapter only concerns motors in version "E".

6.5.10.1 Starter malfunction

If the starter is running without load (the starter turns but the motor

does not run with it) the starter gear may be broken. In this case the

starter has to be changed.

If the starter does not react when you are trying to start please check

following points:

• Check the battery voltage. This should be >12,5V.

• Check the voltage between battery (+) pole and crankcase.The battery voltage

must be the same. If not, the battery(-) pole cable to the crankcase is broken or

loose.

From here on all measurements should be done against the crank-

case (crankcase is 0V/GND).

• 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 position "OFF" or "ON" there should be 0 Volt – when it is set to "START"

voltage has to be battery voltage. If this does not coincide either the cable

connection (1) or (2) or the switch itself is broken.

If all above measure points coincide with the battery voltage, the

starter itself is probably broken and must be replaced.

Dynamo

(mounted behind ﬂywheel)

Electric starter

Battery (+) cable ≥16mm²

RED

BROWN

BLACK

RED

Battery (-) cable ≥16mm²

Ground connection

on motor case

(crankcase)

Start key

OFF

START

Schematics of start key:

Loading output +12V ≥2,5mm²

Battery(+) ≥2,5mm²

WHITE

Starter relais ≥2,5mm²

Battery

regulator

6.5.10.2. Battery does not charge

When the motor has started, the starter battery is charged via the

built in dynamo. If this is not the case please follow these instruc-

tions:

• Disconnect the battery. Isolate the plus pole cable in order to avoid a short and

start the motor manually.

• Measure the voltage of the dynamo when the engine is running and the battery

is disconnected (2 isolated cables coming from the crankcase and connected

with the loading regulator). The output voltage of the dynamo should be at

around 18 Volt AC. If the voltage is 0V, the dynamo is probably broken and must

be replaced.

• If this measurement coincides, measure the output voltage of the loading regu-

lator against the crankcase. The output voltage is about 14V DC. If the voltage

is 0V the loading regulator is broken.

• If this measurement also coincides check the cables (1) and (2) and check the

key-switch.

EN20

6.6. Maintenance intervals

before

each

start

after

50 hours

(Initial)

all

200 hours

(6month)

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!

This manual suits for next models

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