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Summary of Contents for Rotek EG4-5 Series
- Page 1 Air-cooled single cylinder gasoline engine EG4-5 series User- and maintenance manual LT1812, effective April 2021 EG4-0210-5 EG4-0270-5 EG4-0420-5...
- Page 2 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.
- Page 3 Index 6. Maintenance 1. Safety Instructions 6.1. Instructions about maintenance 1.1. Equipment 6.2. Precautions 1.2. Risks from noise development 6.3. Starter battery 1.3. Risks posed by moving parts 6.4. Cleaning the crankcase 1.4. Risks posed by gas emissions 6.5 Upkeep 1.5.
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Page 4: Safety Instructions
Do not linger around a running engine and always wear ear protection. closed spaces, tunnels, containers), unless those installations were expressly approved by ROTEK. The engine must never be operated without a muffler. Exhaust gases are toxic. They can cause loss of consciousness or even death. -
Page 5: Transportation And Storage
2. Transportation and storage 2.2. Storage as new device • If the device is not used instantly, the engine has to be stored 2.1 Transportation for assembly at a safe, clean, dry and vibration free location. • If gasoline or motor oil were already filled into the motor, drain Incorrect handling can cause serious damage to the device! them and clean the fuel tank if necessary. -
Page 6: Specification
3. Specification 3.1. Technical data Model EG4-0210-5 EG4-0270-5 EG4-0420-5 Build type 1-cylinder 4-stroke air-cooled gasoline engine with carburator Displacement 212 ccm 270 ccm 419 ccm Bore x Stroke 70 x 55 mm 77 x 58 mm 90 x 66 mm Compression 8,8 (±0,2) : 1 8,2 (±0,2) : 1... -
Page 7: Performance Curves
3.2. Performance curves EG4-0210-5 EG4-0270-5 P: Power, Me: Torque, ge: Consumption P: Power, Me: Torque, ge: Consumption P [ kW ] P [ kW ] Me [ Nm ] Me [ Nm ] 2.000 2.500 3.000 3.600 r [ min 2.000 2.500 3.000... - Page 8 3.3. Flange and shaft measurements EG4-0210-5 CRANKSHAFT-OPTION: Q1 [ 3/4“(19,05)x61,7 ] CRANKSHAFT-OPTION: S1 [ KW20x53 ] Key 3/16“x3/16“ 45,5 4-M8x1,25 61,7 CRANKSHAFT-OPTION: V1 [ TP19x72 ] CRANKSHAFT-OPTION: V5 [ TP25x54,5 ] 1:5,3333 65 ± 0,05 5/16-24UNF Deep 20 14,3 52,3 54,5 EG4-0270-5 CRANKSHAFT-OPTION: S2 [ KW25x88,2 ]...
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Page 9: Installation
4. Installation 4.4. Exhaust gas system 4.4.1. Mounting the muffler The installation has to be done by professionals. Poor installation can damage the device (ex. bearing failure because of inadequate paralle- The muffler contained in the order is made to be used in industrial are- lism). - Page 10 4.6. Coupling 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- Before the motor can be connected to a load their compatibility sured precisely. needs to be checked! It is important to check •...
- Page 11 4.7. Concluding mechanical installation instructions 4.9.2. Starter battery After the first start-up the correct alignment is to be checked while the A starter battery and a battery cable are not included in the delivery, motor is as warm as it usually is while operating.. they can however be ordered separately as add-ons.
- Page 12 5. Usage Adjusting speed for max. rotation/speed 5.1. Illustration Throttle (Model EG4-0420 in version "E" is showed below) Fast Slow Tank cap Muffler Air filter assy. Tank Cylinder head Crankshaft Oil gauge Choke START OPERATION Oil filling port Engine flange Fuel Cock Tank cap Muffler...
- Page 13 5.2. Information about engine performance 5.5. Start-up The performance refer to standard conditions (0m sea level, +25°C 5.5.1 Special information about initial start-up ambient temperature). For higher temperature or usage at higher sea The motor must only be started up when the device was installed fol- level it is necessary to calculate a derating of the maximum perfor- lowing the rules and instructions of this manual and the engine base is mance.
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Page 14: Maintenance
6. Maintenance 6.5.1 Changing the engine oil Always check the oil level before starting up! There are marks on the Regular service and maintenance prolongs the life-span of your de- dipstick marking the minimum and maximum – when the device is vice and enables an undisturbed user experience. - Page 15 6.5.2.1. Spark plug chart Overheating The insulator is chalky white and there is absolutely no EG4-0210 residue visible. The motor got way too hot! The cause Technical data EG4-0420 could be a too low heating value of the spark plug or a too light fuel air alloy.
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Page 16: Starter Malfunction
6.5.2.3. Solving ignition problems If there is a problem, measure (M) against ground (crankcase). There should be a resistance of 1,0-1,5 Ohm. Now measure (N) (=spark If there are still problems after exchanging the spark plug and there plug connector) against ground. There should be a resistance of is no spark, follow these instructions: 10-11 kOhm. -
Page 17: Fuel Supply
If a stronger dynamo is required in order to operate side aggregates 6.5.3. Fuel Supply or lights, an external dynamo has to be assembled. Either you use a During check-ups of the appearance of the spark plug you may have standard dynamo with a pulley or a small generator with permanent noticed that the gasoline supply is too less. -
Page 18: Cleaning The Carburetor
6.5.3.1. Cleaning the carburetor 6.5.4. Cleaning and exchanging the air filter Close the fuel cock and drain the gasoline using the drain-screw of If the air filter is loose or dirty the engine performance will be low (ex. the carburator or by unsrewing the float chamber of the carburator. motor produces black gas under load). -
Page 19: Speed Setting
6.5.6. Speed setting 5-7mm spare for regulation (withstand) The actual speed of the motor is set up over a mechanically adjus- table speed governor. If there are just small deviations the rotational speed can be set via the adjusting screw. Because the mechani- cal regulator always has a negative deviation, adjust the rotational speed without load to about 2-4% above the target speed. - Page 20 6.5.9. Other Unusual noises might be caused by worn piston, piston-rings, cylin- der, piston bolt, bearings, etc.. Metallic tingling is caused by the motor misfiring. Causes are resi- due on piston/crankcase, extremely early ignition, worn spark plug, too light alloy or bad gasoline quality. Too little compression might be caused by worn pistons, broken cylinders, incorrect set up or leaking valves.
- Page 21 6.6. Possible errors and their solutions Problem Cause Solution Main switch turned off Turn on the main switch Battery broken or too weak Charge battery externally and check the state of the battery again. Electrical problem in version "E" Wiring damaged or loose Check the battery cables to the starter as well as the control cables to the starting relais Electric starter is broken Test electric starter according to maintenance instructions...
- Page 22 6.7. Maintenance intervals before after every every every every each start 200h 400h 800h 1.600h (daily) running in or 6M or 12M or 24M or 36M Refuel ● Fuel Check the fuel tube for leaks ● Check oil level ● Check whether any oil is leaking ●...
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Page 23: Warranty Conditions
The warranty repair will be done at the location of Rotek or at the location of a from Rotek authorized service subsidiary. - Page 24 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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