SERVICE MANUAL 4-Stroke Engine MPE 850 IND NA This service manual is valid for the following engine variants: –– 406555 406555_SHB Rev 1.0 10.07.2012 en_English Read this service manual thoroughly before operating the engine for the first time.
- Translation of the original service manual - Weber Motor GmbH strives to make continual improvements as part of the ongoing technical development of its products. All documentation is therefore subject to technical modifications. Reprints and translations, in whole or in part, require written permission from Weber Motor GmbH. All rights reserved according to the copyright law. Weber Motor GmbH Otto-Lilienthal-Str. 5 88677 Markdorf Germany www.weber-motor.
Table of contents Table of contents 1 About this document 1.1 2 4 5 Meaning of the symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety 2.1 2.2 3 6 7 Meaning of the safety alert symbol and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Important safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Description 11 3.1 3.2 3.3 3.4 3.5 3.6 3.
Table of contents 9 8.3.1 Changing engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2 Replacing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Checking and adjusting valve play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Checking valve play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 About this document 1.1 1 Meaning of the symbols and signal words About this document This service manual was designed to help you operate the engine safely and reliably. Observe the following information: –– Read this service manual thoroughly before operating the engine for the first time. –– The service manual is for the engine in your portable fire pump. –– Keep the service manual in a safe place. –– Make sure that all personnel using the portable fire pump have access to the service manual.
2 Safety 2.1 2 Meaning of the safety alert symbol and signal words Safety This engine is state-of-the-art and built according to recognized safety-technical regulations. Ignoring the information in this service manual may result in personal injury or property damage. Read and observe the following safety messages carefully before operating the engine for the first time.
2 Safety 2.2 2.2 Important safety messages Important safety messages Service tasks In order to keep your engine in a safe operating condition, regular servicing is essential. It is your responsibility to ensure that the engine is serviced correctly. ►► Perform regular inspections and observe the specified service intervals. Service tasks in the workshop All service tasks described in Chapter 8 Service tasks in the workshop require special technical knowledge of the engine.
2 2.2 Safety Important safety messages Engine power supply Some service tasks require disconnection of the engine from the power supply. Starting the engine inadvertently may endanger the safety of personnel. Read the portable fire pump manufacturer‘s documentation for more information. ►► Disconnect the engine from the power supply when requested. Engine exhaust gases Engine exhaust gases contain carbon monoxide (CO).
2 Safety 2.2 Important safety messages California Proposition 65 10 Warning against chemicals/hazardous materials according to the law of the state of California. This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. SHB MPE850 Rev 1.
3 Description 3.1 3 Description 3.1 Intended use Intended use | 3.2 Identification The MPE 850 IND NA has been designed for powering portable fire pumps. The engine was not designed or intended for any other use. 3.2 Identification Each engine is assigned two identification numbers. Both numbers are printed on a label affixed to the engine. The 6-digit part number engine variant. is the number of the 2 The 8-digit serial number for each individual engine.
3 Description 3.3 Fuel | 3.4 Engine oil 3.3 Fuel Engine damage and loss of power caused by fuel with an insufficient octane rating. Fuel with an insufficient octane rating causes knocking during combustion. Which results in excessive loads and damage to the crank drive within a short time. ►► Always use fuel with the recommended octane rating. Fuel quality unleaded gasoline („super unleaded“), with an octane rating of at least 95 ROZ or 85 MOZ USA: at least Premium 91, unleaded 3.
3 Description 3.5 3.5 Coolant Coolant Freezing, overheating or corrosion due to incorrect mixing ratio or unauthorized coolant additives. An incorrect mixing ratio reduces the cooling capacity. Combining different coolant additives may trigger a chemical reaction and they may lose their effectiveness. ►► Use the same coolant throughout the year in the mixing ratio specified. ►► When topping up the coolant, do not change the mixing ratio.
3 Description 3.6 3.6 Engine components and information Engine components and information –– Coolant circuit vent –– Exhaust ducts –– Oil filter 1 2 3 1 –– Coolant circuit to the heat exchanger 4 2 –– Coolant circuit from the heat exchanger 5 –– Engine oil supply –– Engine oil return 6 7 3 4 5 6 7 –– 1st cylinder 8 –– 2nd cylinder –– Fuel supply –– Air intake 8 9 9 10 10 11 –– Engine rotation direction –– Stub shaft 13 –– Crankcase vent 12 11 14 12 13 14 14 SHB MPE850 Rev 1.
3 Description 3.7 Technical specifications 3.7 Technical specifications Type 4-stroke gasoline engine, parallel twin with balance shaft and overhead camshaft (SOHC) Displacement 846 cm³ Number of cylinders 2 Bore x stroke 89 mm x 68 mm [3.5 in x 2.
4 Operation 4.1 Service intervals 4 Operation Familiarize yourself with the portable fire pump before operating the engine. Read the portable fire pump manufacturer‘s documentation. 4.1 Service intervals In order to keep your engine in a safe operating condition, regular servicing is essential. The following service tasks can be performed by trained mechanics. Activity Check oil level Check coolant level 1 16 before operation ■1 ■1 or at least once a week SHB MPE850 Rev 1.
4 4.1 Operation Service intervals The following service tasks require mechanical knowledge and special technical knowledge of this engine. These service tasks must be performed in a workshop authorized by Weber Motor or the portable fire pump manufacturer.
4 Operation 4.2 Operation during the break-in period 4.2 Operation during the break-in period The way you operate the engine during the first five hours of operation is a major factor in achieving the required performance and extending the service life of the engine.
4 4.3 4.3 Before operation 4.3.1 Checking coolant level Operation Before operation See the portable fire pump manufacturer‘s documentation. Danger of overheating caused by a lack of coolant. Insufficient coolant leads to deformation, stress cracking and leaks in the cylinder head gasket. The increase in pressure will cause the hoses to leak. ►► Always check the coolant level before operating the engine. 4.3.2 Checking oil level See the portable fire pump manufacturer‘s documentation.
5 Special scenarios 5.1 Engine idle for more than 30 days 5 Special scenarios 5.1 Engine idle for more than 30 days If you do not intend to operate the engine for 30 days or more, prepare the engine for storage. Preparing the engine for storage will prevent the cylinder from corroding and ensure the engine starts again correctly at the end of the storage period. Preparations for storage require special technical knowledge.
6 Malfunctions 6 Malfunctions In the event of a malfunction, please contact a workshop authorized by Weber Motor or the portable fire pump manufacturer immediately. SHB MPE850 Rev 1.
7 Dealer and servicing network 7.1 Locating a workshop | … 7 Dealer and servicing network 7.1 Locating a workshop An extensive global dealer and servicing network is available. The dealer and servicing network provides assistance with any queries relating to the engine. Visit our web site www.weber-motor.com for a list of all authorized Weber Motor workshops. 7.2 Service and spare parts Weber Motor offers a selection of accessories to prepare you for the most important situations.
8 Service tasks in the workshop 8.1 8 Service tasks in the workshop 8.1 Safety messages workshop Safety messages workshop Service tasks in the workshop All service tasks described in the following chapter require mechanical knowledge and special technical knowledge of this engine. ►► All service tasks described in chapter 8 Service tasks in the workshop must be performed by a workshop authorized by Weber Motor or the portable fire pump manufacturer.
8 Service tasks in the workshop 8.2 Tools and accessories 8.2 Tools and accessories 8.2.1 Weber Motor service case Weber Motor offers a service case that contains the following service parts. Visit your local portable fire pump dealer or our web site www.weber-motor.com for more information. Figure Description Figure Description Oil filter Valve adjustment shims in different sizes Spark plug Champion RC7PYCBX Serrated lock washer Feeler gauge 0.
8 Service tasks in the workshop 8.2 8.2.2 Tools and accessories Equipment workshop In addition to the service case, you will require the following tools and accessories for service tasks. The figures are only examples of suitable tools. All tools and accessories are available from specialist retailers.
8 Service tasks in the workshop 8.2 Tools and accessories 8.2.3 Supplies You will require the following supplies to perform service tasks. Unless otherwise specified, use the products as directed by the manufacturer. All supplies are available from specialist retailers.
8.3 Changing engine oil and oil filter 8.3.1 Changing engine oil 8 Service tasks in the workshop 8.3 Changing engine oil and oil filter See the portable fire pump manufacturer‘s documentation. 8.3.2 Replacing oil filter –– Protective gloves –– Oil filter ►► –– Universal strap wrench –– Sealing surface cleaner Pump engine oil out. (See the portable fire pump manufacturer‘s documentation.) CAUTION! Risk of burning on oil filter. The oil filter can become very hot. Wear protective gloves.
8 Service tasks in the workshop 8.4 Checking and adjusting valve play 8.4 Checking and adjusting valve play 8.4.1 Checking valve play –– Sealing kit valve cover –– Serrated lock washers –– Feeler gauge –– Anti-Seize assembly paste –– Hexagon screwdriver 5 mm –– Torque wrench –– Hexagon screwdriver socket 5 mm Check valve play with a cold engine. WARNING! Danger of serious cuts from the gear on the camshaft when the engine is started. Disconnect the engine from the power supply.
8 8.4 Service tasks in the workshop Checking and adjusting valve play I n f o rma t i on ! The camshaft is turned using the crankshaft. The portable fire pump manufacturer has devised a suitable procedure for this. Read the portable fire pump manufacturer‘s documentation for more information. Always turn the crankshaft in the same direction as the engine rotates. (See chapter 3.6 Engine components and information.) Two rotations of the crankshaft correspond to one rotation of the camshaft.
8 Service tasks in the workshop 8.4 Checking and adjusting valve play Checking the valve play on the 1st cylinder ►► Turn the camshaft until the position of the camshaft is as illustrated. (See the portable fire pump manufacturer‘s documentation.) The camshaft is marked at the 2nd cylinder end only. The marking 10 is not visible. on the cylinder have a All rocker arms certain amount of play. 11 ►► 10 11 Check the valve play 12 of all valves on the cylinder using a feeler gauge.
8 8.4 ►► Clean the sealing surface surface cleaner. 14 Service tasks in the workshop Checking and adjusting valve play with sealing 14 ►► Put the valve cover ►► Apply Anti-Seize assembly paste to all bolts 16 . ►► Tighten the bolts in the sequence shown . 15 on. 17 15 8 17 Tightening torque: 2 16 4 5 6 3 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] 1 7 ►► Insert the ignition coils ►► Replace serrated lock washers 19 .
8 8.4 Service tasks in the workshop Checking and adjusting valve play 8.4.2 Adjusting valve play with valve adjustment kit –– Valve adjustment shims –– Caliper –– Bar magnet –– Valve adjustment kit –– Hexagon screwdriver 5 –– Torque wrench –– Hexagon screwdriver socket 5 I n f o rma t i on ! The camshaft is turned using the crankshaft. The portable fire pump manufacturer has devised a suitable procedure for this. Read the portable fire pump manufacturer‘s documentation for more information.
8 8.4 Service tasks in the workshop Checking and adjusting valve play Adjusting the valve play on the 1st cylinder ►► Turn the camshaft until the position of the camshaft is as illustrated. (See the vehicle manufacturer‘s documentation.) The camshaft is marked at the 2nd cylinder end only. The marking 3 ends flush with the cross bar. Otherwise, no inscription is visible. 3 4 All rocker arms 4 on the cylinder have a certain amount of play. ►► Continue with the section Replacing valve adjustment shim.
8 8.4 ►► Service tasks in the workshop Checking and adjusting valve play Position the rocker arm pusher rocker arm 9 . 8 on the 8 9 ►► Press down the slide plate 11 using the rocker arm pusher 10 until the pin 12 engages. 10 11 12 ►► Remove the valve adjustment shim using a bar magnet. ►► Measure the valve adjustment shim using a caliper. ►► Insert the new valve adjustment shim. 13 13 34 SHB MPE850 Rev 1.
8 8.4 ►► Hold the rocker arm pusher ►► Press down the slide plate the rocker arm pusher. ►► Slide the pin ►► Slowly release the rocker arm pusher. 16 14 15 in position. slightly using Service tasks in the workshop Checking and adjusting valve play 14 forward by hand. 15 The valve spring slides the slide plate upwards again. 16 . ►► Unscrew the bolts ►► Remove the valve adjustment tool ►► Remove the cover from the chain channel. 17 18 .
8 Service tasks in the workshop 8.4 Checking and adjusting valve play 8.4.3 Adjusting valve play without special tool –– Valve adjustment shims –– Caliper –– Bar magnet –– Universal pliers I n f o rma t i on ! The camshaft is turned using the crankshaft. The portable fire pump manufacturer has devised a suitable procedure for this. Read the portable fire pump manufacturer‘s documentation for more information. Always turn the crankshaft in the same direction as the engine rotates. (See chapter 3.
8 Service tasks in the workshop 8.4 Checking and adjusting valve play Adjusting the valve play on the 1st cylinder ►► Turn the camshaft until the position of the camshaft is as illustrated. (See the vehicle manufacturer‘s documentation.) The camshaft is marked at the 2nd cylinder end only. The inscription 3 is not visible. on the cylinder have a All rocker arms certain amount of play. 4 ►► 3 4 Continue with the section Replacing valve adjustment shim. Replacing valve adjustment shim.
8 Service tasks in the workshop 8.4 ►► Checking and adjusting valve play Insert the new valve adjustment shim 9 . 9 ►► Hold the rocker arm ►► Check if the circlip ►► Slide in the rocker axle ►► Remove the cover from the chain channel. 10 12 in position. is installed. 11 . 10 NOTICE! Valve breakage due to insufficient valve play. ►► Check the valve play. 11 ►► Continue with chapter 8.4.1 Checking valve play. 12 38 SHB MPE850 Rev 1.
6 Service tasks in the workshop 6.5 6.5 Replacing spark plugs Replacing spark plugs –– –– –– –– Spark plugs Serrated lock washer Hexagon screwdriver 5 mm Torque wrench –– Reversible ratchet –– Hexagon screwdriver socket 5 mm –– Spark plug wrench Remove spark plugs with a cold engine. ►► Disconnect the wire harness connectors from the ignition coils 1 . ►► Unscrew bolts ►► Unplug ignition coils 2 . 3 1 2 . 3 ►► Remove the spark plugs plug wrench. ►► Replace the spark plugs.
6 Service tasks in the workshop 6.5 Replacing spark plugs ►► Insert the ignition coils ►► Replace serrated lock washers 6 . Assemble the bolts 7 , washers 8 and serrated lock washers as illustrated. 5 . Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] 5 6 7 8 ►► Connect the wire harness connectors to the ignition coils 9 . ►► Start the engine and allow to run for 1 – 2 minutes. 40 9 SHB MPE850 Rev 1.
8 Service tasks in the workshop 8.6 8.6 Checking spark plugs Checking spark plugs –– –– –– –– Serrated lock washer Hexagon screwdriver 5 mm Torque wrench Reversible ratchet –– Hexagon screwdriver socket 5 mm –– Spark plug wrench –– Feeler gauge –– Spark plug brush Remove spark plugs with a cold engine. ►► Disconnect the wire harness connectors from the ignition coils 1 . ►► Unscrew bolts ►► Unplug ignition coils 2 . 3 1 2 . 3 ►► Remove the spark plugs plug wrench.
8 8.6 Servicearbeiten in der Werkstatt Zündkerzen prüfen ►► If the electrodes 5 are extremely sooty, clean carefully using a spark plug brush. ►► Check the spark plug gap gauge. 6 using a feeler Required spark plug gap: 0,69 – 0,84 mm [0.028 – 0.032 in] ►► If the spark plug gap is not satisfactory, replace the spark plug. Always replace spark plugs in pairs. 5 6 ►► Install the spark plugs plug wrench. 7 using a spark Tightening torque: 20 Nm +6 Nm [14.8 lbf ft ±4.
8 Servicearbeiten in der Werkstatt 8.6 ►► Connect the wire harness connectors to the ignition coils 12 . ►► Start the engine and allow to run for 1 – 2 minutes. SHB MPE850 Rev 1.
8 Service tasks in the workshop 8.7 8.7 Changing coolant | … Changing coolant See the portable fire pump manufacturer‘s documentation. 8.8 Replacing fuel filter See the portable fire pump manufacturer‘s documentation. 44 SHB MPE850 Rev 1.
8.9 8 Service tasks in the workshop 8.9 Preparing the engine for storage Preparing the engine for storage –– Engine internal preservative –– Fuel stabilizer ►► Change engine oil and oil filter (See chapter 8.3 Changing engine oil and oil filter.) ►► Fill up the fuel tank. Add a fuel stabilizer according to the manufacturer's instructions. ►► Check spark plugs. (See chapter 8.6 Checking spark plugs.
8 Service tasks in the workshop 8.10 8.10 Disposal Disposal When disposing of operating materials, replaced parts or the whole engine, always comply with the relevant applicable national laws and guidelines. 46 SHB MPE850 Rev 1.
9 9 Confirmation of service tasks Confirmation of service tasks Have the workshop personnel provide certification confirming that your engine was serviced. You can use the following documents.
9 Confirmation of service tasks Date: Status hours of operation: Work carried out: Engine oil and oil filter changed Valve play checked Spark plugs replaced Coolant changed Fuel Filter replaced Date: Status hours of operation: ...................................... ...................................... ...................................... ...................................... Company seal, signature Date: Status hours of operation: ...................................... ................
Appendix Engine manufacturer Appendix Engine manufacturer Engine manufacturer Weber Motor GmbH Otto-Lilienthal-Str. 5 88677 Markdorf Germany www.weber-motor.com SHB MPE850 Rev 1.
Appendix Index Index B Break-in period, engine 18 C Components, engine 14 Coolant, change 44 Coolant level, check 19 Coolant, specification 13 D Dealer and servicing network 22 Direction of rotation, engine 14 Disposal 46 E Engine oil, change 27 Engine oil, specification 12 F Service case, overview 24 Service intervals 16 Spark plugs, check 41 Spark plugs, replace 39 Spark plugs, spark plug gap 41 Storage, preparation 45 Supplies, overview 26 T Technical specifications 15 Tools, overview 25 V Valve play,
