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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.com
Table of contents
Table of contents
Dealer and servicing network 22
Service tasks in the workshop 23
4 SHB MPE850 Rev 1.1 | 406555 |
Table of contents
Confirmation of service tasks 47
SHB MPE850 Rev 1.1 | 406555 | 5
1 About this document
1.1 Meaning of the symbols and signal words
1 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.
– If you sell the portable fire pump, always pass on the service manual to the new owner.
– The latest version of the service manual is available for download in other languages from our web site www.weber-motor.com.
– Always read the portable fire pump manufacturer‘s documentation.
– Some figures in this service manual are general illustrations and may differ from the actual engine.
1.1 Meaning of the symbols and signal words
Item
NOTICE
Information
Meaning
The signal word NOTICE indicates potential property damage.
The signal word Information indicates specific features and recommendations.
Tools, service parts and supplies required for tasks covered in the chapter.
6 SHB MPE850 Rev 1.1 | 406555 |
2 Safety
2.1 Meaning of the safety alert symbol and signal words
2 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.
Observe all generally applicable laws and regulations in addition to the information in this service manual:
– accident prevention
– environmental protection
– handling of hazardous materials
– personal safety equipment
– traffic laws
2.1 Meaning of the safety alert symbol and signal words
Item Meaning
WARNING
CAUTION
The safety alert symbol draws your attention to possible dangers.
The signal word WARNING indicates a potentially dangerous situation that may lead to a serious or fatal injury.
The signal word CAUTION indicates a potentially dangerous situation that may lead to a minor or moderately severe injury.
SHB MPE850 Rev 1.1 | 406555 | 7
2 Safety
2.2 Important safety messages
2.2 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.
► 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.
Malfunctions Engine malfunctions pose a safety risk to personnel.
► Only operate the engine when in perfect condition.
► All malfunctions must be repaired immediately in a workshop authorized by Weber Motor or the portable fire pump manufacturer.
Spare parts All the components in your engine have been carefully tested and fulfill strict quality and safety requirements. Externally supplied parts cannot fulfill these requirements.
► Always use original Weber Motor spare parts.
Add-on parts and modifications The consequences of attaching add-on parts and making unauthorized modifications to the engine are unknown and pose a safety risk to personnel.
► Modifications and the attachment of add-on parts is only permitted if approved or instigated by Weber Motor.
Hot engine components Engine components become extremely hot during operation.
► Do not touch any engine components during operation.
► Switch off the engine and wait until the components have cooled.
8 SHB MPE850 Rev 1.1 | 406555 |
Engine power supply
2 Safety
2.2 Important safety messages
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). Inhalation of carbon monoxide can deprive the body of oxygen and result in organ damage or even death by asphyxiation.
► When operating the engine in enclosed spaces, use exhaust hoses to direct the engine exhaust gases into the open.
Handling of fuel, engine oil and coolant
Operating materials pose a health risk.
► Always read the manufacturer's instructions.
► Always wash your hands prior to eating, smoking and using the toilet as well as at the end of the working shift when working with operating materials.
Operating materials are hazardous to the environment.
► Never allow operating materials to escape into the groundwater, water courses or sewage system. Always dispose of operating materials according to applicable national regulations.
Danger of slipping on spilled fluids.
► Always use a filler neck or funnel when filling components with operating materials.
► Always clean up any spilled operating materials immediately.
Fuel Fuel is highly flammable. Vapors may ignite and cause an explosion.
► Do not smoke in the vicinity of the engine and do not allow naked flames or sparks near the engine or the fuel system.
► Never fill with fuel while the engine is running.
► Do not start the engine if there is a smell of fuel or you suspect that fuel is leaking. Have a workshop authorized by Weber Motor or the portable fire pump manufacturer inspect the engine immediately.
► Fuel on hot surfaces can cause fires.
► Do not extinguish with water. In the event of a fire, use foam, dry chemical or carbon dioxide extinguishers.
SHB MPE850 Rev 1.1 | 406555 | 9
2 Safety
2.2 Important safety messages
California Proposition 65 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.
10 SHB MPE850 Rev 1.1 | 406555 |
3 Description
3.1 Intended use | 3.2 Identification
3 Description
3.1 Intended use
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 1 affixed to the engine.
The 6-digit part number 2 is the number of the engine variant.
The 8-digit serial number 3 is a unique number for each individual engine.
1
2
3
009999
The labels with the part number and the serial number are located on the valve cover 4 .
The 8-digit serial number is also engraved on the crankcase 5 .
Take the time to enter the part number and serial number in chapter 9 Confirmation of service
tasks. Both numbers are required when making queries about your engine.
4
5
SHB MPE850 Rev 1.1 | 406555 | 11
3 Description
3.3 Fuel | 3.4 Engine oil
3.3 Fuel
Fuel quality
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.
unleaded gasoline („super unleaded“), with an octane rating of at least
95 ROZ or 85 MOZ
USA: at least Premium 91, unleaded
3.4 Engine oil
Engine damage due to incorrect engine oil grade or viscosity.
An incorrect engine oil grade or viscosity causes excessive wear and moving parts may start to seize up.
► Always use the recommended engine oil.
► Do not mix engine oils of different grades or degrees of viscosity.
Engine oil
Fill quantity
0W 40 completely synthetic, at least API SJ, ACEA A3/B3
See the portable fire pump manufacturer‘s documentation.
Information!
Weber Motor recommends you always keep a supply of engine oil to hand. Consult your local portable fire pump dealer.
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3 Description
3.5 Coolant
3.5 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.
► Always use approved coolant additives when topping up the coolant.
Coolant additive
Mixing ratio
Fill quantity
Approved coolant additives
Coolant additive based on ethylene glycol, silicate- and nitrite- free, suitable for aluminium engines
50 % water + 50 % coolant additive
See the portable fire pump manufacturer‘s documentation.
BASF Glysantin G 30
Chevron Havoline Extended Life Coolant XLC+B
Valvoline Zerex G 30
Information!
Weber Motor recommends you always keep an adequate supply of ready mixed coolant to hand. Consult your local portable fire pump dealer.
SHB MPE850 Rev 1.1 | 406555 | 13
3 Description
3.6 Engine components and information
3.6 Engine components and information
– Coolant circuit vent 1
– Exhaust ducts 2
– Oil filter 3
– Coolant circuit to the heat exchanger 4
– Coolant circuit from the heat exchanger 5
– Engine oil supply 6
– Engine oil return 7
1
2
3
4
5
– 1st cylinder 8
– 2nd cylinder 9
– Fuel supply 10
– Air intake 11
– Engine rotation direction 12
– Stub shaft 13
– Crankcase vent 14
8
9
10
11
12
6
7
13
14
14 SHB MPE850 Rev 1.1 | 406555 |
3 Description
3.7 Technical specifications
3.7 Technical specifications
Type
Displacement
Number of cylinders
Bore x stroke
Compression ratio
Engine power
Speed limit
Idle speed
Carburation
Lubrication system
Cooling system
Engine management system
Throttle body
Ignition system
Starter system
Generator, internal
Weight
Dimensions
4-stroke gasoline engine, parallel twin with balance shaft and overhead camshaft (SOHC)
846 cm³
2
89 mm x 68 mm [3.5 in x 2.7 in]
11,5 : 1
Godiva 1710: 42 kW [57 PS] @ 5600 min -1 [rpm] SAE J1349
Godiva 1210: 22 kW [30 PS] @ 5250 min-1 [rpm] SAE J1349
6500 min -1 [rpm]
1250 – 1750 min -1 [rpm] sequential multipoint intake manifold dry sump closed coolant circuit
Synerject Easy-U electronically controlled, dia. = 44 mm [1.73 in] electronic ignition electric starter
> 450 W @ 4000 min -1 [rpm]
55 kg [121 lb] without engine oil and coolant see figure
420 mm [17 in] 408 mm [16 in]
SHB MPE850 Rev 1.1 | 406555 | 15
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 or at least once a week before operation
■ 1
■ 1
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4 Operation
4.1 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.
Activity
1st service after 25 h 1
■ 2 subsequent service intervals every 100 h 1 every 200 h 1
■ 2 preparing for storage 4
■
Change engine oil and oil filter
Check and adjust valve play
■ ■ 3
Replace spark plugs
■ 3
Check spark plugs
■
Change coolant
See the portable fire pump manufacturer‘s documentation.
Engine internal preservative
■
Fuel stabilizer
Replace fuel filter
See the portable fire pump manufacturer‘s documentation.
1 h = hours of operation
2 or at least once a year if the hours of operation specified above are not reached before that
3 or at least every two years if the hours of operation specified above are not reached before that
4 if you do not intend to operate the engine for more than 30 days
■
SHB MPE850 Rev 1.1 | 406555 | 17
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.
Observe the following points to ensure that the engine parts break in properly:
Avoid
Good
Engine speeds over 5500 min-1 [rpm] long periods of idle operation long operating periods at low engine speeds long operating periods at the same engine speed long operating periods at full load changes in engine speed when the engine is warm, momentary bursts of acceleration
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4 Operation
4.3 Before operation
4.3 Before operation
4.3.1 Checking coolant level
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.
Information!
Your engine uses a dry sump lubrication system. Engine oil is pumped from the engine into the oil tank while the engine is operating. When the engine is switched off, a portion of the engine oil flows from the oil tank slowly back into the engine. Therefore inspect the oil level immediately after switching off the engine.
Engine damage caused by a lack of engine oil.
A lack of engine oil will cause moving components in the engine to seize.
► Always check the oil level before operating the engine.
Engine damage caused by excessive engine oil.
If the quantity of engine oil is excessive, oil may enter the intake system through the crankcase vent and damage the engine.
► Check the oil level as described in the portable fire pump manufacturer‘s documentation.
► Measure the engine oil filling quantity before topping up the engine oil.
SHB MPE850 Rev 1.1 | 406555 | 19
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. Preparations must be performed in a workshop authorized by Weber Motor or the portable fire pump manufacturer.
20 SHB MPE850 Rev 1.1 | 406555 |
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 1.1 | 406555 | 21
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. Visit your local portable fire pump dealer or our web site www.weber-motor.com for more information.
7.3 Repairs
Repairs require mechanical knowledge and special technical knowledge of this engine. Weber Motor recommends you have any repairs performed by a workshop authorized by Weber Motor or the portable fire pump manufacturer.
7.4 Warranty
In the case of warranty claims, always consult a workshop authorized by the portable fire pump manufacturer. If that is not possible, contact your local portable fire pump dealer.
22 SHB MPE850 Rev 1.1 | 406555 |
8 Service tasks in the workshop
8.1 Safety messages workshop
8 Service tasks in the workshop
8.1 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.
Service manual
Engine power supply
Protective equipment
Before reading chapter 8 Service tasks in the workshop, you must have read and understood all other information in the service manual.
► Read through the service manual carefully before performing any service tasks. Pay particular attention to the safety messages.
All 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 before performing any servicing tasks.
► Only reconnect the power supply to the engine once all service tasks are complete and all protective equipment is correctly fitted.
Missing protective equipment poses a safety risk to personnel.
► Attach all protective equipment after completing the service tasks.
Tools Unsuitable tools pose a safety risk to personnel.
► Always use tools listed in chapter 8.2 Tools and accessories.
SHB MPE850 Rev 1.1 | 406555 | 23
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
Valve adjustment shims in different sizes Oil filter
Spark plug
Champion RC7PYCBX
Feeler gauge
0.05 – 2 mm
Serrated lock washer
Valve adjustment kit
Sealing kit valve cover
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8 Service tasks in the workshop
8.2 Tools and accessories
8.2.2 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.
Figure Description Figure Description
Bar magnet
Spark plug wrench
Wrench size 16 mm
[5/8“]
Diameter: maximum
22 mm [0.87 in]
Hexagon screwdriver 5
Torque wrench
8 – 32 Nm
[5 – 24 lbf ft] with extension and insert adapter
Reversible ratchet with extension and insert adapter
Hexagon screwdriver socket 5
Caliper
Measuring accuracy
0.05 mm
Spark plug brush
Universal strap wrench
Universal pliers
SHB MPE850 Rev 1.1 | 406555 | 25
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.
Supplies
Anti-Seize assembly paste for lubricating threaded connections
Recommended products
Weicon Anti-Seize „High-Tech“ ASW 040 P
Loctite 8150
Engine internal preservative
Fuel stabilizer
Sealing surface cleaner
Liqui Moly, Germany
Liqui Moly, Germany
Liqui Moly brake and parts cleaner AIII, Germany
26 SHB MPE850 Rev 1.1 | 406555 |
8.3 Changing engine oil and oil filter
8.3.1 Changing engine oil
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.
► Unscrew the oil filter 1 using a universal strap wrench.
1
8 Service tasks in the workshop
8.3 Changing engine oil and oil filter
► Replace the oil filter 2 .
► Clean the sealing surface 3 with sealing surface cleaner.
► Coat the oil filter seal 4 lightly with engine oil.
► Screw in the oil filter by hand.
Anziehdrehmoment:
10 Nm [7.4 lbf ft]
► Fill with engine oil. (See the portable fire pump manufacturer‘s documentation.)
► Start the engine and allow to run for
1 – 2 minutes.
2
3
4
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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.
► Disconnect the wire harness connector from the ignition coils 1 and sensor camshaft
2 .
1
2
► Unscrew bolts 3 .
► Unplug ignition coils 4 .
3
4
► Unscrew bolts 5 .
► Remove valve cover 6 .
5
6
28 SHB MPE850 Rev 1.1 | 406555 |
8 Service tasks in the workshop
8.4 Checking and adjusting valve play
Information!
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.
Checking the valve play on the 2nd 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 7 ends flush with the cross bar.
All rocker arms 8 on the cylinder have a certain amount of play.
7
8
► Check the valve play 9 of all valves on the cylinder using a feeler gauge.
Required valve play:
0,2 – 0,3 mm
► If the valve play of one or more valves is not right, continue with chapter 8.4.2 Adjusting
valve play.
9
SHB MPE850 Rev 1.1 | 406555 | 29
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.
All rocker arms 11 on the cylinder have a certain amount of play.
10
11
► Check the valve play 12 of all valves on the cylinder using a feeler gauge.
Required valve play:
0,2 – 0,3 mm
► If the valve play of one or more valves is not right, continue with chapter 8.4.2 Adjusting
valve play.
12
► Replace valve cover seals 13 .
13
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8 Service tasks in the workshop
8.4 Checking and adjusting valve play
► Clean the sealing surface 14 with sealing surface cleaner.
14
► Put the valve cover 15 on.
► Apply Anti-Seize assembly paste to all bolts
16 .
► Tighten the bolts in the sequence shown 17
.
Tightening torque:
8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]
15
16
17
5
8
3
1
2
4
7
► Insert the ignition coils 18 .
► Replace serrated lock washers 19 .
Assemble the bolts 20 , washers 21 and serrated lock washers as illustrated.
Tightening torque:
8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]
18
19
20
21
► Connect the wire harness connectors to the ignition coils 22 and sensor camshaft 23 .
► Start the engine and allow to run for
1 – 2 minutes.
22
23
6
SHB MPE850 Rev 1.1 | 406555 | 31
8 Service tasks in the workshop
8.4 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
Information!
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.
Adjusting the valve play on the 2nd cylinder
WARNING! Danger of serious cuts from the gear on the camshaft when the engine is started. Disconnect the engine from the power supply.
► 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 1 ends flush with the cross bar.
All rocker arms 2 on the cylinder have a certain amount of play.
► Continue with the section Replacing valve
adjustment shim.
1
2
32 SHB MPE850 Rev 1.1 | 406555 |
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.
All rocker arms 4 on the cylinder have a certain amount of play.
► Continue with the section Replacing valve
adjustment shim.
3
4
Replacing valve adjustment shim.
NOTICE! Engine damage from small components in the engine or cylinder head. Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize.
► Cover the chain channel 6 .
► Hold the valve adjustment tool 7 in position.
► Screw in the bolts 5 .
Tightening torque:
8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]
5
6
7
8 Service tasks in the workshop
8.4 Checking and adjusting valve play
SHB MPE850 Rev 1.1 | 406555 | 33
8 Service tasks in the workshop
8.4 Checking and adjusting valve play
► Position the rocker arm pusher 8 on the rocker arm 9 .
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 13 using a bar magnet.
► Measure the valve adjustment shim using a caliper.
► Insert the new valve adjustment shim.
13
34 SHB MPE850 Rev 1.1 | 406555 |
► Hold the rocker arm pusher 14 in position.
► Press down the slide plate 15 slightly using the rocker arm pusher.
► Slide the pin 16 forward by hand.
► Slowly release the rocker arm pusher.
The valve spring slides the slide plate upwards again.
14
15
16
► Unscrew the bolts 17 .
► Remove the valve adjustment tool 18 .
► Remove the cover from the chain channel.
NOTICE! Valve breakage due to insufficient valve play.
► Check the valve play.
► Continue with chapter 8.4.1 Checking valve
play.
17
18
8 Service tasks in the workshop
8.4 Checking and adjusting valve play
SHB MPE850 Rev 1.1 | 406555 | 35
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
Information!
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.
Adjusting the valve play on the 2nd cylinder
WARNING! Danger of serious cuts from the gear on the camshaft when the engine is started. Disconnect the engine from the power supply.
► 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 1 ends flush with the cross bar.
All rocker arms 2 on the cylinder have a certain amount of play.
► Continue with the section Replacing valve
adjustment shim.
1
2
36 SHB MPE850 Rev 1.1 | 406555 |
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.
All rocker arms 4 on the cylinder have a certain amount of play.
► Continue with the section Replacing valve
adjustment shim.
3
4
Replacing valve adjustment shim.
NOTICE! Engine damage from small components in the engine or cylinder head. Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize.
► Cover the chain channel 5 .
► Remove the rocker axle 6 using a universal pliers.
5
6
► Remove the rocker arm 7 .
► Remove the valve adjustment shim 8 using a bar magnet.
► Measure the valve adjustment shim using a caliper.
7
8
8 Service tasks in the workshop
8.4 Checking and adjusting valve play
SHB MPE850 Rev 1.1 | 406555 | 37
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 10 in position.
► Check if the circlip 12 is installed.
► Slide in the rocker axle 11 .
► Remove the cover from the chain channel.
NOTICE! Valve breakage due to insufficient valve play.
► Check the valve play.
► Continue with chapter 8.4.1 Checking valve
play.
10
11
12
38 SHB MPE850 Rev 1.1 | 406555 |
6.5 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 .
1
6 Service tasks in the workshop
6.5 Replacing spark plugs
► Unscrew bolts 2 .
► Unplug ignition coils 3 .
2
3
► Remove the spark plugs 4 using a spark plug wrench.
► Replace the spark plugs.
► Install the spark plugs using a spark plug wrench.
Tightening torque:
20 Nm +6 Nm [14.8 lbf ft ±4.4 lbf ft]
4
SHB MPE850 Rev 1.1 | 406555 | 39
6 Service tasks in the workshop
6.5 Replacing spark plugs
► Insert the ignition coils 5 .
► Replace serrated lock washers 6 .
Assemble the bolts 7 , washers 8 and serrated lock washers as illustrated.
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.
9
40 SHB MPE850 Rev 1.1 | 406555 |
8 Service tasks in the workshop
8.6 Checking spark plugs
8.6 Checking spark plugs
– Serrated lock washer
– Hexagon screwdriver 5 mm
– Torque wrench
– Reversible ratchet
– Hexagon screwdriver socket 5 mm
– Spark plug wrench
– Feeler gauge
Remove spark plugs with a cold engine.
► Disconnect the wire harness connectors from the ignition coils 1 .
1
– Spark plug brush
► Unscrew bolts 2 .
► Unplug ignition coils 3 .
2
3
► Remove the spark plugs 4 using a spark plug wrench.
4
SHB MPE850 Rev 1.1 | 406555 | 41
8 Servicearbeiten in der Werkstatt
8.6 Zündkerzen prüfen
► If the electrodes 5 are extremely sooty, clean carefully using a spark plug brush.
► Check the spark plug gap 6 using a feeler gauge.
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 7 using a spark plug wrench.
Tightening torque:
20 Nm +6 Nm [14.8 lbf ft ±4.4 lbf ft]
7
► Insert the ignition coils 8 .
► Replace serrated lock washers 9 .
Assemble the bolts 10 , washers 11 and serrated lock washers as illustrated.
Tightening torque:
8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]
8
9
10
11
42 SHB MPE850 Rev 1.1 | 406555 |
► Connect the wire harness connectors to the ignition coils 12 .
► Start the engine and allow to run for
1 – 2 minutes.
12
8 Servicearbeiten in der Werkstatt
8.6 Zündkerzen prüfen
SHB MPE850 Rev 1.1 | 406555 | 43
8 Service tasks in the workshop
8.7 Changing coolant | …
8.7 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 1.1 | 406555 |
8 Service tasks in the workshop
8.9 Preparing the engine for storage
8.9 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.)
► Spray engine internal preservative into the cylinder through the spark plug bores 1 according to the manufacturer's instructions.
Do not start the engine again.
1
SHB MPE850 Rev 1.1 | 406555 | 45
8 Service tasks in the workshop
8.10 Disposal
8.10 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 1.1 | 406555 |
9 Confirmation of service tasks
9 Confirmation of service tasks
Have the workshop personnel provide certification confirming that your engine was serviced. You can use the following documents.
Engine variant (6-digit)
Serial number (8-digit)
_ _ _ _ _ _
_ _ _ _ _ _ _ _
Date of initial registration
_________________
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
SHB MPE850 Rev 1.1 | 406555 | 47
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
48
Date:
Status hours of operation:
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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
......................................
......................................
......................................
......................................
Company seal, signature
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:
Work carried out:
Engine oil and oil filter changed
Valve play checked
Spark plugs replaced
Coolant changed
Fuel Filter replaced
......................................
......................................
......................................
......................................
Company seal, signature
SHB MPE850 Rev 1.1 | 406555 |
Appendix
Engine manufacturer
Engine manufacturer Weber Motor GmbH
Otto-Lilienthal-Str. 5
88677 Markdorf
Germany www.weber-motor.com
Appendix
Engine manufacturer
SHB MPE850 Rev 1.1 | 406555 | 49
Appendix
Index
Index
B
C
D
Dealer and servicing network 22
Direction of rotation, engine 14
E
I
F
L
M
O
P
R
S
50
Spark plugs, spark plug gap 41
T
V
Valve play, adjust without special tool 36
Valve play, adjust with valve adjustment kit 32
W
SHB MPE850 Rev 1.1 | 406555 |
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