Weber 4-Stroke Engine MPE 850 IND NA, Service Manual

Page 1: ...0 07 2012 MPE 850 IND NA 406555 This service manual is valid for the following engine variants Read this service manual thoroughly before operating the engine for the first time SERVICE MANUAL 4 Strok...

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Page 3: ...ber 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 transl...

Page 4: ...cations 15 4 Operation 16 4 1 Service intervals 16 4 2 Operation during the break in period 18 4 3 Before operation 19 4 3 1 Checking coolant level 19 4 3 2 Checking oil level 19 5 Special scenarios 2...

Page 5: ...ve play 28 8 4 2 Adjusting valve play with valve adjustment kit 32 8 4 3 Adjusting valve play without special tool 36 6 5 Replacing spark plugs 39 8 6 Checking spark plugs 41 8 7 Changing coolant 44 8...

Page 6: ...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 d...

Page 7: ...mation in this service manual accident prevention environmental protection handling of hazardous materials personal safety equipment traffic laws 2 Safety 2 1 Meaning of the safety alert symbol and si...

Page 8: ...riginal Weber Motor spare parts 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 att...

Page 9: ...hyxiation When operating the engine in enclosed spaces use exhaust hoses to direct the engine exhaust gases into the open Engine exhaust gases Some service tasks require disconnection of the engine fr...

Page 10: ...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 California...

Page 11: ...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 3 1 Intended use The labels with the part number and the serial...

Page 12: ...and Consult your local portable fire pump dealer Engine damage due to incorrect engine oil grade or viscosity An incorrect engine oil grade or viscosity causes excessive wear and moving parts may star...

Page 13: ...ot change the mixing ratio Always use approved coolant additives when topping up the coolant Information Weber Motor recommends you always keep an adequate supply of ready mixed coolant to hand Consul...

Page 14: ...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 1st cylinder 8 2nd cylinder 9 Fuel supply 10 Air...

Page 15: ...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 ignitio...

Page 16: ...e yourself with the portable fire pump before operating the engine Read the portable fire pump manufacturer s documentation In order to keep your engine in a safe operating condition regular servicing...

Page 17: ...portable fire pump manufacturer s documentation The following service tasks require mechanical knowledge and special technical knowledge of this engine These service tasks must be performed in a work...

Page 18: ...f the engine Observe the following points to ensure that the engine parts break in properly Engine speeds over 5500 min 1 rpm long periods of idle operation long operating periods at low engine speeds...

Page 19: ...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...

Page 20: ...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 Prepara...

Page 21: ...21 SHB MPE850 Rev 1 1 406555 6 Malfunctions In the event of a malfunction please contact a workshop authorized by Weber Motor or the portable fire pump manufacturer immediately 6 Malfunctions...

Page 22: ...e 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...

Page 23: ...ntly 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 task...

Page 24: ...mp dealer or our web site www weber motor com for more information 8 2 1 Weber Motor service case 8 Service tasks in the workshop 8 2 Tools and accessories Figure Description Oil filter Spark plug Cha...

Page 25: ...suring accuracy 0 05 mm 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...

Page 26: ...tive Liqui Moly Germany Fuel stabilizer Liqui Moly Germany Sealing surface cleaner Liqui Moly brake and parts cleaner AIII Germany You will require the following supplies to perform service tasks Unle...

Page 27: ...oil filter 1 using a universal strap wrench Protective gloves Oil filter Universal strap wrench Sealing surface cleaner 8 3 1 Changing engine oil 8 Service tasks in the workshop 8 3 Changing engine oi...

Page 28: ...he power supply Disconnect the wire harness connector from the ignition coils 1 and sensor camshaft 2 8 4 1 Checking valve play Unscrew bolts 3 Unplug ignition coils 4 Unscrew bolts 5 Remove valve cov...

Page 29: ...n of the camshaft 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...

Page 30: ...ting 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...

Page 31: ...equence shown 17 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Insert the ignition coils 18 Replace serrated lock washers 19 Assemble the bolts 20 washers 21 and serrated lock washers as illustrat...

Page 32: ...ation 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 Replacin...

Page 33: ...ition Screw in the bolts 5 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Adjusting the valve play on the 1st cylinder Turn the camshaft until the position of the camshaft is as illustrated See the...

Page 34: ...sher 10 until the pin 12 engages Remove the valve adjustment shim 13 using a bar magnet Measure the valve adjustment shim using a caliper Insert the new valve adjustment shim 8 Service tasks in the wo...

Page 35: ...nd Slowly release the rocker arm pusher The valve spring slides the slide plate upwards again Unscrew the bolts 17 Remove the valve adjustment tool 18 Remove the cover from the chain channel NOTICE Va...

Page 36: ...nd 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 8 Service tas...

Page 37: ...ection Replacing valve adjustment shim Remove the rocker arm 7 Remove the valve adjustment shim 8 using a bar magnet Measure the valve adjustment shim using a caliper Replacing valve adjustment shim N...

Page 38: ...talled 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 8 S...

Page 39: ...nition coils 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 Spark pl...

Page 40: ...rs 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 Connect the wire harness connectors to the ignition coils 9 Start the eng...

Page 41: ...rs from the ignition coils 1 Unscrew bolts 2 Unplug ignition coils 3 Remove the spark plugs 4 using a spark plug wrench Serrated lock washer Hexagon screwdriver 5 mm Torque wrench Reversible ratchet H...

Page 42: ...cearbeiten in der Werkstatt 8 6 Z ndkerzen pr fen Install the spark plugs 7 using a spark plug wrench Tightening torque 20 Nm 6 Nm 14 8 lbf ft 4 4 lbf ft If the electrodes 5 are extremely sooty clean...

Page 43: ...43 SHB MPE850 Rev 1 1 406555 12 Connect the wire harness connectors to the ignition coils 12 Start the engine and allow to run for 1 2 minutes 8 Servicearbeiten in der Werkstatt 8 6 Z ndkerzen pr fen...

Page 44: ...1 406555 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 8 Service tasks in the workshop...

Page 45: ...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 acco...

Page 46: ...1 1 406555 8 10 Disposal When disposing of operating materials replaced parts or the whole engine always comply with the relevant applicable national laws and guidelines 8 Service tasks in the worksh...

Page 47: ...placed Status hours of operation Company seal signature Date Work carried out Engine oil and oil filter changed Valve play checked Spark plugs replaced Coolant changed Fuel Filter replaced Status hour...

Page 48: ...ugs replaced Coolant changed Fuel Filter replaced Status hours of operation Company seal signature Date Work carried out Engine oil and oil filter changed Valve play checked Spark plugs replaced Coola...

Page 49: ...49 SHB MPE850 Rev 1 1 406555 Appendix Engine manufacturer Weber Motor GmbH Otto Lilienthal Str 5 88677 Markdorf Germany www weber motor com Engine manufacturer Appendix Engine manufacturer...

Page 50: ...fikation engine 11 Intended use engine 11 L Locating a workshop 22 M Malfunctions 21 Manufacturer engine 49 O Oil Filter replace 27 Oil level check 19 P Part number engine 11 R Repairs 22 S Serial num...