operation manual · 20 august 2016 10, 20 oil specification change – now use 0w/40 api sj and...

Portable Fire Pump

Operation Manual

Publication: GP/282 Issue 11, February 2019

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©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

AMENDMENT RECORD Model: Powerflow 12/10, 17/10 Portable Fire Pumps Mod Date Page/s Amendment New Issue No.

1 May 2012 All New document 1 2 July 2012 8 Lifting information 2 2 July 2012 23 Maintenance schedule revision 2 3 July 2012 19,24 Revised oil level check procedure 2 4 August

2012 26 Pressure Test – delete reference to

Priming Valve 3

4 August 2012

5 Location of serial number plate 3

5 August 2012

22 “Engine Management” is now “Malfunction indicator lamp”

3

6 August 2012

8 Revised pump weights 3

7 November 2012

10,19,20, 25

Revised oil level check procedure 4

8 November 2012

8 Revised Lifting Information 4

9 August 2013

20 Add battery connection information 5

10 August 2013

21 Add Battery Strap pulling information 5

11 August 2013

19-20 Revised oil dipstick – longer stick 5

12 August 2013

24-27 Wheel assembly and extending handles 5

13 August 2013

28-30 Auxiliary fuel tank 5

14 August 2013

31, 34 Add raw water filter information 5

15 August 2013

All pages Add Hale logo to document for dual Godiva/Hale branding

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16 November 2015

17, 24 Add information on maintaining a flow of water to keep engine cool

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17 November 2015

15 Indicator lights – revised layout of lights 6

18 June 2016

19 Revised oil check procedure 7

19 June 2016

18, 34 Fuel condition guide 7

20 August 2016

10, 20 Oil specification change – now use 0W/40 API SJ and 10W/40 API SJ, fully synthetic oils.

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21 September 2016

18 New heat exchanger – reading coolant level

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22 November 2017

6-7 Information on auxiliary fuel tank provision to prolong running time

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23 November 2017

23-24 Control of pump flow and securing delivery valve hand wheels

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24

November 2017

29 Auxiliary fuel tank – add .75m between pump and tank

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25 February 2019

33 Engine oil level checking revised 11

26 February 2019

22, 31-32 Additional information about battery charging and floodlight

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CONTENTS AMENDMENT RECORD .................................................................................................. 1

CONTENTS ...................................................................................................................... 2

IMPORTANT NOTES ....................................................................................................... 5

FUEL SYSTEM CARE .................................................................................................................... 5 PUMP SERIAL NUMBER ............................................................................................................... 5

SAFETY RELEVANT DATA ............................................................................................ 6

MAINTENANCE ............................................................................................................................ 6 TRAINING ................................................................................................................................... 6 SAFETY POINTS .......................................................................................................................... 6 LIFTING INFORMATION ................................................................................................................. 8

ENVIRONMENTAL PROTECTION .................................................................................. 9

GENERAL DATA ........................................................................................................... 10

ENGINE .................................................................................................................................... 10 WEIGHT & MATERIALS .............................................................................................................. 10 MATERIALS OF CONSTRUCTION ................................................................................................. 11 PUMP ...................................................................................................................................... 11 MAXIMUM OPERATING PRESSURE ............................................................................................. 12 OPTIONAL EQUIPMENT .............................................................................................................. 12 AUXILIARY SOCKET ................................................................................................................... 12 ASSOCIATED PUBLICATIONS ...................................................................................................... 12

MAJOR COMPONENTS AND CONTROLS 17/10 AND 12/10 MODELS...................... 13

GENERAL ARRANGEMENT - LEFT HAND VIEW (FROM FRONT) ....................................................... 13 GENERAL ARRANGEMENT - RIGHT HAND SIDE (FROM REAR) ....................................................... 14 GENERAL ARRANGEMENT – CONTROLS AND INSTRUMENTS ......................................................... 14 INDICATOR LIGHTS .................................................................................................................... 15

SYSTEM OVERVIEW ..................................................................................................... 16

PUMP ...................................................................................................................................... 16 CROSS SECTION OF PUMP ........................................................................................................ 16 COOLING SYSTEM ..................................................................................................................... 17 PRIMING SYSTEM, EXHAUST GAS PRIMER .................................................................................. 17 FUEL TANK ............................................................................................................................... 17 FRAME ..................................................................................................................................... 17

LIFTING INFORMATION ................................................................................................ 18

PREPARATION .............................................................................................................. 18

FUEL FILLING ........................................................................................................................... 18 COOLANT FILLING ..................................................................................................................... 18 OIL FILLING .............................................................................................................................. 19 BATTERY.................................................................................................................................. 21 BATTERY STRAP ....................................................................................................................... 21 BATTERY CHARGING ................................................................................................................. 22

OPERATION .................................................................................................................. 24

FROM OPEN WATER - ................................................................................................................ 24 FROM HYDRANT SUPPLY – ........................................................................................................ 25

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TO STOP PUMP – ...................................................................................................................... 25 WARNING LIGHTS ..................................................................................................................... 26

ACCCESSORIES - OPERATION ................................................................................... 27

WHEEL ASSEMBLY AND EXTENDING HANDLES ............................................................................. 27 AUXILIARY FUEL TANK .............................................................................................................. 30 FLOODLIGHT ............................................................................................................................ 32

MAINTENANCE SCHEDULE - 17/10 AND 12/10 MODELS .......................................... 34

MAINTENANCE OPERATIONS - ENGINE .................................................................... 35

ROUTINE MAINTENANCE ........................................................................................................... 35 ENGINE FLUID CHECK & CHANGE .............................................................................................. 35

Engine Oil Check .................................................................................................................................. 35 Coolant ................................................................................................................................................. 35 Engine Oil and Oil Filter ....................................................................................................................... 35 Air Filter Element .................................................................................................................................. 35

ENGINE – SPARK PLUGS, VALVES .............................................................................................. 35 Spark Plugs .......................................................................................................................................... 35 Check and adjust valve play................................................................................................................. 35 Engine internal preservation ................................................................................................................. 36 Fuel condition guide ............................................................................................................................. 36

MAINTENANCE OPERATIONS - PUMP ....................................................................... 37

VOLUTE DRAIN ......................................................................................................................... 37 RAW WATER FILTER .................................................................................................................. 37 GAUGES .................................................................................................................................. 37 CLEANING THE PUMP ................................................................................................................ 37 PUMP TESTS ............................................................................................................................ 38

Running Test ........................................................................................................................................ 38 Vacuum Test - Exhaust Gas Priming ................................................................................................... 38 Pressure Test ....................................................................................................................................... 38

BATTERY CARE ........................................................................................................................ 38 Safety ................................................................................................................................................... 38 Terminals .............................................................................................................................................. 38 Charging ............................................................................................................................................... 38

FAULT TRACING ........................................................................................................... 39

ENGINE .................................................................................................................................... 39 PUMP ...................................................................................................................................... 40

PUMP LOG SHEET ........................................................................................................ 41

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IMPORTANT NOTES Please read this manual before operating the machinery. CRITICAL: Ex works, there is NO lubricating oil in the engine sump or coolant in the heat exchanger. Refer to section titled Preparation (page 18) for oil and coolant data. Correct lubrication and maintenance is vital if satisfactory performance is to be maintained. Other than when priming, do NOT run the pump without water in the pump casing. The terms ‘Left Hand’ (LH) and ‘Right Hand’ (RH) apply when the pump unit is viewed from the suction tube end. For specific engine information please refer to the Weber Operating and Maintenance Instructions.

Fuel system Care To ensure availability and reliability of gasoline powered units, please note the following petrochemical industry guidelines: Unleaded gasoline has a maximum shelf life of six months. To avoid moisture in systems, keep fuel tanks FULL at all times. Run engines up to normal operating temperature, pumping water, once every

month. Regarding fuel inhibitors, please consult the engine manufacturer.

Pump Serial Number Pump Serial number ________________________ Specification GP12/10/ ___ Year manufactured _____ GP17/10/ ___ Year manufactured _____ The serial number, model specification and year of manufacture can be found on a plate attached to the engine intake manifold, on the right hand side of the pump.

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SAFETY RELEVANT DATA Thank you for purchasing a Godiva Pump. Godiva Pumps are designed to give safe and reliable service. BEFORE use, it is essential that the Operating and Installation Instructions are carefully read and understood.

Maintenance It is the responsibility of the user to ensure that the equipment is maintained in a safe operational condition. Local legislative conditions may apply. UK only, Maintenance (Regulation 5) of the Provision and Use of Work Equipment Regulations 1998 applies.

Training It is ESSENTIAL that Godiva pumps are operated ONLY by TRAINED PERSONNEL. Please contact Godiva Ltd to discuss your training needs. To avoid damage and personal injury, operating procedures laid down in this document MUST be observed.

Safety Points Please read this manual before operating the machinery. Safety notices -

= non-compliance could affect safety = in case of damage to pump = in case of personal hazards The following points apply to pumps driven by petrol, diesel or other means:

The exhaust system becomes VERY HOT in use, DO NOT TOUCH. Allow the system to cool before maintenance or inspection.

DO NOT OPERATE the unit close to flammable materials or structures. ENSURE that exhaust fumes are safely ventilated. DO NOT SMOKE while operating the unit. DO NOT inhale fumes or gases.

DO NOT REFUEL unless the engine is stationary and COLD *see note below

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IMPORTANT

!

ATTENTION

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ENSURE that the fuel cap is secure and DO NOT overfill the tank. Avoid prolonged skin contact with fluids, particularly if corrosive or

carcinogenic. When in use, keep ALL UNTRAINED people AWAY from the unit. Where appropriate, eye protection should be worn. DO NOT run the engine with the battery disconnected. Disconnect the negative (-ve) battery lead first and reconnect last when working on the electrical systems. Isolate the electrical supply when working on the pump. DO NOT lift heavy weights without assistance. DO NOT remove protective guards or shields. When cleaning the pump and engine use hot soapy water, do not use

flammable degreasers. Noise Operators must wear suitable EAR PROTECTION when the pump is running. Gauges Do not clean the glass surfaces of the gauges with abrasive or solvent cleaners. These will cloud the glass surface. Use a mild detergent and water. *Note Refuelling while running. If you need to re-fuel with the pump in operation, an auxiliary fuel tank is available which does permit safe re-fuelling in operation. See page 29 for further information.

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Lifting Information

Aluminium Pump GP12/10 GP17/10

Dry Wet Dry Wet

Weight Kg 125 145 128 148

Centre of gravity (mm)

X 386 393 386 393 Y 244 255 244 255 Z 276 274 276 274

Lifting forces (kg)

P1 25.1 26.2 25.7 30.3 P2 28.5 27.3 29.1 31.6 P3 38.0 38.0 38.9 44.0 P4 33.5 36.5 34.3 42.2

Gunmetal Pump GP12/10 GP17/10

Dry Wet Dry Wet

Weight Kg 157 177 160 180

Centre of gravity (mm)

X 350 363 350 363 Y 255 262 255 262 Z 276 274 276 274

Lifting forces (kg)

P1 37.0 41.1 37.7 41.8 P2 38.6 40.7 39.3 41.4 P3 41.6 47.3 42.4 48.1 P4 39.8 47.9 40.6 48.7

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ENVIRONMENTAL PROTECTION It is prohibited to pour engine oil and other contaminants onto the ground, down sewers, drains, or into water courses. Dispose of lubricants through authorised waste disposal contractors, licensed waste disposal sites, or to the waste reclamation trade. If in doubt, contact your Local Environmental Agency for advice regarding disposal policies. End of life disposal – please dispose of the pump according to local regulations relating to recycling of materials.

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GENERAL DATA

Engine Engine type Weber MPE 850 NA Power – 17/10 model 52kW (70 HP) @ 7500 min-1 [rpm] ECE-R 85

12/10 model 40kW (54 HP) @ 7500 min-1 [rpm] ECE-R 85 Capacity 846 cc Number of Cylinders 2 cylinder Ignition system Electronically controlled Spark Plug Gap 0.7 – 0.8mm Spark Plug Type Champion RC7 PYCB X Lubrication Pressurised Full Flow System

Service Oil Fill Capacity

2 litres, 0W/40, fully synthetic, API SJ. Alternative – 10W/40 fully synthetic API SJ, only for operation under ambient conditions > 0°C

Oil Filter Metal spin on type Fuel Type Unleaded gasoline EU 95 RON, US 91 RON/MON Fuel Feed Electric pump Fuel Capacity 18 litres Run Time - 17/10 model 60 minutes running at rated performance 12/10 model 75 minutes running at rated performance

Battery 12v, 19Ah Absorbent glass material type, no filling required

Coolant 4 litres, ethylene glycol, silicate and nitrite free Suitable for aluminium engines, 50/50 water/coolant. Acts as anti-freeze in winter and coolant In summer

Manual start 12/10 (and later versions of 17/10) fitted with hand pulled recoil starter

Weight & Materials

Model 17/10

Model 12/10

Aluminium pump

Weight, dry 128Kg 125Kg

Weight, wet 148Kg 145Kg

Bronze pump

Weight, dry 160Kg 157Kg

Weight, wet 180Kg 177Kg

Note: The wet weight is inclusive of the full capacity of engine oil, fuel, coolant and battery.

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Materials of Construction Aluminium Pump Bronze Pump Pump Casing Aluminium Bronze Impeller Aluminium Bronze Pump shaft Stainless steel Stainless steel Suction tube Aluminium Bronze Wearing rings Delrin Delrin Engine - Cylinder Head Aluminium Aluminium Engine - Cylinder Block Aluminium Aluminium Frame 17/10 Stainless steel Stainless steel

12/10 Aluminium, black powder coated

Aluminium, black powder coated

Control panel 17/10 Stainless steel Stainless steel

12/10 Aluminium, black powder coated

Aluminium, black powder coated

Pump Maximum output at 10 bar – 17/10 1700 l/min 12/10

1200 l/min Rated output at 10 Bar - 17/10 1500 l/min – FPN 10-1500 12/10 1000 l/min – FPN 10-1000 Maximum Flow 17/10 2450 l/min at 3 bar 12/10 2150 l/min at 3 bar Maximum Pump Discharge Pressure 17/10 17 bar (with boosted suction)

12/10 17 bar (with boosted suction) Maximum Suction Inlet Pressure 10 bar Priming time to 7.5m <30 seconds Dimensions (L x W x H) 677 x 525 x 620 mm Maximum angle of inclination 30° in any plane Ambient operating temperature -15° to 55°C in ambient air 45°C maximum for water in pump Dangerous goods identification category Class 9 UN3166

Data source: Godiva 17/10, 12/10 light alloy pump with 4" suction; 2 x 2½" delivery valve (typical connector configuration)

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Maximum Operating Pressure Maximum suction inlet pressure 10 bar Maximum delivery pressure for 17 bar (12/10 and 17/10) (achieved under boosted suction conditions) Operating beyond these parameters exceeds the limits of the pump specification, and the pump could subsequently suffer damage.

Optional Equipment Detachable floodlight – rated @ 55w. Detachable wheel assembly for transporting pump over long distances. Frame with extendable handles. Additional fuel tank with quick release connection extension hose.

Auxiliary Socket The 3-pin socket is provided for use with auxiliary equipment, e.g. floodlight or battery charger. The socket is located on the right side of the pump just below the top of the frame. Connect a plug to the equipment according to the equipment manufacturer’s instructions. Note: on certain pump specifications this will be a 2-pin DIN type socket. A battery charger suitable for AGM batteries should be used compatible with a 12V 19AH battery. Please see page 22 for further instructions on charging procedure and page 32 for floodlight use.

Associated Publications Publication Part

Quick Start Guide GP/301 Workshop Manual GP/291 Pump Parts List GP/292

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MAJOR COMPONENTS AND CONTROLS 17/10 AND 12/10 MODELS

General Arrangement - Left Hand View (from front)

1 Priming valve – automatic operation 2 Engine oil filter 3 Coolant fill 4 Battery 5 Fuel filler cap 6 Delivery valve 7 Carrying handle – shown in stored position 8 Suction tube (shown with Round Thread connection) 9 Engine exhaust 10 Hand pulled recoil starter (behind volute)

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4 5

8

1

2

7

9

3

10

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General Arrangement - Right Hand Side (from rear)

12 Air filter 13 Oil fill cap

General Arrangement – Controls and instruments

14 Priming lever 15 Engine on/off switch 16 Pressure gauge (17/10 – 80mm dia. 12/10 – 60mm dia.) 17 Vacuum gauge (17/10 – 80mm dia. 12/10 – 60mm dia.) 18 Throttle – controls pump speed 19 Engine start

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13

15

16

18

19 14

17

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Indicator Lights

20 Fuel level indicator 21 Service Required (17/10 model only) 22 Battery warning light 23 Low oil pressure warning light 24 Not used (17/10 model only) 25 Malfunction indicator light 22 Coolant temperature warning light 23 Hours run counter Indicator Meaning Action Fuel level Shows fuel level Refill at ¼ full tank

Service (17/10 only) Routine service required

Refer to workshop manual

Battery Charge insufficient Charge battery

Low oil pressure Engine oil pressure is too low


Malfunction indicator lamp

Engine management system fault identified


Coolant temperature Engine temperature too high

Allow cold water to flow through heat exchanger or slow engine. Unblock filter.

Hours run counter Total hours run For maintenance schedule

20 24 25 26

27

21 22 23

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SYSTEM OVERVIEW

For both 17/10 and 12/10 Models unless stated

Pump The pump is primarily designed for use with clear water for firefighting operations. It can also be used for transferring water in a relay from remote locations or a hydrant, to a frontline fire fighting pump usually mounted on a fire appliance. The Godiva single stage centrifugal pump is directly mounted to a Weber MPE 850 NA engine. The pump incorporates a self-adjusting mechanical shaft seal and exhaust gas priming. Standard coupling connections are. Suction - 4” round thread Delivery - 21/2” British instantaneous valve couplings, 2 off. The valves on may be fixed in either one of two positions, approximately 90o disposed. Note: Alternative couplings are available. The pump body and impeller are made of aluminium alloy. The wear rings are Polyacetal.

Cross Section of Pump

Impeller

Front wear ring

Volute

Pump Body

Mechanical seal

Rear wear ring

Shaft

Filter – water for engine cooling

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Cooling system To enable normal operating temperatures to be maintained over extended running periods, a closed-circuit engine-cooling system is used. The system incorporates a heat exchanger and header tank. Raw water is piped from the volute through a strainer to the heat-exchanger tubes and returned to the suction tube. The closed-circuit engine-cooling system takes coolant from the engine which is then passed through the heat exchanger where it comes into contact with the internal tubes containing the pumped raw water. Note: The raw water and engine coolant do not come into direct contact but the heat transfer takes place through the walls of the internal tubes. IMPORTANT NOTE: It is VERY IMPORTANT that a DIFFERENTIAL PRESSURE OF 3 BAR is maintained and a small flow of water from the pump delivery valve. This is to ensure that the cool pumped water is being circulated through the heat exchanger to prevent overheating of the engine unit.

Priming System, Exhaust Gas primer Priming is achieved by an exhaust gas ejector, the priming unit being mounted on the engine exhaust. Operating the priming lever closes an exhaust butterfly valve, which deflects the exhaust gases through the ejector and creates a vacuum on the pump suction side. When water reaches the pump and all air is evacuated the impeller develops a pressure in the volute, as registered on the pressure gauge. Note: The automatic priming valve opens to allow the priming action to work and closes when the prime is achieved. It also remains closed when a pressurised water source is fed into the pump.

Fuel Tank The fuel tank is mounted on the right of the engine and is equipped with a screw-type filler cap. Always allow the engine to cool before filling with fuel. NOTE: A full tank is sufficient for approximately 1 hours running when pumping at the rated performance.

Frame 17/10 – polished stainless steel frame and control panel 12/10 – black control panel and aluminium frame A lighting mast is available that clips on to the upper part of the frame.

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LIFTING INFORMATION Godiva Ltd. recommends ‘team’ lifting to be adopted if no other form of lifting is available. Always use the lifting handles.

PREPARATION For both 17/10 and 12/10 Models unless stated

Fuel Filling Fill the fuel tank with 18 litres of unleaded gasoline. EU 95 RON, US 91 RON/MON. Never fill the tank when the engine is hot. Fuel condition guide – please refer to page 36 for guidance on maintaining optimum fuel condition for efficient engine running.

Coolant Filling Fill the cooling system with a 4 litre approximate mixture, so that the coolant is just at the side of the heat exchanger tubes inside the tank –

50% water + 50% coolant additive. Coolant additive based on ethylene glycol, silicate and nitrite-free, suitable for aluminium engines. Suitable additives - BASF Glysantin G 30 Chevron Havoline Extended Life Coolant XLC+B Valvoline Zerex G 30

Heat exchanger cross section, as viewed from rear of pump

Fill coolant to this level Internal tubing

Approximately 35mm From top of filler cap to surface of coolant

Coolant must be to this level here to be correctly filled.

Note: certain models of heat exchanger allow a small amount of coolant to collect on one side of the tank above the internal tubing. This can give a false indication of coolant level. To ensure correct coolant level always look to both sides of the internal tubing.

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The coolant additive acts as anti-freeze in winter and coolant in summer and must be used all year round. Be careful when filling the cooling system not to let the coolant spill on to the exhaust insulation below, the coolant is a flammable liquid.

Oil Filling For a new engine - Fill the engine with 2 litres of oil, through the combined oil tank cap/dipstick (3). At this stage do not check the oil level on the dipstick, as this will not be a true representation of the oil level. This is a dry sump lubrication engine. 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 may flow from the oil tank back into the engine. The dipstick allows for checking the oil level when the engine is in two distinct conditions 1. Engine has just started running and is cold. 2. Engine has been running for some time.

3

1 2

4

IMPORTANT

!ATTENTION

3A

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1. When engine oil is cold (<40˚C) Start engine and run for two minutes at idle. Stop engine, wait one minute, and check oil level. The level should be between the lower and centre line on the dipstick. 2. When engine oil is hot (>90˚C) Ensure engine is up to full working temperature. Stop engine and wait one minute. Check oil level. Level should be between centre and upper line on dipstick. The dipsticks should be screwed fully into the tank when checking the oil level. The oil volume between two adjacent marks is approximately 0.5 litres. When running the engine if possible keep water in the pump to ensure the main seal is lubricated. If necessary top up the oil level or drain off some oil to achieve the correct level. It is advisable to fill the engine in small quantities with repeat checking of the oil level to ensure the correct amount is used. If excessive oil is indicated (above the maximum mark on the dipstick) drain a small quantity of oil from the engine by using the drain plug at the bottom of the oil tank (3A), or by inserting an oil suction pump into the top of the oil tank. In total 2 litres of oil should be used to fill a new engine. Specification – 0W/40, fully synthetic, API SJ. Alternative oil is 10W/40 fully synthetic API SJ but only for use in temperatures above 0°C. Note: earlier dipstick models did not feature the distinction between cold and hot running engines, and showed only one minimum and one maximum line.

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For subsequent oil checks - Follow the procedures above noting the distinction between the hot and cold running engine and the effect this will have on the oil level showing on the dipstick.

Battery Battery is the absorbent glass matt type. Supplied as a sealed unit. Use a volt meter to check that the battery has retained a charge during transit and storage, if necessary re-charge the battery until a minimum of 12.4 volts are measured. If the battery needs connecting to the wiring harness, follow these instructions –

Connect the three red leads to the positive terminal first.

Then connect the two black leads to the negative terminal. Note: On later models only one black lead is fitted.

Note: if the battery has been disconnected or removed from the unit, this procedure must be followed to restart - 4.1 Reconnect the battery (red leads to positive terminal, black to negative terminal, in that order). 4.2 Place throttle in closed position (see item 26, page 15). 4.3 Turn on the engine (see item 15, page 15) but do not press the starter. 4.4 Wait one minute - a click will be heard from the throttle body after precisely one minute. 4.5 The unit is ready to be used.

Battery Strap When securing the battery in the frame, please be aware that the strap can be tightened to maximum effect by pulling the strap down to the left and right, alternatively. This will secure the battery in the frame and avoid it moving around when in operation.

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Battery Charging The pump is supplied with a charging socket fitted on the side of the pump frame. The standard type is a three pin socket and an alternative two pin DIN type socket is fitted to German specification pumps. When connected to a suitable battery charger, this socket will enable the battery to be recharged if necessary. The pump unit can be started and run using the recoil hand starter with the battery discharged, but under no circumstances should the engine be run if the battery is disconnected or removed, serious damage to the alternator will occur if this is attempted. A battery charger suitable for AGM batteries, compatible with a 12V 19AH battery, should be used for charging. The socket can also be used to connect a Godiva floodlight, see page 32.

Standard type plug and socket shown

Pull to the left and down

Pull to the right and down

Socket for battery charger or floodlight

Mating plug supplied with pump

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Standard type plug - wiring

DIN type plug for German specification pumps

DIN type plug wiring

Connect -ve lead to N terminal

Connect +ve lead to L terminal

Socket for battery charger or floodlight

Mating plug supplied with pump

Remove the plug cover and connect the charger positive lead to the pin marked “L”, and the negative lead to the pin marked “N”. The 3rd connection is not used. Replace the cover.

Release the pin housing from the outer housing by undoing 2 screws on the side. Pull the pin housing away from the outer housing.

The positive pin is indicated with the + symbol and negative with a – symbol. The wiring connections are on the reverse of the pin housing.

DIN type plug – note where the wires connect on the inside of the plug. When both wires are connected, replace the pin housing inside the outer housing and secure with the 2 screws.

+ve lead connection

-ve lead connection

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OPERATION For both 17/10 and 12/10 Models unless stated (17/10 model shown) Note: when the engine first starts it emits a rattle due to the decompression system operating (before oil pressure is generated) – this is normal and disappears when oil pressure is generated.

From open water - 1.1 Connect Suction and delivery hoses – Close delivery valves Starting engine with electric starter - 1.2 Turn on engine – move switch to on position 1.3 Keep throttle in closed position 1.4 Press engine start button. Starting engine with hand pulled recoil starter – 1.5 Turn on engine – move switch to on position 1.6 Keep throttle in closed position 1.7 Grab the recoil starter handle securely 1.8 Pull handle and cord out of pump smoothly and swiftly to the full extent of the cord, approximately 1.5m. The engine will turn over and start. If the engine does not start on the first attempt, repeat this action When engine has started (by electric start or hand pulled recoil starter) 1.9 Pull priming lever

1.10 Increase engine speed to 100% 1.11 Watch vacuum and pressure gauges 1.12 When pressure is achieved, release priming lever 1.13 Slowly open a delivery valve. Allow water to discharge. 1.14 Pump is now primed.

1.2, 1.5

1.1

1.4 1.3, 1.6

1.9

1.7, 1.8 Hand start option

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1.15 Now open both delivery valves fully. Control pump performance by increasing/decreasing throttle to achieve requirements, i.e. regulate flow adjusting engine speed with the delivery valves fully open.

1.16 If it is necessary to discharge water through both valves with differing flowrates,

the valve in the hi-flow line should be fully open, and the other valve may be partially closed to obtain the required operating condition.

Note that the valves may be subject to opening or closing due to vibration from the engine or water flow, so the hand wheels may need to be secured against movement with a lanyard or similar. It is VERY IMPORTANT that a DIFFERENTIAL PRESSURE OF 3 BAR is maintained and a small flow of water from the pump delivery valve. This is to ensure that the cool pumped water is being circulated through the heat exchanger to prevent overheating of the engine unit. Do not allow the pump to idle for more than two minutes.

From Hydrant supply – 1.17 Start the engine (electric start or hand pulled recoil starter) 1.18 Open the hydrant - priming is not necessary 1.19 Regulate flow by opening/closing delivery valve and engine speed 1.20 Do not allow vacuum gauge to drop below Zero – this will damage the mains supply or collapse suction hoses.

To stop pump – 1.21 Return engine throttle to idle for 1 minute. 1.22 Turn off engine – move switch to off position.

1.10, 1.14 1.11

1.12

1.13, 1.14

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Important: Do not run the pump without water, other than when priming, or damage to the internal shaft seal may occur.

Warning Lights Indicator Meaning Action Fuel level Shows fuel level Refill at ¼ full tank

Service (17/10 only) Routine service required


Battery Charge insufficient Charge battery

Low oil pressure Engine oil pressure is too low


Malfunction indicator lamp

Engine management system fault identified


Coolant temperature Engine temperature too high

Allow cold water to flow through heat exchanger or slow engine. Unblock filter.

Hours run counter Total hours run For maintenance schedule

1.20

1.21

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ACCCESSORIES - OPERATION

Wheel assembly and extending handles 1.1 The wheel assembly (p/n 68066) allows one person to move the pump as a “wheel

barrow” type arrangement.

1.2 The wheel assembly is best operated with the extended handles option.

(the extended handles can be specified with a new pump or retro-fitted).

1.3 The carrying handles are opened by pressing down on the handle and turning to a position 90° to the frame, in this position the handles will move up and lock in position.

1.4 To open the extended handle version, turn the handle anti-clockwise, after several turns the outer handle will become loose from the inner handle, this allows it to be pulled away from the frame.

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1.5 Pull the handle away from the frame until it engages with the locking thread at the other end of the inner handle.

1.6 Turn the outer handle anti-clockwise to lock onto the inner handle in the extended position.

Repeat the operation with the other handles if necessary. To operate the wheel assembly only the front two handles need to be extended. The wheel assembly fits to the rear, engine end, of the pump. The lower part of the assembly hooks under the pump frame, while the upper part of the frame rests against the frame higher up.

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1.7 The picture below shows where the lower part of the assembly hooks to the pump frame.

1.8 When the pump is lifted up at the front end the wheel assembly is retained in place

by the weight of the pump pressing down on the frame, this allows the pump to be pushed forward or backwards on the wheel.

Pump pushes down

Weight of pump ensures the wheel assembly remains engaged, allowing forward or backward movement

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Auxiliary Fuel Tank The auxiliary fuel tank is designed to extend the running time of the Powerflow 12/10 and 17/10 portable pump units. To use the tank follow these instructions, which apply to both 12/10 and 17/10 models. 1.1 Run the pump until the fuel gauge shows one red lamp and one green lamp are

illuminated, as shown here -

1.2 Place the auxiliary fuel tank at the side of the pump away from the exhaust. Try to

position the tank on the same level as the pump and at least .75m from the pump. The auxiliary tank can be filled with up to 22 litres of fuel (Unleaded gasoline EU 95 RON, US 91 RON/MON).

1.3 Locate the fuel inlet connector on the pump frame. This is on the front end of the pump, at the right hand side, just below the suction tube

1.4 Connect the auxiliary tank hose to this connector. Push the hose onto the connector until it clicks. The auxiliary tank hose is 2m long.

Minimum .75m Between pump and tank

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1.5 Unscrew the vent valve, on top of the auxiliary tank, to allow air into the tank. This allows the fuel level in both the pump tank and auxiliary tank to equalise.

1.6 Fuel can be added to the auxiliary tank while the pump is running to sustain

continuous pumping.

1. 7 Disconnecting the auxiliary tank. After use Close the vent valve on top of the auxiliary tank.

Release the hose from the pump connector by pressing the button on top and pulling the connector away.

32


1. 8 IMPORTANT NOTE Do not connect the auxiliary fuel tank until the fuel gauge lamps are at the correct level. This prevents excess fuel from building up in the auxiliary tank and exiting through the filler cap vent. Always use the tank on the cold side of the pump.

Floodlight 1.1 The battery charging socket will also power the floodlight when required. Floodlight part number 56504, with a standard type plug connected. Part number 68226/001 with a DIN type plug for German specification pumps. A base mounting to hold the floodlight post is located at the side of the instrument panel. There is an ON/OFF switch on top of the floodlight. It is recommended that the floodlight is only used when the pump is running, however a maximum of 30 minutes without the engine is acceptable with a fully charged battery, using the light longer than this may result in draining the battery.

1.2 Place the floodlight into the mounting bracket.

33


1.3 Connect the floodlight to the pump through the battery charging socket.

1.4 Turn on the floodlight by pulling the switch up. Press down to turn off.

OFF

ON

34


MAINTENANCE SCHEDULE - 17/10 AND 12/10 MODELS

Activity Before use

After each use

Every Month

After 1st 25 hours

Every 100

hours

Every 200

hours

Every 3

years

Preparation for storage4

Pump/ engine

Pump tests (running test, vacuum test, pressure test)

Yes

Pump Drain the pump volute

Yes

Pump Flush pump with clean water

Yes

Pump Raw water filter

Yes2

Engine Check oil level

Yes1

Engine Check coolant level

Yes1

Engine Change engine oil and oil filter

Yes2 Yes2 Yes

Engine Check/clean air filter

Yes2

Engine Check and adjust valve play

Yes Yes3

Engine Replace spark plugs

Yes3

Engine Check spark plugs

Yes

Engine Change coolant

Yes

Engine Replace fuel filter

Yes

Engine Fuel stabilizer Yes

Engine Internal preservative

Yes

Note: 1 Or at least once a week 2 Or at least once a year if the specified hours of operation are not reached before that 3 Or at least every two years if the specified hours of operation are not reached before that 4 If the pump is not to be used for more than 30 days

35


MAINTENANCE OPERATIONS - ENGINE

Routine Maintenance Please refer to section Maintenance Schedule for interval detail.

Engine Fluid Check & Change Using the maintenance schedule, please observe the following:

Engine Oil Check

This is a dry sump lubrication 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 may flow from the oil tank back into the engine over time. Follow the oil level checking procedure outlined on pages 19-20. Note the distinction between checking the oil level in a cold engine compared to a hot engine. If running the pump to check oil level, keep water in the pump to ensure the main seal is lubricated.

Coolant

Check when engine is cold. Remove the coolant tank cap, the coolant level must cover the sides of the tubes inside the tank, see page 18. If more coolant is needed to top up, add coolant in the proportions given on page 10, General Data. Be careful not to spill coolant outside the coolant tank.

Engine Oil and Oil Filter Refer to Workshop Manual for this operation. Change the Oil and filter in accordance with the maintenance schedule. The oil filter is located on the left hand side behind the heat shield. The oil is drained from a plug at the bottom of the tank. See page 19 for details of how to re-fill the engine with oil.

Air Filter Element

Refer to Workshop Manual for this operation. Clean the air filter in accordance with the maintenance schedule.

Engine – Spark plugs, Valves Spark Plugs

Refer to the Weber Service Manual for this operation. Service the spark plugs in accordance with the maintenance schedule

Check and adjust valve play

Refer to Weber Service Manual for this operation. Adjust the valve play in accordance with the maintenance schedule.

36


Engine internal preservation Refer to Weber Service Manual for this operation.

Fuel condition guide The PowerFlow GP12/10 and GP17/10 have been designed and tested to operate in a range of environments. However in some environments, especially in regions with high humidity, small but significant amounts of water can collect in fuel. If fuel with higher than normal water content is used in the Powerflow 12/10 or 17/10, It is very unlikely that this will led to a noticeable degradation of pump performance. However in some circumstances it can accelerate internal corrosion of some parts of the fuel system, such as the fuel pump. If you feel this may be a risk for your application, the following additional precautions will help to minimise the amount of water in the fuel:

• Keep your fuel tank full when the pump is not in use. This minimises the air-volume in the tank and thus limits the amount of water ingress from condensation in the tank.

• Where possible re-fuel using fresh sources of fuel and minimise the used of fuel that has been stored for a prolonged period in humid conditions.

• Ensure any central store of fuel is properly stored and kept free of water. Adopt

an appropriate fuel management processes to limit the amount of water that can collect in the stored fuel.

• If available, use low-ethanol content fuels. Ethanol can absorb water in the air

and carry it round the fuel system.

• Consider the use of 3rd-party additives designed to absorb water in fuel (typically containing isopropanol). Godiva has not tested any additives and cannot recommend any additive or accept any liability for loss or damage caused by use of an additive. If in doubt about the suitability of a fuel additive please refer to the Engine Manufacturer.

• If you feel you have significant amounts of water in your tank, we recommend the

tank is drained and refilled with fresh uncontaminated fuel. Please contact Godiva for detail instructions of how this should be done or see the service manual.

37


MAINTENANCE OPERATIONS - PUMP

Volute Drain After each use and if frost is expected, drain the pump volute casing by opening the drain valve.

Raw water filter The raw water filter is located on the front of the pump just below the left side discharge valve. The filter prevents large items from circulating around the heat exchanger circuit. Unscrew the filter using a 24mm spanner, flush the filter in fresh water to remove any accumulated debris.

Gauges Do not clean the glass surfaces of the gauges with abrasive or solvent cleaners. These will cloud the glass surface. Use a mild detergent and water.

Cleaning the pump When cleaning the pump and engine use hot soapy water, do not use flammable degreasers.

Volute drain valve

38


Pump Tests Running Test

Note: Valves, hoses and connectors may vary with customer specification. To ensure the pump is kept in good condition and keep the battery charged, it is recommended that the pump should be run once a month for 30 minutes.

1. Connect the pump to suction at a depth of between 1 metre and 3 metres. 2. Start and run the engine. 3. Prime the pump. 4. Open the delivery valve. 5. Run the pump at a pressure of 3 bar for approximately 30 minutes. 6. Stop the pump and drain volute.

Vacuum Test - Exhaust Gas Priming Secure the suction tube blanking cap, close the delivery valves. Start the engine, fully open the throttle and pull up the priming lever. With a vacuum reading of -0.6 bar (18“hg) registering on the compound gauge, release the priming lever and stop the engine. The vacuum reading must be maintained for a minimum of 15 seconds. If vacuum retention fails, proceed to a pressure test to identify the cause. Should the pump be incapable of developing a vacuum of 0.6 bar, but hold whatever vacuum it does develop, a fault in the priming system or gauge is indicated. NOTE: Do not run the pump for more than 30 seconds when conducting this test or damage may occur to the pump gland seal components.

Pressure Test The purpose of this test is to trace a vacuum leak. Connect the pump to a water supply capable of exerting a pressure of 3.5 / 7.0 bar (50 / 100 lbf / in2). This may be achieved either by fitting an adaptor in the pump casing and then connecting this to a hose, or by using a hydrant to suction tube adaptor. To allow air to escape, partially open a delivery valve and apply water pressure. With the pump casing full of water, close the delivery valve and build up the pressure to 3.5 / 7.0 bar (50 / 100 lbf / in2). If there are any leaks, their locations will be shown by the seepage of water at those points.

Battery Care Safety

Wear protective clothing and protect your eyes when working with batteries. Have a copious supply of water available.

Terminals Apply a thin film of petroleum jelly to both terminals and connectors.

Charging Should charging become necessary, the input current (amps) must not be more than 10% of the battery rated capacity. Note: if the battery has been disconnected or removed from the unit, this procedure must be followed to restart -

!

39


1. Reconnect the battery (red lead to positive terminal, black to negative terminal). 2. Place throttle in closed position (see item 26, page 15). 3. Turn on the engine (see item 15, page 15) but do not press the starter. 4. Wait one minute - a click will be heard from the throttle body after precisely one minute. 5. The unit is ready to be used.

FAULT TRACING

Engine For specific engine related information, please refer to the Weber Repair manual. Safety When using the hand pulled starter - cord retraction (kickback) may pull your hand towards the engine. Ensure that the fuel cap is secure. Allow the engine to cool for at least two minutes before removing the fuel cap. Check the fuel system regularly for cracks and leaks. When tilting the engine, keep the spark plug side uppermost.

DEFECT CAUSE REMEDY Engine will not start No fuel Add fuel Engine Flooded Allow engine to rest Spark plug fouled Check gap and adjust if

required Renew spark plug Engine rough running or emitting smoke

Fouled spark plug Renew

Malfunction indicator light is on

Requires engine diagnostics – contact Godiva or distributor

Blocked, or oil saturated air filter

Clean or renew as required

!

40


Pump DEFECT CAUSE REMEDY

High negative reading on vacuum gauge or reduced lift

Suction strainers blocked

Remove and clean

Failure to hold or lift water

Suction hose joints leaking.

Check and secure

Suction strainers not completely immersed.

Submerge

Leaking gland seal. Pressure test and repair as required

Delivery valve leak Check and secure Delivery jet uneven

Suction strainers not completely immersed.

Submerge

Leakage in suction side

Check and secure joints

In the event of the above information not leading to a solution, carry out the Monthly pump tests for Pressure and Vacuum. Use the following log sheet (or photocopy) to keep an historical record of your maintenance and parts renewals, in accordance with the recommended maintenance schedule of Godiva Ltd. This information may be useful should you need to contact the manufacturer on any related matter.

41


PUMP LOG SHEET Model __________ Serial No. ___________ Date Entered Service _______

Date Location Hours

Run Inspection / Fault Parts

Used Reason For Renewal Initial

42


Godiva Limited A Unit of IDEX Corporation Charles St Warwick CV34 5LR England Tel: +44 (0)1926 623600 Fax: +44 (0)1926 623666 www.godiva.co.uk [email protected]

http://www.godiva.co.uk/

TD410045

Rev B

25.05.2018

MPE 850 INDUSTRIAL

– 406555 I2 846 IND

– 407556 I2 846 IND

– 408307 I2 846 IND

This service manual is valid for the following engine models:

Read this service manual thoroughly before operating the engine for the first time.

SERVICE MANUAL4-Stroke Engine

en_English

TEXTRON MOTORS GmbH

Daimlerstraße 5

88677 Markdorf

Germany

WWW.TEXTRONMOTORS.COM

CALIFORNIA Proposition 65 Warning

This engine and engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

- Translation of the original service manual -

TEXTRON MOTORS 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 TEXTRON MOTORS GmbH.

All rights reserved according to the copyright law.

3TD410045-B SHB

Table of conTenTs

ABOUT THIS DOCUMENT 4

Meaning of the symbols and signal words . . . . . . 4

SAFETY 5

Meaning of the safety alert symbol and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Important safety messages . . . . . . . . . . . . . . . . . 5

DESCRIPTION 8

Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Components and information . . . . . . . . . . . . . . . 10Technical specifications . . . . . . . . . . . . . . . . . . . 11

OPERATION 12

Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . 12Operation during the break-in period . . . . . . . . . 13Put the engine into operation . . . . . . . . . . . . . . . 13

Checking coolant level . . . . . . . . . . . . . . . . . 13Checking oil level . . . . . . . . . . . . . . . . . . . . . 14

Special scenarios . . . . . . . . . . . . . . . . . . . . . . . . 14Engine storage for more than 30 days . . . . . 14

Dealer and servicing network . . . . . . . . . . . . . . . 14Locating a workshop . . . . . . . . . . . . . . . . . . 14Tools and accessories . . . . . . . . . . . . . . . . . 14

SERVICE TASKS IN THE WORKSHOP 15

Safety messages workshop . . . . . . . . . . . . . . . . 15Tools and accessories . . . . . . . . . . . . . . . . . . . . 16

TEXTRON MOTORS Service parts . . . . . . . 16TEXTRON MOTORS Diagnostic case . . . . . 16Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Changing engine oil and oil filter . . . . . . . . . . . . 18Checking valve lash . . . . . . . . . . . . . . . . . . . . . . 19Adjusting valve lash . . . . . . . . . . . . . . . . . . . . . . 22

Replacing valve adjustment shim with valve adjustment kit . . . . . . . . . . . . . . . . . . . . . . . . 22

Replacing valve adjustment shim without special tool . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Replacing spark plugs . . . . . . . . . . . . . . . . . . . . 24Checking spark plugs . . . . . . . . . . . . . . . . . . 26

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Preparing engine for storage . . . . . . . . . . . . 26

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

CONFIRMATION OF SERVICE TASKS 27

INDEX 29

Table of conTenTs

4 TD410045-B SHB

About this documentAbout this document

meAninG oF the sYmboLs And siGnAL WoRds

item meaning

NOTICE The signal word NOTICE indicates potential property damage.

information The signal word information indicates specific features and recommendations.

This service manual was designed to help you with operating the engine safely and reliably.

Observe the following references:

– Read this service manual before operating the engine for the first time.

– Always observe the manufacturer's documentation of the portable fire pump.

– This service manual is for the engine in your portable fire pump. See the manufacturer‘s documentation for specific information of the portable fire pump.

– Keep this service manual in a safe place.

– Make sure that all persons using the portable fire pump have access to this service manual.

– If you sell the portable fire pump, always pass on this service manual to the new owner.

– The latest version of the service manual is available in other languages on WWW.TEXTRONMOTORS.COM

– Some figures in this service manual are general illustrations and may differ from the actual engine.

5TD410045-B SHB

SafetySafety

MeaNING Of tHe Safety aLeRt SyMBOL aND SIGNaL WORDS

Item Meaning

The safety alert symbol draws your attention to possible dangers.

WaRNINGThe signal word WaRNING indicates a potentially dangerous situation that may lead to a serious or fatal injury.

CaUtIONThe signal word CaUtION indicates a potentially dangerous situation that may lead to a minor or moderately severe injury.

IMPORtaNt Safety MeSSaGeS

Regular service is essential to keep your engine in a safe operating condition. It is your responsibility to ensure that the engine is serviced correctly.

► Perform regular inspections and observe the specified service intervals.

All tasks described in the SERVICE TASKS IN THE WORKSHOP chapter require special technical knowledge of this engine.

► Ensure your workshop is qualified to service your engine.

► All TEXTRON MOTORS authorized workshops are qualified to service your engine.

Service tasks

Service tasks in the workshop

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

6 TD410045-B SHB

Safety

Engine malfunctions pose a safety risk.

► Only operate the engine in perfect condition.

► Perform all service tasks according to the service intervals in this service manual.

► All malfunctions must be immediately addressed by a qualified workshop.

All the components in your engine have been carefully tested and fulfill strict quality and safety requirements.

► TEXTRON MOTORS offers spare parts to the highest quality. Ensure that equivalent spare parts corresponds with this quality requirements.

Engine modifications may pose a safety risk.

► Do not install add-on parts or modify the engine.

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.

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.

► Never operate the engine in enclosed spaces.

Operating materials pose a health risk.

► Always observe the manufacturer's documentation.

► 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 engine fluids immediately.

Malfunctions

Spare parts

Add-on parts and modifications

Hot engine components

Engine exhaust gases

Fuel, engine oil and coolant handling

7TD410045-B SHB

Safety

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.

► Always turn off the engine before fueling.

► 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.

► Engine oil 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.

Engine oil is flammable and can emit toxic gases.

► Do not smoke in the vicinity of the engine and do not allow open flames or sparks near the engine.

► Engine oil 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.

Fuel

Engine oil

8 TD410045-B SHB

Date:Part No.:

Serial No.:

26.10.2012999999

9999999999

1

5

3

2

4

DescriptionDescription

intenDeD Use

iDentiFicAtion

The MPE 850 INDUSTRIAL has been designed for powering portable fire pumps. The engine was not designed or intended for any other use.

All specifications in this service manual are only valid for the unmodified engine delivered by TEXTRON MOTORS. Engine modifications are not permissible and in addition, may void the warranty or violate federal laws.

Each engine will be clearly identified by two numbers. Both numbers are printed on a label 1 affixed to the engine.

The part number "Part No." 2 is the number of the engine model.

The serial number "Serial No." 3 is an unique number for each individual engine.

The labels with the part number and the serial number are located on the valve cover 4 .

The serial number is also engraved on the crankcase 5 .

Take the time to enter the part number and serial number in the CONFIRMATION OF SERVICE TASKS chapter. Both numbers are important in questions regarding your engine.

9TD410045-B SHB

Description

FUeL

enGine oiL

Fuel Unleaded gasoline

Recommended fuel quality 95 ROZ or 85 MOZ USA "Premium 91"

Engine oil NOTICE! Engine damage caused by incorrect engine oil grade. Always use the recommended engine oil. Do not mix engine oils of different grades or viscosity.

0W 40 completely synthetic, at least API SJ, ACEA A3/B3

Fill quantity See the manufacturer‘s documentation of the portable fire pump.

cooLAnt

Coolant additive Coolant additive based on ethylene glycol, silicate- and nitrite- free, suitable for aluminium engines.

Suggested coolant additives NOTICE! Insufficient cooling due to incompatibilities of coolant. Combining different coolant additives may trigger a chemical reaction and they may lose their effectiveness. The suggested coolant additives are laboratory tested for compatibility. If you use another coolant additive verify the compatibility previously. – BASF Glysantin G 30 – Chevron Havoline Extended Life Coolant XLC+B – Valvoline Zerex G 30

Mixing ratio NOTICE! An incorrect mixing ratio reduces the cooling capacity. When topping up the coolant, do not change the mixing ratio. Use the same coolant throughout the year in the mixing ratio specified.

50 % water + 50 % coolant additive

Fill quantity See the manufacturer‘s documentation of the portable fire pump.

10 TD410045-B SHB

67

23

4

5

89

10

11

12

13

14

1

Description

coMponents AnD inForMAtion

– Permanent vent coolant circuit 1

– Exhaust ports 2 / Exhaust side

– Oil filter 3

– Coolant circuit to the heat exchanger 4

– Coolant circuit from the heat exchanger 5

– Engine oil, oil tank to engine 6

– Engine oil, engine to oil tank 7

– First cylinder 8

– Camshaft sensor 9 / Second cylinder

– Fuel supply 10

– Throttle body 11 / Air intake

– Direction of engine rotation 12

– Stub shaft 13 / Power take off

– Crankcase vent / Engine oil return 14

11TD410045-B SHB

Description

tecHnicAL speciFicAtions

Type 4-stroke gasoline engine, parallel twin with balance shaft and single overhead camshaft (SOHC)

Displacement 846 cm³

Number of cylinders 2

Bore x stroke 89 x 68 mm [3.5 x 2.7 in]

Compression ratio 11.5 : 1

Engine power SAE J1349

22 kW @ 5250 min-1 [rpm]

32 kW @ 5750 min-1 [rpm]

42 kW @ 5600 min-1 [rpm]

Engine speed limit 6500 min-1 [rpm]

Idle speed 1250 – 1750 min-1 [rpm]

Fuel system Sequential multipoint manifold injection

Lubrication system Dry sump

Cooling system Closed coolant circuit

Engine management system

Synerject Easy-U

Throttle body Electronically controlled throttle body (drive-by-wire), dia. = 44 mm [1.73 in]

Ignition system Electronically controlled distributorless ignition system with individual coils

Starter system Electric starter

Generator, internal > 450 W @ 4000 min-1 [rpm]

Weight 55 kg [121 lb] without engine oil and coolant

Dimensions L x B x H 420 mm [17 in] x 408 mm [16 in] x 482 mm [19 in]

12 TD410045-B SHB

OperatiOnOperatiOn

Regular service is essential to keep your engine in a safe operating condition. The following tasks are described in the manufacturer‘s documentation of the portable fire pump.

procedure Before operation1

Checking coolant level ■

Checking oil level ■

1 or at least once a week

SerViCe interVaLS

Familiarize yourself with the portable fire pump before operating the engine. Read the manufacturer‘s documentation of the portable fire pump.

The following service tasks require special technical knowledge of this engine. These service tasks must be performed in a qualified workshop. All TEXTRON MOTORS authorized workshops are qualified to service your engine.

All tasks are described in the SERVICE TASKS IN THE WORKSHOP chapter.

procedure See

page

First service subsequent service intervals

preparing for Storage4after 25 h2

every 100 h2

or at least once a year

every 200 h2

or at least every 2 years

Changing engine oil and oil filter

18 ■ ■ ■

Checking and adjusting valve lash

19 ■ ■3

Replacing spark plugs 24 ■

Checking spark plugs 26 ■

– Fuel stabilizer – Engine internal

preservation

26■

Changing coolant – See the manufacturer‘s documentation of the portable fire pump.

2 h = hours of operation3 These service intervals are only required after the specified hours of operation4 If you do not operate the engine for more than 30 days

13TD410045-B SHB

OperatiOn

The way you operate the engine is a major factor in determining engine performance and useful life.

This affects the way you operate in the

– first 5 hours of operation.

– first 5 hours of operation after extensive repairs, where the engine was completely disassembled.

– first minutes until the engine is warm.Observe the following guidance to achieve optimal break-in:

Avoid – engine speeds over 5500 min-1 [rpm]. – long periods of idle operation. – long periods of operation at low engine speeds. – long periods of operation at the same engine speed. – long periods of operation at full load.

Perform – vary engine speed. – momentary bursts of acceleration, when the engine is warm.

OperatiOn DUrinG tHe BreaK-in periOD

pUt tHe enGine intO OperatiOn

The following procedure is not a complete description of the commissioning, it describes only the engine-specific requirements. Observe the manufacturer's documentation of the portable fire pump.

1. Check the coolant level. (See chapter Checking coolant level.)

2. Start the engine and warm up. (See chapter Operation during the break-in period.)

3. Check the oil level. (See chapter Checking oil level.)

CHECKING COOLANT LEVEL

Check the coolant level with a cold engine. See the manufacturer‘s documentation of the portable fire pump.

engine damage caused by a lack of coolant or overfilling.

Insufficient coolant leads to deformation, stress cracking and leaks in the cylinder head gasket.

Overfilled coolant increases the cooling system pressure and may cause leaks in hoses.

► Check the coolant level, as described in the manufacturer‘s documentation of the portable fire pump.

NOTICE

14 TD410045-B SHB

OperatiOn

CHECKING OIL LEVEL

information! Your engine features 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 turned off, some engine oil flows slowly from the oil tank back into the engine. Therefore inspect the oil level immediately after turning off the engine.

Check the oil level with a warm engine. See the manufacturer‘s documentation of the portable fire pump.

engine damage caused by a lack of engine oil or overfilling.

A lack of engine oil will cause moving components in the engine to seize.

If the quantity of engine oil is excessive, oil may enter the intake syste through the crankcase vent and damage the engine.

► Check the oil level, as described in the manufacturer‘s documentation of the portable fire pump.

► Refill engine oil in small quantities with repeatedly checking.

Prepare the engine if you plan to store the engine for 30 days or more. 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.

Preparation for storage requires special technical knowledge of this engine. These tasks must be performed in a qualified workshop. All TEXTRON MOTORS authorized workshops are qualified to prepare your engine for storage.

ENGINE STORAGE FOR MORE THAN 30 DAYS

SpeCiaL SCenariOS

DeaLer anD SerViCinG netWOrK

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.TEXTRONMOTORS.COM for a list of all authorized TEXTRON MOTORS workshops.

TOOLS AND ACCESSORIES

TEXTRON MOTORS offers a selection of accessories to prepare you for the most important situations. Visit your local portable fire pump dealer or WWW.TEXTRONMOTORS.COM for more information.

NOTICE

15TD410045-B SHB

Service taSkS in the workShopService taSkS in the workShop

SaFetY MeSSaGeS workShop

All tasks described in the SERVICE TASKS IN THE WORKSHOP chapter require special technical knowledge of this engine.

► Ensure your workshop is qualified to service your engine.

► All TEXTRON MOTORS authorized workshops are qualified to service your engine.

Before reading the SERVICE TASKS IN THE WORKSHOP chapter, you must have read and understood all other information in the service manual.

► Read the entire service manual carefully before performing any service tasks.

► Pay particular attention to the safety messages.

Starting the engine inadvertently may endanger the safety.

► Disconnect the engine from the power supply before performing any service tasks. (See the manufacturer‘s documentation of the portable fire pump.)

► Only reconnect the engine’s power supply once all service tasks on the engine are complete and all protective equipment is correctly fitted.

Missing protective equipment poses a safety risk.

► Attach all protective equipment after completing the service tasks.

Unsuitable tools pose a safety risk.

► Use tools listed in the TOOLS AND ACCESSORIES chapter or equivalent tools.

Service tasks in the workshop

Service manual

Engine power supply

Protective equipment

Tools

16 TD410045-B SHB

Service taSkS in the workShop

TEXTRON MOTORS offers a diagnostic case that contains the TEXTRON MOTORS diagnostic tool. The TEXTRON MOTORS Diagnostic tool has been designed for fault diagnostics and service tasks for Textron engines using a Synerject engine management system. Visit your local portable fire pump dealer or WWW.TEXTRONMOTORS.COM for more information.

TEXTRON MOTORS DIAGNOSTIC CASE

Figure Description

Oil filter

Spark plugs Champion RC7PYCBX

Feeler gauge 0,05 – 2 mm

Sealing kit valve cover

TEXTRON MOTORS offers a service case that contains the following service parts. Visit your local portable fire pump dealer or WWW.TEXTRONMOTORS.COM for more information.

Figure Description

Valve adjustment shims in different sizes

Serrated lock washer

Valve adjustment kit

tooLS anD acceSSorieS

TEXTRON MOTORS SERVICE PARTS

17TD410045-B SHB


Figure Description

Torque wrench8 – 32 Nm[5 – 24 lbf ft]with extension and insert adapter

Reversible ratchetwith extension and insert adapter

Hexagon screwdriver and inserts5 mm

Spark plug wrenchWrench size 16 mm [5/8“]Diameter: maximum 22 mm [0.87 in]

Spark plug brush

Figure Description

Bar magnet

Universal pliers

Universal strap wrench

CaliperMeasuring accuracy 0,05 mm

TOOLS

The figures are examples of suitable tools. All tools and accessories are available from specialist retailers.

SUPPLIES

The following supplies are required when working on the engine. Unless otherwise specified, use the products as directed by the manufacturer's instructions.

Supplies examples of suitable products

Engine internal preservative – Liqui Moly, Germany

Fuel stabilizer – Liqui Moly, Germany

Sealing surface cleaner – Liqui Moly brake and parts cleaner AIII

Anti-Seize assembly paste for lubricating threaded connections

– WEICON® Anti-Seize "High-Tech" ASW 040 P – LOCTITE® LB 8150

18 TD410045-B SHB

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chanGinG enGine oiL anD oiL FiLter

1. Start the engine and warm up. (See chapter Operation during the break-in period.)

2. Drain the engine oil. (See the manufacturer‘s documentation of the portable fire pump.)

caUtion! Scalding caused by hot engine oil. wear protective gloves.

3. Remove the oil filter 1 using an universal strap wrench.

4. Replace the oil filter 2 .

5. Clean the sealing surface 3 using a sealing surface cleaner.

6. Coat the oil filter seal 4 lightly with engine oil.

7. Screw in the oil filter by hand.

Tightening torque:

10 Nm [7.4 lbf ft]

8. Fill engine oil. (See the manufacturer‘s documentation of the portable fire pump.)

9. Check the oil level. (See the manufacturer‘s documentation of the portable fire pump.)

10. Clear the service counter for service light. (See the TEXTRON MOTORS Diagnostic tool manual.)

11. Update the engine control unit calibration. (See the TEXTRON MOTORS Diagnostic tool manual.)

12. Start the engine and allow to run for 1 – 2 minutes.

19TD410045-B SHB

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3

4

2

56


checkinG vaLve LaSh

2. 5 mm: Remove four bolts 3 .

3. Remove two ignition coils 4 .

4. 5 mm: Remove eight bolts 5 .

5. Remove the valve cover 6 .

Check the valve lash 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. (See the manufacturer‘s documentation of the portable fire pump.)

1. Disconnect the wire harness connectors from two ignition coils 1 and camshaft sensor 2 .

20 TD410045-B SHB

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8

7

10

9


6. Turn the crankshaft until the position of the camshaft is as illustrated. (See the manufacturer‘s documentation of the portable fire pump.)

The marking 7 ends flush with the cross bar.

All rocker arms 8 on the second cylinder have a certain amount of play.

or


The marking 9 is not visible.

All rocker arms 10 on the first cylinder have a certain amount of play.

8. Check the valve lash 11 of all valves on the cylinder using a feeler gauge.

Required valve lash:

0,2 – 0,3 mm

9. If the valve lash of one or more valves is not right, continue with the ADJUSTING VALVE LASH chapter.

10. Turn the crankshaft in the direction of engine rotation until the rocker arms on the other cylinder have a certain amount of play.

11. Repeat the procedure on the other cylinder.

information! The camshaft is turned by turning the crankshaft. Read the manufacturer‘s documentation of the portable fire pump for instructions. Always turn the crankshaft in the direction of engine rotation. See chapter COMPONENTS AND INFORMATION. Two rotations of the crankshaft correspond to one rotation of the camshaft.

21TD410045-B SHB

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19

17

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16

20

21

14

155

3

7

1

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6

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12. Clean the grooves for gaskets 13 and the sealing surfaces on the valve cover.

13. Clean the sealing surfaces on the cylinder head.

14. Replace three valve cover seals 12 .

15. Insert three valve cover seals dry and without supplies into the grooves.

22. Connect the wire harness connectors to two ignition coils 20 and camshaft sensor 21 .




16. Apply the valve cover 15 .

17. Apply Anti-Seize assembly paste to all bolts.

Install all bolts in the sequence as illustrated 14 .

18. 5 mm: Install eight bolts.

Tightening torque:

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

19. Insert two ignition coils 16 .

20. Replace two serrated lock washers 17 .

21. 5 mm: Install four bolts 18 , two washers 19 and two serrated lock washers as illustrated.

Tightening torque:


22 TD410045-B SHB

4

3

1

3

2

2

1




All rocker arms 4 on the first cylinder have a certain amount of play.

3. Continue with the REPLACING VALVE ADJUSTMENT SHIM WITH VALVE ADJUSTMENT KIT chapter.

or

Continue with the REPLACING VALVE ADJUSTMENT SHIM WITHOUT SPECIAL TOOL chapter.

NOTICE! Engine damage caused by 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.

1. Cover the chain channel 2 .

2. Hold the valve adjustment tool 3 in position.

3. 5 mm: Install two bolts 1 .

Tightening torque:


REPLACING VALVE ADJUSTMENT SHIM WITH VALVE ADJUSTMENT KIT

aDJUStinG vaLve LaSh



All rocker arms 2 on the second cylinder have a certain amount of play.

or

23TD410045-B SHB

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4. Position the rocker arm pusher 4 on the rocker arm 5 .

5. Press down the slide plate 7 using the rocker arm pusher 6 until the pin 8 engages.

6. Remove the valve adjustment shim 9 using a bar magnet.

7. Measure the valve adjustment shim using a caliper.

8. Insert the new valve adjustment shim.

9. Hold the rocker arm pusher 10 in position.

10. Press down the slide plate 11 slightly using the rocker arm pusher.

11. Slide the pin 12 forward by hand.

12. Slowly release the rocker arm pusher.

The valve spring slides the slide plate upwards again.

13. 5 mm: Remove two bolts 13 .

14. Remove the valve adjustment tool 14 .

15. Remove the cover from the chain channel.

NOTICE! Valve breakage due to insufficient valve lash.

16. Check the valve lash.

17. Continue with the CHECKING VALVE LASH chapter.

24 TD410045-B SHB

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7. Hold the rocker arm 5 in position.

8. Check if the circlip 7 is installed.

9. Insert the rocker axle 6 .

10. Remove the cover from the chain channel.

NOTICE! Valve breakage due to insufficient valve lash.

11. Check the valve lash.

12. Continue with the CHECKING VALVE LASH chapter.

3. Remove the rocker arm 3 .

4. Remove the valve adjustment shim 4 using a bar magnet.

5. Measure the valve adjustment shim using a caliper.

6. Insert the new valve adjustment shim.

repLacinG Spark pLUGS

Remove the ignition coils and spark plugs with a cold engine.

1. Discnnect the wire harness connectors from two ignition coils 1 .

NOTICE! Engine damage caused by 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.

1. Cover the chain channel 1 .

2. Remove the rocker axle 2 using a universal pliers.

REPLACING VALVE ADJUSTMENT SHIM WITHOUT SPECIAL TOOL

25TD410045-B SHB

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8

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10


2. 5 mm: Remove four bolts 2 .

3. Remove two ignition coils 3 .

4. 16 mm: Remove two spark plugs 4 .

5. Replace two spark plugs.

6. 16 mm: Install two spark plugs.

Tightening torque:

22 Nm +10 Nm [16.2 lbf ft +7.4 lbf ft]

7. Insert two ignition coils 5 .

8. Replace two serrated lock washers 6 .

9. 5 mm: Install four bolts 7 , two washers 8 and two serrated lock washers as illustrated.

Tightening torque:


10. Connect the wire harness connectors to two ignition coils 9 and camshaft sensor 10 .




26 TD410045-B SHB

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2

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CHECKING SPARK PLUGS

1. Remove two spark plugs. (See chapter Replacing spark plugs.)

2. If the electrodes 1 are extremely sooty, clean carefully using a spark plug brush.

3. Check the spark plug gap 2 using a feeler gauge.

Required spark plug gap:

0,69 – 0,84 mm [0.028 – 0.032 in]

4. If the spark plug gap is incorrect, replace the spark plug. Always replace spark plugs in pairs.

5. Install two spark plugs.

PREPARING ENGINE FOR STORAGE

1. Change the engine oil and oil filter. (See chapter Changing engine oil and oil filter.)

2. Fill up the fuel tank.

3. Add a fuel stabilizer according to the manufacturer's instructions.

4. Check the spark plugs. (See chapter Checking spark plugs.)

5. Spray engine internal preservative into the cylinder through the spark plug bores 1 according to the manufacturer's instructions.

6. Do not start the engine again.

StoraGe

DiSpoSaL

When disposing of engine fluids, replaced parts or the whole engine, always comply with the relevant applicable national laws and guidelines.

27TD410045-B SHB

__________________________________

_________________

Confirmation of serviCe tasksConfirmation of serviCe tasks

Date:

Work carried out: Engine oil and oil filter changed Valve lash checked Spark plugs replaced Coolant changed

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Status hours of operation:

Company seal, signature

Date of initial registrationEngine model

Serial number

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28 TD410045-B SHB

Confirmation of serviCe tasks

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29TD410045-B SHB

IndexIndex

Power 11

S

Serial number 8Service intervals 12Service parts 16Spark plug gap, required 26Spark plugs, checking 26Spark plugs, replacing 24Specifications 11Storage, preparing engine 26Supplies 17

T

Tools 14, 17Tools and accessories 16

V

Valve lash, adjusting 22Valve lash, checking 19Valve lash, required 20

W

Weight 11

A

Accessories 14

B

break-in period 13

C

Compression ratio 11Confirmation of service tasks 27Coolant 9Coolant level, checking 13Cylinder, first 10Cylinder, number 11Cylinder, second 10

d

Dealer and servicing network 14Diagnostic case 16Dimensions 11Direction of engine rotation 10Displacement 11Disposal 26

e

Engine oil 9Engine oil, changing 18

F

Fuel 9

I

Identification 8Index 29Intended use 8

L

Locating a workshop 14

O

Oil filter 10Oil filter, changing 18Oil level, checking 14

P

Part number 8

TEXTRON MOTORS GmbH

Daimlerstraße 5

88677 Markdorf

Germany

WWW.TEXTRONMOTORS.COM

operation manual · 20 august 2016 10, 20 oil specification change – now use 0w/40 api sj and...

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