Weber 4-Stroke Engine MPE 850 IND NA User manual

406555_SHB
Rev 1.0
10.07.2012
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-Stroke Engine
en_English

Weber Motor GmbH
Otto-Lilienthal-Str. 5
88677 Markdorf
Germany
www.weber-motor.com
- Translation of the original service manual -
Weber Motor GmbH strives to make continual improvements as part of the ongoing technical development of
its products. All documentation is therefore subject to technical modifications.
Reprints and translations, in whole or in part, require written permission from Weber Motor GmbH.
All rights reserved according to the copyright law.

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Table of contents
Table of contents
1 About this document 6
1.1 Meaning of the symbols and signal words .......................................6
2 Safety 7
2.1 Meaning of the safety alert symbol and signal words ..............................7
2.2 Important safety messages ..................................................8
3 Description 11
3.1 Intended use ............................................................ 11
3.2 Identification............................................................. 11
3.3 Fuel ...................................................................12
3.4 Engine oil ...............................................................12
3.5 Coolant................................................................. 13
3.6 Engine components and information .......................................... 14
3.7 Technical specifications .................................................... 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 20
5.1 Engine idle for more than 30 days ............................................20
6 Malfunctions 21
7 Dealer and servicing network 22
7.1 Locating a workshop ......................................................22
7.2 Service and spare parts ....................................................22
7.3 Repairs................................................................. 22
7.4 Warranty................................................................22
8 Service tasks in the workshop 23
8.1 Safety messages workshop .................................................23
8.2 Tools and accessories .....................................................24
8.2.1 Weber Motor service case .............................................24
8.2.2 Equipment workshop .................................................25
8.2.3 Supplies ...........................................................26
8.3 Changing engine oil and oil filter .............................................27

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Table of contents
8.3.1 Changing engine oil ..................................................27
8.3.2 Replacing oil filter ...................................................27
8.4 Checking and adjusting valve play............................................ 28
8.4.1 Checking valve 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
8.8 Replacing fuel filter .......................................................44
8.9 Preparing the engine for storage ............................................. 45
8.10 Disposal ................................................................46
9 Confirmation of service tasks 47
Appendix 49
Engine manufacturer ...................................................... 49
Index ..................................................................50

6 SHB MPE850 Rev 1.1 | 406555 |
This service manual was designed to help you operate the engine safely and reliably.
Observe the following information:
– Read this service manual thoroughly before operating the engine for the first time.
– The service manual is for the engine in your portable fire pump.
– Keep the service manual in a safe place.
– Make sure that all personnel using the portable fire pump have access to the service manual.
– If you sell the portable fire pump, always pass on the service manual to the new owner.
– The latest version of the service manual is available for download in other languages from our web site
www.weber-motor.com.
– Always read the portable fire pump manufacturer‘s documentation.
– Some figures in this service manual are general illustrations and may differ from the actual engine.
1 About this document
1.1 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.
Tools, service parts and supplies required for tasks covered in the chapter.
1About this document
1.1 Meaning of the symbols and signal words

7SHB MPE850 Rev 1.1 | 406555 |
This engine is state-of-the-art and built according to recognized safety-technical regulations. Ignoring the
information in this service manual may result in personal injury or property damage.
Read and observe the following safety messages carefully before operating the engine for the first time.
Observe all generally applicable laws and regulations in addition to the information in this service manual:
– accident prevention
– environmental protection
– handling of hazardous materials
– personal safety equipment
– traffic laws
2 Safety
2.1 Meaning of the safety alert symbol and signal words
Item Meaning
The safety alert symbol draws your attention to possible dangers.
WARNING
The signal word WARNING indicates a potentially dangerous situation that may
lead to a serious or fatal injury.
CAUTION
The signal word CAUTION indicates a potentially dangerous situation that may
lead to a minor or moderately severe injury.
2Safety
2.1 Meaning of the safety alert symbol and signal words

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2.2 Important safety messages
In order to keep your engine in a safe operating condition, regular
servicing is essential. It is your responsibility to ensure that the engine is
serviced correctly.
►Perform regular inspections and observe the specified service
intervals.
Engine malfunctions pose a safety risk to personnel.
►Only operate the engine when in perfect condition.
►All malfunctions must be repaired immediately in a workshop
authorized by Weber Motor or the portable fire pump manufacturer.
All the components in your engine have been carefully tested and fulfill
strict quality and safety requirements. Externally supplied parts cannot
fulfill these requirements.
►Always use original Weber Motor spare parts.
The consequences of attaching add-on parts and making unauthorized
modifications to the engine are unknown and pose a safety risk to
personnel.
►Modifications and the attachment of add-on parts is only permitted if
approved or instigated by Weber Motor.
Service tasks
Malfunctions
Spare parts
Add-on parts and modifications
All service tasks described in Chapter 8 Service tasks in the workshop
require special technical knowledge of the engine.
►All service tasks described in chapter 8 Service tasks in the
workshop must be performed by a workshop authorized by Weber
Motor or the portable fire pump manufacturer.
Service tasks in the workshop
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.
Hot engine components
2Safety
2.2 Important safety messages

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Handling of fuel, engine oil and
coolant
Operating materials pose a health risk.
►Always read the manufacturer's instructions.
►Always wash your hands prior to eating, smoking and using the
toilet as well as at the end of the working shift when working with
operating materials.
Operating materials are hazardous to the environment.
►Never allow operating materials to escape into the groundwater,
water courses or sewage system. Always dispose of operating
materials according to applicable national regulations.
Danger of slipping on spilled fluids.
►Always use a filler neck or funnel when filling components with
operating materials.
►Always clean up any spilled operating materials immediately.
Engine exhaust gases contain carbon monoxide (CO). Inhalation of
carbon monoxide can deprive the body of oxygen and result in organ
damage or even death by asphyxiation.
►When operating the engine in enclosed spaces, use exhaust hoses
to direct the engine exhaust gases into the open.
Engine exhaust gases
Some service tasks require disconnection of the engine from the power
supply. Starting the engine inadvertently may endanger the safety of
personnel.
Read the portable fire pump manufacturer‘s documentation for more
information.
►Disconnect the engine from the power supply when requested.
Engine power supply
Fuel is highly flammable. Vapors may ignite and cause an explosion.
►Do not smoke in the vicinity of the engine and do not allow naked
flames or sparks near the engine or the fuel system.
►Never fill with fuel while the engine is running.
►Do not start the engine if there is a smell of fuel or you suspect that
fuel is leaking. Have a workshop authorized by Weber Motor or the
portable fire pump manufacturer inspect the engine immediately.
►Fuel on hot surfaces can cause fires.
►Do not extinguish with water. In the event of a fire, use foam, dry
chemical or carbon dioxide extinguishers.
Fuel
2Safety
2.2 Important safety messages

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Warning against chemicals/hazardous materials according to the law of
the state of California. This product contains chemicals known to the State
of California to cause cancer, birth defects, or other reproductive harm.
California Proposition 65
2Safety
2.2 Important safety messages

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009999
2
1
3
4
5
3 Description
The MPE 850 IND NA has been designed for powering portable fire pumps.
The engine was not designed or intended for any other use.
3.2 Identification
Each engine is assigned two identification
numbers. Both numbers are printed on a label 1
affixed to the engine.
The 6-digit part number 2is the number of the
engine variant.
The 8-digit serial number 3is a unique number
for each individual engine.
3.1 Intended use
The labels with the part number and the serial
number are located on the valve cover 4.
The 8-digit serial number is also engraved on the
crankcase 5.
Take the time to enter the part number and serial
number in chapter 9 Confirmation of service
tasks. Both numbers are required when making
queries about your engine.
3Description
3.1 Intended use | 3.2 Identification

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3.3 Fuel
3.4 Engine oil
Engine damage and loss of power caused by fuel with an insufficient
octane rating.
Fuel with an insufficient octane rating causes knocking during combustion.
Which results in excessive loads and damage to the crank drive within a
short time.
►Always use fuel with the recommended octane rating.
Information! Weber Motor recommends you always keep a supply of engine oil to hand. 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 start to seize up.
►Always use the recommended engine oil.
►Do not mix engine oils of different grades or degrees of viscosity.
unleaded gasoline („super unleaded“), with an octane rating of at least
95 ROZ or 85 MOZ
USA: at least Premium 91, unleaded
Fuel quality
0W 40 completely synthetic, at least API SJ, ACEA A3/B3
See the portable fire pump manufacturer‘s documentation.
Engine oil
Fill quantity
3Description
3.3 Fuel | 3.4 Engine oil

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3.5 Coolant
Freezing, overheating or corrosion due to incorrect mixing ratio or
unauthorized coolant additives.
An incorrect mixing ratio reduces the cooling capacity.
Combining different coolant additives may trigger a chemical reaction and
they may lose their effectiveness.
►Use the same coolant throughout the year in the mixing ratio
specified.
►When topping up the coolant, do not change the mixing ratio.
►Always use approved coolant additives when topping up the
coolant.
Information! Weber Motor recommends you always keep an adequate supply of ready mixed
coolant to hand. Consult your local portable fire pump dealer.
Coolant additive based on ethylene glycol, silicate- and nitrite- free,
suitable for aluminium engines
50 % water + 50 % coolant additive
See the portable fire pump manufacturer‘s documentation.
BASF Glysantin G 30
Chevron Havoline Extended Life Coolant XLC+B
Valvoline Zerex G 30
Coolant additive
Mixing ratio
Fill quantity
Approved coolant additives
3Description
3.5 Coolant

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4
2
1
14
5
13
11
3
12
9
8
7
6
10
3.6 Engine components and information
– Coolant circuit vent 1
– Exhaust ducts 2
– Oil filter 3
– Coolant circuit to the heat
exchanger 4
– Coolant circuit from the heat
exchanger 5
– Engine oil supply 6
– Engine oil return 7
– 1st cylinder 8
– 2nd cylinder 9
– Fuel supply 10
– Air intake 11
– Engine rotation direction 12
– Stub shaft 13
– Crankcase vent 14
3 Description
3.6 Engine components and information

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482 mm [19 in]
420 mm [17 in]
408 mm [16 in]
3.7 Technical specifications
3Description
3.7 Technical specifications
4-stroke gasoline engine, parallel twin with balance shaft and overhead
camshaft (SOHC)
846 cm³
2
89 mm x 68 mm [3.5 in x 2.7 in]
11,5 : 1
Godiva 1710: 42 kW [57 PS] @ 5600 min-1 [rpm] SAE J1349
Godiva 1210: 22 kW [30 PS] @ 5250 min-1 [rpm] SAE J1349
6500 min-1 [rpm]
1250 – 1750 min-1 [rpm]
sequential multipoint intake manifold
dry sump
closed coolant circuit
Synerject Easy-U
electronically controlled, dia. = 44 mm [1.73 in]
electronic ignition
electric starter
> 450 W @ 4000 min-1 [rpm]
55 kg [121 lb] without engine oil and coolant
see figure
Type
Displacement
Number of cylinders
Bore x stroke
Compression ratio
Engine power
Speed limit
Idle speed
Carburation
Lubrication system
Cooling system
Engine management system
Throttle body
Ignition system
Starter system
Generator, internal
Weight
Dimensions

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4.1 Service intervals
Activity before operation
Check oil level
■1
Check coolant level
■1
4 Operation
Familiarize 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 is essential.
The following service tasks can be performed by trained mechanics.
1or at least once a week
4Operation
4.1 Service intervals

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Activity
1st service
after 25 h1
subsequent service intervals preparing for
storage4
every 100 h1every 200 h1
Change engine oil and oil filter
■2■2■
Check and adjust valve play
■ ■3
Replace spark plugs
■3
Check spark plugs
■
Change coolant
See the portable fire pump manufacturer‘s
documentation.
Engine internal preservative
■
Fuel stabilizer
■
Replace fuel filter
See the portable fire pump manufacturer‘s
documentation.
The following service tasks require mechanical knowledge and special technical knowledge of this engine.
These service tasks must be performed in a workshop authorized by Weber Motor or the portable fire pump
manufacturer.
1h = hours of operation
2or at least once a year if the hours of operation specified above are not reached before that
3or at least every two years if the hours of operation specified above are not reached before that
4if you do not intend to operate the engine for more than 30 days
4Operation
4.1 Service intervals

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4.2 Operation during the break-in period
The way you operate the engine during the first five hours of operation is a major factor in achieving the
required performance and extending the service life of the engine.
Observe the following points to ensure that the engine parts break in properly:
Engine speeds over 5500 min-1 [rpm]
long periods of idle operation
long operating periods at low engine speeds
long operating periods at the same engine speed
long operating periods at full load
Avoid
changes in engine speed
when the engine is warm, momentary bursts of acceleration
Good
4Operation
4.2 Operation during the break-in period

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4.3 Before operation
4.3.1 Checking coolant level
Danger of overheating caused by a lack of coolant.
Insufficient coolant leads to deformation, stress cracking and leaks in the
cylinder head gasket.
The increase in pressure will cause the hoses to leak.
►Always check the coolant level before operating the engine.
See the portable fire pump manufacturer‘s documentation.
4.3.2 Checking oil level
Information! Your engine uses a dry sump lubrication system. Engine oil is pumped from the
engine into the oil tank while the engine is operating. When the engine is switched off, a portion of the
engine oil flows from the oil tank slowly back into the engine. Therefore inspect the oil level immediately
after switching off the engine.
Engine damage caused by a lack of engine oil.
A lack of engine oil will cause moving components in the engine to seize.
►Always check the oil level before operating the engine.
See the portable fire pump manufacturer‘s documentation.
Engine damage caused by excessive engine oil.
If the quantity of engine oil is excessive, oil may enter the intake system
through the crankcase vent and damage the engine.
►Check the oil level as described in the portable fire pump
manufacturer‘s documentation.
►Measure the engine oil filling quantity before topping up the engine
oil.
4Operation
4.3 Before operation

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5.1 Engine idle for more than 30 days
If you do not intend to operate the engine for 30 days or more, prepare the engine for storage. Preparing the
engine for storage will prevent the cylinder from corroding and ensure the engine starts again correctly at the
end of the storage period.
Preparations for storage require special technical knowledge. Preparations must be performed in a workshop
authorized by Weber Motor or the portable fire pump manufacturer.
5 Special scenarios
5Special scenarios
5.1 Engine idle for more than 30 days