Power Solutions International, Inc.
8.8L LP Engine Operation and Maintenance Manual
Power Solutions International, Inc.
US EPA & CARB HD-SI Certification
201 Mittel Dr.
Wood Dale, IL 60191
36100015 - Rev 4
May 2019
NOTICE
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IMPORTANT
The information, specifications, and illustrations contained in this manual are based on data that was current at the time of
publication. Power Solutions International, Inc. reserves the right to make changes and/or improvements at any time
without notification, liability, or without applying those changes or improvements to vehicles previously manufactured and/or
sold.
Be advised that this motor vehicle may be equipped with
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individual to download data or information relating
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or
entity
violation of law and may subject that person or
to
criminal penalties.
computer
authorized
the operation or performance of this vehicle.
to
The stored data or information may be neither
nor retrieved except by the vehicle’s registered owner, or,
the
by the registered owner, (e.g., Certified Service Dealer)
who may need this data or information to properly
or diagnose this vehicle for repair or following an accident.
Any access to this information without the owner’s consent
be in
may
entity
TABLE OF CONTENTS
FOREWORD
SAFETY INFORMATION
WARRANTY
EPA and CARB Emission System Warranty 9
Manufacturer's Warranty Coverage
Owner's Warranty Responsibilities
Warranty Exclusions
1
3
9
9
10
11
SECTION 1 – ENGINE SYSTEMS
Engine Serial Number
Engine Emission Label
Engine Accessories
Engine Specification 15
Engine Description
Engine Features 19
Engine Related Optional Features 20
Component Location – Top
Component Location – Front
Component Location – Left
Component Location – Right
Component Location – Rear
13
14
14
15
23
24
25
26
27
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT
Fuel
29
Acceptable Fuel Blends
Unacceptable Fuel and Blends
Unsafe Practices 29
29
29
TABLE OF CONTENTS
Engine Oil
Engine Oil Quality and Service Categories
SAE Oil Viscosity Grade
Coolant
Coolant Mixtures
Contamination of Coolant
30
30
30
30
30
30
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES
Instrument Panel Gauge Cluster
Warning Lamps
Wait to Start Lamp
Maintenance Lamp
Amber Warning Lamp (AWL)
RED Stop Lamp (RSL)
Malfunction Indicator Lamp (MIL)
Gauges
Typical Water Temperature Gauge
Oil Temperature Gauge 33
Oil Pressure Gauge
31
31
31
31
31
32
32
33
33
33
SECTION 4 – ENGINE OPERATION
Preoperation Checklist
Preparing the Fuel System
Starting the Engine
Emergency Starting
35
36
37
39
TABLE OF CONTENTS
Operation
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Idle Speed
Cold Weather Operation
Hot Weather Operation
Engine Shutdown
Engine Warning Protection System (EWPS)
EMD Overview
Road Speed Governor (RSG)
Road Operation
40
40
41
41
43
43
43
40
42
Maintenance Schedule
Service Procedures
Oil Level
Coolant Level
External Leakage
Belt, Air Intake Piping and Clamps
Coolant Freeze Point
Engine Oil and Filter
Electrical System 55
SECTION 6 – LONG TERM STORAGE
General Information
SECTION 7 – SERVICE RECORDS
Maintenance Service Record
Daily Care and Report
APPENDIX
45
47
47
48
49
50
53
53
57
60
61
67
FOREWORD
FOREWORD
Page 1
Foreword
Power Solutions International, Inc. is committed to continuous
research and development to improve products and introduce
technological advances. Procedures, specifications, and
parts defined in published technical service literature may be
altered.
NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact.
This manual includes necessary information and specifications
for operators to operate and maintain the PSI 8.8L LP engine.
Contact your dealer for more information.
Refer to the applicable technical service literature
Engine Service & Diagnostic Manual
Warranty Policy and Procedures Manual
Technical Service Literature is revised periodically. Use only
up-to-date service information.
To order technical service literature, contact your dealer.
All marks are trademarks of their respective owners.
About the Manual
This manual contains information needed to correctly operate
and maintain your engine as recommended by PSI. Numerous
illustrations, symbols and feature descriptions are
understanding the meaning of the text. The
symbols or feature descriptions may not be
applications, please contact your dealer for
information. Both metric and U.S. customary values
in this manual. The U.S. Customary value is listed
followed by the metric value in brackets. For additional
literature refer to Service Literature noted in this
manual does not cover vehicle or equipment
procedures.
When referring to the left-hand or right-hand side of the
engine, this will be as viewed from the rear. (Looking at the
flywheel)
Consult the original vehicle or equipment manufacturer for
specific maintenance recommendations.
used to aid in
illustrations,
available for all
complete
are listed
service
manual. This
maintenance
first,
Page 2
SAFETY INFORMATION
Page 3
SAFETY INFORMATION
Safety Information
This manual provides general and specific maintenance
procedures essential for reliable engine
safety. Since many variations in
parts exist, advice for all
hazards cannot be stated.
Read safety instructions before doing any service and test
procedures for the engine. See related manuals for more
information.
Obey Safety Instructions, Warnings, Cautions, and Notes in this
manual. Not following Warnings, Cautions, and Notes can lead
to injury, death, or damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe operation of
the engine: Warning, Caution, and Note.
Warning: A warning describes actions necessary to prevent
eliminate conditions, hazards, and unsafe practices that can
cause personal injury or death.
Caution: A caution describes actions necessary to prevent or
eliminate conditions that can cause damage to the engine or
vehicle.
procedures, tools, and service
possible safety conditions and
operation and your
or
Safety Instructions
Work Area
•
Keep work area clean, dry, and organized.
•
Keep tools and parts off the floor.
•
Make sure the work area is ventilated and well lit.
•
Make sure a First Aid Kit is available.
Safety Equipment
•
Use correct lifting devices.
•
Use safety blocks and stands.
Protective Measures
•
Wear protective safety glasses and shoes.
•
Wear correct hearing protection.
•
Wear cotton work clothing.
•
Wear sleeved heat protective gloves.
•
Do not wear rings, watches or other jewelry.
•
Restrain long hair.
Note: A note describes actions necessary for correct, efficient
engine operation.
Page 4
SAFETY INFORMATION
Vehicle
•
Shift transmission to park or neutral, set parking brake, and
block wheels before doing diagnostic or service procedures.
•
Clear the area before starting the engine.
Engine
•
The engine should be operated or serviced only by
qualified individuals.
•
Provide necessary ventilation when operating engine in a
closed area.
•
Keep combustible material away from engine exhaust
system and exhaust manifolds.
•
Install all shields, guards, and access covers before
operating engine.
•
Do not run engine with unprotected air inlets or exhaust
openings. If unavoidable for service reasons, put protective
screens over all openings before servicing engine.
•
If an engine is not safe to operate, tag the engine and ignition
key.
Fire Prevention
2.
Type B — Flammable liquids
3.
Type C — Electrical equipment
Batteries
•
Always disconnect the main negative battery cable first.
•
Always connect the main negative battery cable last.
•
Avoid leaning over batteries.
•
Protect your eyes.
•
Do not expose batteries to flame or sparks.
•
Do not smoke in workplace.
Compressed Air
•
Use an OSHA approved blow gun. Limit blow gun air
pressure to 30 psi (207 kPa).
•
Wear safety glasses or goggles.
•
Wear hearing protection.
•
Use shielding to protect others in the work area.
•
Do not direct compressed air at body or clothing.
•
Make sure charged fire extinguishers are in the work area.
NOTE: Check the classification of each fire extinguisher to ensure the following fire types can be extinguished.
1.
Type A — Wood, paper, textiles, and rubbish
Page 5
SAFETY INFORMATION
Tools
•
Make sure all tools are in good condition.
•
Make sure all standard electrical tools are grounded.
•
Check for frayed power cords before using power tools.
Fluids Under Pressure
•
Use extreme caution when working on systems under
pressure. Pay close attention when working with the fuel
system.
•
Follow approved procedures only.
Fuel
•
Do not smoke in the work area.
•
Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
•
Reinstall all safety guards, shields, and covers after
servicing the engine.
•
Make sure all tools, parts, and service equipment are
removed from the engine and vehicle after all work is done.
Propane Safety Instructions
Warnings:
•
Never loosen fittings or vent any propane. Escaping propane
can cause frostbite and severe freeze burns. Wear insulated
PVC rubber gloves resistant to propane, goggles for
protection against accidental release of pressurized
products, and thermal protective clothing when handling
refrigerated liquids.
•
Do not remove any valves, bulkheads, or fittings from a tank
unless the tank has been drained completely. The pressure
inside a propane tank can push a loosened bulkhead or
valve out with enough force to cause injury or death.
Keep all sources of ignition away from propane vehicles
•
while the fuel system is being serviced. Even if the tank and
fuel lines are empty, there may still be flammable vapors
near the vehicle.
•
Do not disconnect any propane hoses unless they have
been completely drained using the proper procedure.
•
Do not vent or release propane indoors or near sewers, pits
or low lying areas. Propane can accumulate in low spots,
creating a fire hazard. Propane can also displace oxygen,
creating a suffocation hazard.
•
Always unplug the fuel control box or disconnect the battery
before you work on any part of the fuel system.
NOTE: It is recommended that you obtain and read the NFPA (National Fire Protection Association) #58, Standard for the Storage and Handling of Liquefied Petroleum Gases.
Page 6
SAFETY INFORMATION
First Respondent and Operator Warning
Material ID Number: 1075
Guide Number: 115
NOTE: Please refer to Cautions and Warnings in the
Emergency Response Guidebook. (Pipeline and
Material Safety Administration)
1/4 Turn Safety Shut-Off Valve
The fuel system utilizes a manual shut-off valve to be used in
the case of an emergency.
The valve is located on the front of the left-hand side fuel tank
(driver's side). To operate the valve, grab firmly and pull the
valve down a 1/4 of a full turn (90°) until the tab on the lever
bottoms out on the dowel. This will manually stop fuel flow from
the tanks.
Refer to figure 1 to the right.
PHMSA
Hazardous
Figure 1 - 1/4 Turn Safety Shut-Off Valve
Page 7
SAFETY INFORMATION
Propane Safety Specifications
Specification
Item
Unit
Initial Boiling Point @ 14.7 psi
Weight per 1gal of liquid @ 60°F.
Ignition Temperature in Air
Air/Fuel Ratio by Volume
Air/Fuel Ratio by Weight
Chemical Formula: C3H8
920°-1,120° (493.3°-604.4°)
-44° (-42.2°)
4.24 (7.28)
°F (°C)
lbs/gal (kg/L)
°F (°C)
15.6:1
24:1
Page 8
WARRANTY
Page 9
WARRANTY
Warranty
EPA and CARB Emission System Warranty
WARRANTY PERIOD
Government agencies including the United States
Environmental Protection Agency (EPA) and the California Air
Resources Board (CARB) require Power Solutions International,
Inc. to provide emissions warranty to end users. PSI must
warrant the engine is designed, built and equipped so as to
conform at the time of sale with applicable regulations and be
free from defects in materials and workmanship for a defined
period of years or miles, whichever occurs first (Emissions
Warranty). PSI will provide emissions warranty coverage as
required by the EPA and CARB regulatory agencies. Emissions
Warranty does not cover, remanufactured, dealer rebuilt or
dealer exchange engines.
•
5 years
• 50,000 miles (80,467 km)
The California Air Resources Board, United States
Environmental Protection Agency and Power Solutions
International, Inc. are pleased to explain the emission control
system warranty on your PSI 8.8L LP engine. In California, new
motor vehicles must be designated, built and equipped to meet
the State's stringent anti-smog standards. Power Solutions
International, Inc. warrants the emission control system on your
engine for the periods of time listed, provided there has been
no abuse, neglect or improper maintenance of your vehicle.
Your emission control system includes parts such as the LPG
fuel-injection system, the ignition system, catalytic converter, and
engine computer. Also included may be hoses, belts,
and other emission-related assemblies.
Where a warrantable condition exists, Power Solutions
International, Inc. will repair your truck at no cost to you including
diagnosis, parts and labor.
connectors
Manufacturer's Warranty Coverage
5 years or 50,000 miles (whichever first occurs):
•
Your 8.8L LP engine conforms to U.S. Environmental
Protection Agency (EPA) regulations for emission systems.
Or if covered by any basic or extended warranty (if greater
than above)
1)
If your truck fails a Smog Check inspection, all necessary
repairs and adjustments will be made by Power Solutions
International, Inc. to ensure that your emission control system is
working properly. This is your Emission Control System
PERFORMANCE WARRANTY.
2)
If any emission-related part on your truck is defective, the
part will be repaired or replaced by Power Solutions
International, Inc. This is your short-term emission control
system DEFECTS WARRANTY.
Page 10
WARRANTY
Federal Emission System Warranty (cont.)
Owner's Warranty Responsibilities
As the truck owner, you are responsible for the performance of
the required maintenance listed in your Operation and
Maintenance manual. Power Solutions International, Inc.
recommends that you retain all receipts covering maintenance
on your truck, but Power Solutions International, Inc. cannot
deny warranty solely for the lack of receipts or for your failure to
ensure the performance of all scheduled maintenance.
You are responsible for presenting your truck to a certified
as soon as a problem exists. The warranty repairs should
completed in a reasonable amount of time, not to exceed 30
days.
dealer
be
All receipts and failed parts must be kept in order to receive
compensation for warranted repairs reimbursable due to an
emergency.
If you have any questions regarding your warranty rights and
responsibilities, you should contact Power Solutions
International, Inc. at 888-331-5764 or the California Air
Resource Board at 9528 Telstar Avenue, El Monte, CA 91731.
As the truck owner, you should also be aware that Power
Solutions International, Inc. may deny you warranty coverage if
your truck or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
In the case of emergency when a warranted part or warranty
station is not reasonably available to you, repairs may be
performed at any available service establishment, or by you,
using any replacement part. Power Solutions International, Inc.
will reimburse you for your expenses including diagnostic
charges for such an emergency repair or replacement, which
cannot exceed Power Solutions International, Inc's suggested
retail price for all warranted parts replaced and labor charges
based on Power Solutions International, Inc's recommended time
allowance for the warranty repair and the geographically
appropriate hourly labor rate.
Page 11
WARRANTY
Federal Emission System Warranty (cont.)
WARRANTY EXCLUSIONS
The following items are not reimbursable under the PSI warranty
terms.
•
Any repair on an engine that has exceeded the hour or time
limitation of the stated warranty.
PSI may deny any claims that in their sole discretion are the
•
result of misapplication of the engine or part.
•
Units that are under development (i.e. prototype projects,
engineering projects).
•
Any repair on an engine where the hours of operation or inservice date has been misrepresented.
•
Any repair on an engine if the hour meter has been altered
so that the true hours on the engine cannot be determined.
•
Any repair on an engine where the date of service has been
misrepresented to place an out-of-warranty engine inside the
warranty period.
•
Engines damaged by an Act of God or force majeure.
•
Routine maintenance repairs.
•
Repairs required due to improper storage precautions.
Adjustments made to improve performance beyond PSI
•
estimated normal standards.
•
Use of other than genuine OEM parts, unless in an
emergency situation.
•
Any failure that is a result of the application and not a defect
in the materials or workmanship from PSI as deemed by PSI.
•
Repairs to parts that, upon analysis, are found not to
be defective.
Repairs to engines used for re-powering on-road vehicles.
•
•
All consequential expenses, including, but not limited to, those
resulting from equipment failure such as lodging, food,
downtime or replacement equipment rental.
•
Any misapplication or misuse of the product as deemed
by PSI.
•
Towing or transportation expense for moving an engine or
engine-powered equipment from the customer location to the
repair location.
•
Repairs caused by damage due to poor workmanship.
For additional warranty information please refer to the "Power
Solutions International Warranty Policy and Procedures
Manual".
Page 12
SECTION 1 – ENGINE SYSTEMS
Page 13
SECTION 1 – ENGINE SYSTEMS
Engine Serial Number
The engine serial number can be found in two locations.
The serial number label will be located on the right-hand side
valve cover as shown in figure 3.
The number will also be stamped on the left-hand side of the
engine, near the flywheel as shown in figure 4.
Engine Serial Number Examples
8.8L12345
Engine Serial Number Codes
8.8L - Engine Displacement
12345 - Engine Serial Number
Figure 2 - Serial Number Label Example
Figure 3 - Serial Number Label Location
Figure 4 - Stamped Location of Serial Number
Page 14
SECTION 1 – ENGINE SYSTEMS
Engine Emission Label
Engine Accessories
The U.S. Environmental Protection Agency (EPA) exhaust
emission label is attached to the plate on top of the intake
manifold as shown in figure 6. The EPA label typically includes
the following:
•
Model year
•
Engine family and displacement
•
Advertised horsepower rating
•
Emission family and control systems
Figure 5 - Emission Label Example
Engine Spec Label
There will also be an Engine Spec Label that contains the spec
description, spec number, and an engine spec barcode. This
will be located on the plate mounted to the top of the intake
manifold as shown in figure 6.
The following engine parts may have manufacturer's labels or
identification plates:
•
Alternator
•
Compressor
•
Engine Control Module
Figure 6 - Engine Spec Label
Page 15
SECTION 1 – ENGINE SYSTEMS
Engine Specification
Cylinder Head
Engine Description
The PSI 8.8L LP engine has been designed to produce
greener emissions while providing reliability and power through
the use of a liquid propane fuel injection system.
For additional information on engine specifications please refer
to the Appendix section of the manual.
Air Management System
The PSI 8.8L LP engine uses a naturally aspirated air intake
system that utilizes an electronically controlled throttle body to
control air flow.
Crankcase Assembly
The crankcase is designed to withstand high-pressure loads
during operation. It is a single piece crankcase with parent bore
cylinders and forged pistons. The oil pump is a shaft driven gear
pump, driven by the camshaft drive adapter. The crankcase
also utilizes an internally integrated wire mesh breather system
to vent pressure to the engine intake.
Crankshaft
The crankshaft has five main bearing sets with fore and aft
thrust controlled by the main thrust bearing. Forged connecting
rods are used with a full floating piston pin, the pin is secured in
the piston head by circlips. The rear oil seal carrier is located
between the crankshaft and the oil pan.
The cylinder head has two valves per cylinder for controlled air
flow. The push rod driven valve train uses hydraulic roller lifters
and individual rocker arms. There is a port in the cylinder head
where the fuel injectors are located and the cam gear is driven
by the timing chain.
Electronic Control System
An Engine Control Module (ECM) will monitor and control
engine performance in order to ensure maximum performance
and compliance with EPA emissions requirements.
The ECM monitors the engine and exhaust systems to verify
that operation remains within emissions limits. If emissions
parameters are not met an emissions fault will be logged, the
Malfunction Indicator Lamp (MIL) will illuminate, and one or
more fault codes will be present. This may result in a derate in
engine performance.
SECTION 1 – ENGINE SYSTEMS
Page 16
Engine Description (cont.)
Fuel System
The PSI 8.8L LP engine is equipped with a BiPhase LPEFI®
(Liquid Propane Electronic Fuel Injection) fuel system. This
system utilizes liquid fuel injection to improve power, efficiency
and operating characteristics.
Fuel will be drawn from an LP fuel tank via a supply pump. The
fuel will then pass through a supply lock-off valve, excess flow
valve, and past the fuel pressure and fuel temperature sensors.
The pressurized fuel is then fed to the two fuel rails mounted
on each side of the engine. The liquid fuel is vaporized as it is
being injected into the cylinders and ignited. Excess
pressurized fuel is returned from the fuel rail via a fuel return
line, the fuel will pass through an excess flow valve and a
return lock-off before being returned to the tank.
Fuel System Overview
The LPEFI® system works the same as a gasoline fuel injected
system, with the only difference being that it injects liquid
propane into each intake port. The fuel system will operate just
as a gasoline fuel system, with a slight modification in the fuel
enrichment strategy during engine startup. A typical gasoline
fuel system requires a rich mixture that is very dense and
dependent on ambient temperature. With the liquid propane
injection, the engine is capable of normal startup with a fuel
mixture that is much leaner, thus allowing a reduction in startup
emissions.
The LPEFI® system utilizes three main components: a fuel
tank, the fuel lines, and the fuel injectors. The tank is located
near the back of the vehicle and the lines run from the tank to
the fuel rails that are mounted on each side of the PSI 8.8L LP
engine.
Fuel System - Fuel Lines
Fuel lines in the LPEFI® system are composed of two different
hoses, one inside of the other. The inner nylon hose supplies
LP to the fuel injector while the space between the outside of
the inner hose and the inside of the larger outer hose is utilized
as the fuel return passage. There will be two fuel lines coming
out of the fuel tank. One is used as the supply and return line for
the left side fuel rail while the other line is used for the supply
and return to the right side fuel rail.
SECTION 1 – ENGINE SYSTEMS
Page 17
Engine Description (cont.)
Fuel System - Tanks
The tank is the most complex portion of the LPEFI® system.
The primary tank includes the following components:
Internal Electric Fuel Pump
Fuel Filter
Fuel Supply Valve
Fuel Return Valve
Fuel Pump Baffle (used to keep pump submerged in LP)
Fuel Level Float
Pressure Relief Valve
Overfill Prevention Device
Liquid Service Valves
Vapor Service Valves
Fuel Supply Lock-Off Valve
Fuel Return Lock-Off Valve
A secondary tank can be used to increase fuel capacity in the
system. The secondary fuel tank will simply supply additional
fuel to the primary tank once the fuel level begins to deplete.
The tank levels are monitored and controlled by the
Control Module.
Engine
In order to counter this, the LPEFI® system will go through a
5-30 second system purge at every startup attempt to rid the
system of any vapor.
Fuel System - Injectors and Fuel Rails
The fuel injectors in the LPEFI® system are specifically
designed for use with liquid propane. Electronically the function
will be similar to a gasoline fuel injector, holding a resistance
value between 13 and 15 ohms.
The fuel rails use the same concentric design as the fuel lines
and each injector has a supply and return passage. These
passages in the injectors are separated by the cooling bushing,
which is used to cause a pressure reduction resulting in the fuel
being vaporized. The vaporization of the fuel will help keep the
supply side of the system cool, which in turn helps the fuel
remain in a liquid state while in the supply side of the fuel lines.
The fuel is immediately turned to a vapor when it exits the
injector into the intake port. This can cool the intake air allowing
for additional power and reduced emissions.
The propane will remain a liquid throughout the liquid supply
portion of the system due to the fuel pump maintaining a 35 to
50 psi boost in tank pressure. The pressure will remain in the
fuel line all the way up to the injectors. If the injectors are closed
the fuel will pass through an internal cooling bushing
within the injector before being forced into the return lines and
back to the tank. In some cases, the liquid propane fuel can
become vaporized and cause a loss in power or hard starting
due to excessive heat.
SECTION 1 – ENGINE SYSTEMS
Page 18
Secondary Tank (if applicable)
Engine Description (cont.)
Figure 7 - Fuel System Layout
(For Reference Only)
SECTION 1 – ENGINE SYSTEMS
Page 19
Engine Features
Coolant Temperature Control
The ECM will begin to derate the engine if the coolant
temperature surpasses the allowable range.
Prior to activation of the standard warning system, the ECM will
derate the engine once temperatures exceed above a certain
limit. Derates will occur according to vehicle manufacturer
specifications. For thermostat temperature limits please refer to
the Appendix section.
Electronic Speedometer and Tachometer
The PSI 8.8L LP engine system will calculate vehicle speed.
The calculated speed will be a function of transmission speed,
final drive ratio, and tire size revolutions per minute. The PSI
PowerLink tool can be used to modify any changes that occur to
these systems.
The in-dash tachometer uses a signal generated from the
engines crank sensor.
Engine Starter Engagement Limitations
The ECM will prevent starter engagement when the
transmission is in gear.
Air Compressor
Engine Electronic Governor Control
The engine governor controls will limit engine rpm to ensure
that it remains within a safe operating range.
The low speed governor prevents engine rpm from dropping
below a certain limit when hot or cold. This is done to avoid any
chance of engine stall when various loads are demanded on the
engine. For low speed governor limits refer to the Appendix
section.
The high speed governor is designed to limit the engine rpm
when in neutral, and while in-gear. This is done to avoid any
possibility of engine damage due to excessively high rpm. For
high speed governor limits refer to the Appendix Section
Engine Component Protection System
The PSI 8.8L is designed to protect all systems from damage by
monitoring data such as engine temperature, oil temperature, oil
pressure, coolant level, and engine speed. If critical engine
parameters are exceeded this system will alert the driver by
using a series of warning lamps and derating the engine if
necessary.
To make any modification to the Engine Protection System you
must contact the vehicle Manufacturer or a certified service
dealer.
An air compressor is standard for all applications with air brakes
or air suspension.
SECTION 1 – ENGINE SYSTEMS
Page 20
Engine Features (cont.)
ECM Logging System
The ECM will log any DTC's that occur during engine operation.
Cold Idle Kick
If the ECM senses the engine temperature is below a certain
limit the Cold Idle Kick (CIK) will begin to increase (kick) engine
idle rpm. Once the engine temperature is at or above
temperature the ECM will allow the engine to idle at
idle speed. For idle speeds and temperatures
refer to the Appendix section.
PSI Power Link Password Protection
operating
the normal
VEPS (Vehicle Equipment Programming System)
The PSI 8.8L LP engine will use the Vehicle Equipment
Programming System (VEPS) in order to allow specific ECM
parameters to be modified when necessary. These
modifications can be made with the PSI PowerLink tool or by a
certified service center.
Engine Crank Inhibit (ECI)
ECI prevents starter engagement once the vehicle has been
started and the engine is running.
This feature will prevent unauthorized users from changing any
parameters when using the PSI PowerLink tool. There will be a
specific set of passwords that allow a user certain rights and
capabilities when using the tool. In order to make any
adjustments to ECM parameters you will need to contact the
vehicle manufacturer.
Service Diagnostics
The PSI PowerLink provides diagnostic information using the
J1939 datalink.
Engine Related Optional Features
Cruise Control
The ECM is capable of controlling a cruise control feature.
The system will function similarly for all electronic engines.
The minimum and maximum cruise control speeds will be
dependent upon the application.
SECTION 1 – ENGINE SYSTEMS
Page 21
Engine Related Optional Features (cont.)
Power Take Off (PTO) — In Cab
The in cab engine speed control feature, commonly referred to
as PTO, allows the operator to set and maintain a constant
engine speed without using the accelerator pedal. It is
commonly used for powering auxiliary devices.
The in-cab engine speed control feature provides 3 conditions
in which the operator may select PTO speeds:
•
Stationary Preset - Permits the operator to select up to four
preset speeds while the vehicle is stationary.
•
Stationary Variable Speed - Permits the operator to select
any engine speed within the PTO boundaries.
•
Mobile Variable Speed - Permits the operator to select a
desired variable speed for moving or stationary PTO
operations.
Customer programmable parameters within the ECM provide
in-cab engine speed control related options that can be
adjusted to suit the customer's needs. The accelerator pedal is
disabled for all mobile variable speed modes. Choosing the
rpm set points or presets is one example.
Power Take Off (PTO) — Remote
When control over engine speed is required from outside the
vehicle’s cab, remote mounted switches must be used to turn
on PTO engine speed control and select the desired engine
speed. This functionality is referred to as Remote Engine Speed
Control (RESC). The system provides for two preset rpm
positions. Customer programmable parameters within the ECM
provide RESC related options that can be adjusted to suit the
customer’s needs. Choosing the rpm set point or presets is one
example.
Cold Start Assist
The PSI 8.8L LP engine will have an optional cold start assist
system. This system can be supplied as a plug-in block heater,
a plug-in oil heater, or a combination of both.
The heating option is required if the vehicle routinely operates in
temperatures below the normal operating range. For other
temperature requirements refer to the Appendix section or Cold
Weather Operation section.
A block coolant heater and oil heater is required
at temperatures below -20°F (-28.9°C).
SECTION 1 – ENGINE SYSTEMS
Page 22
Engine Related Optional Features (cont.)
Road Speed Governor (RSG)
RSG is a feature with customer programmable parameters
designed to regulate the maximum vehicle speed as
controlled by the accelerator pedal. A separate setting is
possible when the vehicle is in Reverse.
These options can be enabled by programmable parameters
within the Engine Control Module (ECM).
SECTION 1 – ENGINE SYSTEMS
Page 23
Front
Component Location – Top
Figure 8 - Typical Top View
1.
Oil Cooler
2.
Ignition Coils
3.
Compressor
4.
Throttle Body
5.
Alternator
6.
Oil Fill Cap
7.
Dipstick and Tube
8.
Engine Control Module
(ECM - Chassis Mounted)
9.
Fuel Rails
10.
MAP Sensor
SECTION 1 – ENGINE SYSTEMS
Page 24
Component Location – Front
Figure 9 - Typical Front View
1.
Engine Control Module
(ECM - Chassis Mounted)
2.
Alternator
3.
Throttle Body
4.
Power Steering Pump and Pulley
5.
Compressor
6.
Cam Position Sensor
7.
O2 Sensors (Located in Exhaust)
8.
Water Pump
9.
Dipstick and Tube
SECTION 1 – ENGINE SYSTEMS
Page 25
Component Location – Left
Figure 10 - Typical Left View
1.
Compressor
2.
Engine Control Module
(ECM - Chassis Mounted)
3.
Ignition Coils
4.
Oil Cooler
5.
Leads to Post-Cat O2 Sensors
6.
Crank Position Sensor
7.
Oil Filter
8.
Exhaust Manifold
Front
SECTION 1 – ENGINE SYSTEMS
Page 26
Component Location – Right
Figure 11 - Typical Right View
1.
Oil Cooler
2.
Right Rear Lifting Eye
3.
MAP Sensor
4.
Engine Control Module
(ECM - Chassis Mounted)
5.
Oil Fill Cap
6.
Alternator
7.
Water Pump Pulley
8.
Dipstick and Dipstick Tube
9.
Starter Motor
10. Leads to Post-Cat O2 Sensors
Front
SECTION 1 – ENGINE SYSTEMS
Page 27
Component Location – Rear
Figure 12 - Typical Rear View
1.
Compressor
2.
Left Rear Lifting Eye
3.
MAP Sensor
4. Oil Cooler
5.
Right Rear Lifting Eye
6.
Dipstick and Dipstick Tube
Right Side Knock Sensor
7.
8.
O2 Sensors (in Exhaust)
9.
Oil Drain Plug
10.
Flywheel / Flex Plate
11.
Crank Position Sensor
12.
Left Side Knock Sensor
Page 28
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT
Page 29
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT
Fuel
HD-5 Consumer Grade Propane is required for the PSI 8.8L LP
engine. The gas should meet all requirements of the ASTM
D1835 standard (current year version), and should also be
odorized.
ACCEPTABLE FUEL AND BLENDS
•
HD-5 Commercial Propane
•
More than 90% Propane
•
Less than 5% Propylene
•
Odorized Propane
UNACCEPTABLE FUEL AND BLENDS
•
HD-10 Commercial Propane
•
Standard Commercial Propane
•
Contaminated Propane
•
Less than 90% Propane
•
More than 5% Propylene
•
Odorless Propane
UNSAFE PRACTICES
WARNING: Keep propane gas and containers away
from heat, sparks, and open flames. Avoid contact
with eyes, skin, and clothing.
Caution: To prevent engine damage, do not mix any other fuel
forms with propane. This can cause an unexpected reaction that
may damage the engine and those around it.
Figure 13 - NFPA 704 Hazard Class
Page 30
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT
Engine Oil
ENGINE OIL QUALITY AND SERVICE CATEGORIES
The PSI 8.8L LP engine requires the use of synthetic blend oil
that meets Dexos1® standards. This requirement will provide a
reduction in volatility and oil consumption, significant wear
protection, and improved piston cleanliness. Meeting the
Dexos1® standard can also enhanced aeration control for
improved fuel efficiency while providing better oxidation
properties.
All oil used in the PSI 8.8L LP engine must meet the
Dexos1® specification and display the green Dexos1® logo.
(Shown Below)
Coolant
Coolant Mixtures
It is required that the PSI 8.8L LP engine uses DEX-COOL®
Coolant in the cooling system, or any PSI approved alternative
coolant. DEX-COOL® is a nitrite-, nitrate-,
borate and amine-free formulation that
carboxylate technology to provide maximum
COOL® meets ASTM D 3306 standards and is
use in automotive applications.
The PSI 8.8L LP engine requires the use of a 50/50 mixture
of DEX-COOL® and distilled water. This mixture will not
vary depending on ambient temperature, the mixture will
always remain 50% DEX-COOL® and 50% distilled water.
Contamination of Coolant
phosphate-, silicate-,
uses a patented
protection. DEX-
recommended for
Oil Recommendation
SAE Oil Viscosity Grades
It is required that the Dexos1® oil meet SAE 5W-30 viscosity
standards. This oil weight will be used regardless of ambient
temperature.
Coolant color can help indicate the condition of the coolant.
•
Coolant color should be orange (clear - not cloudy).
•
Coolant must not have floating debris or visible oil.
•
At times, DEX-COOL® may begin to change to a pink color
tone. This is normal and should not be a concern as long as
it has remained clear.
NOTE: A plug in oil heater is an option if the engine is being operated in conditions that may need a cold start assist.
Page 31
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES
Instrument Panel Gauge Cluster
During engine starts and engine operation, gauges and
indicator lamps should be checked periodically.
Gauges may vary with vehicle applications.
and indicator lamps show conditions not indicated by the
gauges.
See the Vehicle Operator Manual for description of
indicator lamps for the drivetrain, chassis components, and
cabin.
WARNING LAMPS
Warning
Wait to Start Lamp
The Wait to Start lamp will illuminate during the fuel system
purge. This will take 5-40 seconds before the engine should
be started (see Fuel System section for details). When the Wait
to Start lamp is extinguished, start the engine. See
the Engine section for further information.
If the operator does not wait for the lamp to extinguish, the result
may be a hard start or no start condition.
Maintenance Lamp
Starting
Warning lights signal when a reading is outside preset
limits.
•
Warning lamps indicate situations that must be
inspected before operating the vehicle.
NOTE: Please reference the vehicle operation manual for visual representations of the Instrument Panel Gauge Cluster.
The Maintenance lamp will illuminate in conjunction with other
warning lights or general text and warning messages. It may be
accompanied by an audible alarm to indicate an alert condition
to the operator.
Amber Warning Lamp (AWL)
The Amber Warning Lamp (AWL) may illuminate by itself, or in
conjunction with other warning lights or general text and warning
messages, to indicate an alert condition to the operator. It is
normal for this lamp to illuminate under certain high load and/or
high ambient temperature conditions. It is safe to
vehicle. However, if the lamp continues to light or
contact an authorized service provider to have the
corrected at the first opportunity.
drive the
remains on,
problem
Page 32
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES
RED Stop Lamp (RSL)
CAUTION: To prevent engine damage, shut down engine
immediately, if the RED Stop Lamp flashes
The RED Stop Lamp indicates that a severe fault condition
exists and the engine should be shut down as soon as it is safe
to do so. Damage to the engine and/or catalytic converter may
already be occurring or have occurred when this lamp
illuminates. When the STOP ENGINE LAMP illuminates the
engine will go into a reduced power mode.
If the engine is shut down while the vehicle is in service, a single
restart attempt may be performed after waiting a minimum of 30
seconds. If, upon restarting, the fault condition still exists the
lamp will come on and the engine should be shut down. At this
point the vehicle is unsafe to drive and should be transported to
an OEM authorized repair facility.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) illuminates when the
Engine Manufacturer Diagnostic (EMD) system detects a
malfunction related to the emissions control system. The
illuminated MIL indicates the vehicle needs to be serviced at the
first convenient opportunity. Lamp may remain active after
repair until system operation confirms repair.
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES
Page 33
GAUGES
Typical Water Temperature Gauge
The water temperature gauge indicates the temperature of
coolant in the cooling system. The gauge operates only when
the ignition switch is turned to ON. For normal operating
temperatures refer to the Appendix section.
CAUTION: To prevent engine damage, do not operate engine
above the maximum allowable temperature; this may cause
internal damage. If the engine reaches maximum temperature,
a derate will occur.
Oil Pressure Gauge
The engine oil pressure gauge indicates operating oil pressure.
The engine oil pressure indicator lamp and alarm will be
activated at critical low oil pressures during various engine
speeds. Shut down the engine immediately if the lamp and alarm
are activated. For detailed oil pressure parameters
the Appendix section.
CAUTION: To prevent engine damage, shut down engine
immediately if the oil pressure indicator lamp and alarm are
act
please see
The indicator lamp will be activated as engine coolant
temperatures increase above the allowable threshold. If engine
temperature suddenly rises, shut down engine and determine
the cause of overheating. If necessary, contact an authorized
service provider. Operating the engine above these
temperatures may result in derate or engine damage. For
temperature limit details refer to the Appendix section.
Oil Temperature Gauge
The engine oil temperature gauge indicates the oil temperature
of the engine.
Page 34
SECTION 4 – ENGINE OPERATION
Page 35
SECTION 4 – ENGINE OPERATION
Preoperation Checklist
WARNING: To prevent personal injury or death,
provide ventilation when operating an engine in a closed
area. Inhalation of exhaust gas can be fatal.
This engine has been given predelivery and delivery service by
your dealer and is ready for operation. The operator should fully
understand the use and function of all controls and instruments.
Figure 14 - Oil Level Gauge (typical)
CAUTION: To prevent engine damage, do not overfill with oil.
1.
Check cooling system level.
2.
Within 10 minutes of shutting down the engine, check for
correct oil level.
3.
Inspect for coolant, fuel or oil leaks.
4.
Inspect air cleaner and piping for tightness and correct
installation of filter element.
5.
Check for loose or hanging electrical connections.
6.
Check belt condition and alignment.
7.
Fill the fuel tank with recommended fuel. See Acceptable
Fuel Blends section.
8.
Inspect exhaust system for obstruction or damage.
Page 36
SECTION 4 – ENGINE OPERATION
Preparing the Fuel System
Purging the Fuel System
Roll the key on as you would to start the vehicle normally.
1.
The Wait to Start lamp will illuminate while the fuel system
WARNING: To prevent personal injury or death, shift
transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures.
WARNING: To prevent personal injury or death, do
not smoke while in or around the vehicle. Keep fuel away
from flames and sparks.
2.
performs the purging procedure. (this will take 5-30
seconds depending on engine heat and engine off time)
Once the fuel system purge is complete, the Wait to Start
3.
lamp will extinguish. The engine is ready to be started at
this time.
See Starting the Engine section for further detail.
NOTE: If the engine runs out of fuel or the fuel filter has
drained and the engine will not start, contact your
dealer.
CAUTION: To prevent engine damage, if engine fails to start
after 20 seconds of cranking, stop cranking engine and wait 2
minutes to allow the starter motor to cool.
been
local
Page 37
SECTION 4 – ENGINE OPERATION
Starting the Engine
1.
Set parking brake and shift transmission to park or neutral.
WARNING: To prevent personal injury or death, do not
use ether, gasoline, gasohol, or other starting aids.
WARNING: To prevent personal injury or death, do not
install ether start equipment, if an engine has a cold starting
device or other cold climate starting aid.
WARNING: To prevent personal injury or death, do not
use ether starting fluid to start the engine.
CAUTION: To prevent damage to the engine, do not depress the
accelerator pedal.
2.
Depress clutch pedal if equipped.
3.
Turn ignition switch to ON. The Wait to Start lamp will
illuminate continuously. Do not crank engine while lamp is
on continuously.
4.
When the Wait to Start lamp is extinguished turn ignition
switch to START. If the vehicle has pushbutton
press and hold starter button.
5.
When the engine starts, release the ignition switch or starter
starting,
button. The ignition switch returns to ON and the engine
continues to run.
6.
With the transmission in neutral, release clutch pedal if
equipped.
Figure 15 - Ignition switch positions
Page 38
SECTION 4 – ENGINE OPERATION
Starting the Engine (cont.)
CAUTION: To prevent damage to the engine, if the engine fails
to start after 20 seconds of cranking, do the following:
•
Turn ignition switch to OFF and wait 2 minutes.
•
Repeat steps 1 through 5.
•
If after three attempts the engine does not start, determine
the cause.
•
If starting attempts are continued, the starter motor can be
damaged.
7.
Verify engine reaches the low idle range. Check all
gauges during warm-up. For idle speeds refer to the
Appendix section
8.
For minimum oil pressure at idle speed refer to the
Appendix section. If oil pressure is too low the low oil
pressure warning may illuminate along with an amber lamp.
A DTC may also become present.
NOTE: If engine starts and then stops, repeat engine starting procedure. If more than three attempts are required, determine the cause of the no-start and correct.
CAUTION: To prevent engine damage – do not increase engine
speed until oil pressure gauge indicates normal. If oil pressure
does not reach the minimum limit after startup, shutdown the
engine as soon as it can be safely turned off.
9.
During normal engine operation the low oil pressure lamp
will illuminate if minimum oil pressures are not met. If the
lamp remains illuminated for an extended period of time a
derate may occur.
Page 39
SECTION 4 – ENGINE OPERATION
Emergency Starting
WARNING: To prevent personal injury or death, do not
use ether starting fluid to start the engine.
WARNING: To prevent personal injury or death, do the
following when jump starting an engine:
•
Wear eye protection.
•
Do not smoke.
•
Keep flame and sparks away from battery.
•
The starting system may require a 12V or 24V system. The
engine system is a 12V system. Please contact your dealer
for this information before jump starting the engine.
CAUTION: To prevent engine damage, do not allow metal tools
to contact positive terminal of battery.
1.
Set parking brake and shift transmission to park or neutral.
2.
Shut off lights, heater, air conditioner, and other electrical
loads in both vehicles.
3.
Make sure vehicles are not touching.
WARNING:
always connect jumper cable for positive battery terminals
first.
WARNING: To prevent personal injury or death, do not
attach jumper cable to a negative (-) dead battery terminal.
This can cause sparks and an explosion.
5.
Connect one end of the second jumper cable to the negative
(-) terminal of the charged battery and the other end to
chassis frame of the vehicle with the dead battery.
6.
Start the engine in the vehicle that has the charged battery.
7.
Start the engine in the vehicle that has the dead battery.
WARNING: To prevent personal injury or death,
always disconnect jumper cable from negative contacts
first.
8.
Disconnect the jumper cable from negative terminal and
chassis frame.
9.
Disconnect the jumper cable from positive battery terminals
or one terminal and jump start stud.
To
prevent
personal
injury
or
death,
4.
Connect one end of the first jumper cable to the positive
(+) terminal of the dead battery or to the positive (+) terminal
of the jump start stud. Connect the other end to the
(+) terminal of the charged battery.
positive
SECTION 4 – ENGINE OPERATION
Page 40
Operation
IDLE SPEED
WARNING: To prevent personal injury or death,
provide ventilation when operating an engine in a closed
area. Inhalation of exhaust gas can be fatal.
Idle speed will vary depending on engine temperature. The
engine will utilize the Cold Idle Kick when engine temperature is
below a certain degree. This will allow rpm to be increased,
providing a quicker engine warmup. During this time, engine
rpm may fluctuate. For normal idle speed please refer to the
Appendix section.
COLD WEATHER OPERATION
WARNING: To prevent personal injury or death, do not
use ether, propane, gasoline or gasohol as starting aids.
NOTE: If operating in temperatures below -20°F (-28.9°C),
contact an authorized service provider or dealer for
information about special cold weather equipment and
precautions.
1.
Before operating the engine at 32°F (0°C) or lower, follow
preoperation checks and check or service the following:
•
Correct battery size
•
2.
Full battery charge and charging system operation
•
Condition of other electrical equipment
•
Cooling system leaks
•
Correct coolant and cooling system level
At the end of each day of operation, perform the following:
•
Fill the fuel tank with the correct fuel.
•
Check oil level.
•
Clean external surfaces of the engine and accessories to
prevent dirt or snow buildup.
•
Clean the outside of the radiator to prevent dirt or snow
build up.
A block coolant heater and oil heater is required at
temperatures below -20°F (-28.9°C).
NOTE: Do not use a Winter Front under any conditions.
of a Winter Front can lead to overheating and possible
engine damage.
Use
SECTION 4 – ENGINE OPERATION
Page 41
Operation (cont.)
HOT WEATHER OPERATION
1.
Before operating the engine above 90°F (32°C), follow
preoperation checks and check or service the following:
•
Full battery charge and charging system operation
•
Condition of other electrical equipment
•
Cooling system leaks
•
Correct coolant and cooling system level
2.
At the end of each day of operation, perform the following:
•
Check oil level.
•
Clean external surfaces of the engine and accessories
to prevent dirt buildup.
•
Clean outside and in between radiators to prevent dirt
buildup.
ENGINE SHUTDOWN
Simply turn the key to the OFF position for proper engine
shutdown.
SECTION 4 – ENGINE OPERATION
Page 42
Operation (cont.)
ENGINE WARNING PROTECTION SYSTEM (EWPS)
EWPS warns the operator of engine conditions that can damage
the engine. Optional engine shutdown is available, contact your
dealer for information.
The EWPS is the base system in which all engines are equipped.
If one or more faults are detected, the ECM will
RED Stop Lamp, and set a corresponding
Code (DTC).
Coolant temperature, coolant level, oil temperature, and oil
pressure will be monitored using this system. If a threshold is
exceeded at any time, a series of lamps may illuminate and the
engine may need to be shutdown as soon as it is safe to be
turned off. A derate may also occur.
If a Warning Threshold is exceeded, the amber warning lamp
will illuminate. If a Critical Threshold is exceeded, the red STOP
lamp will illuminate.
Depending on vehicle configuration options and emissions
certification level, the MIL may also be illuminated when a
derate condition is achieved.
illuminate the
Diagnostic Trouble
•
Coolant Temp Warning Threshold
•
Coolant Temp Critical Threshold
•
Oil Temp Warning Threshold
•
NOTE: These images are for reference only. Refer to the
vehicle operation manual for visual representation of the
warning lamps.
Oil Temp Critical Threshold
•
Oil Pressure W arning Threshold
•
Oil Pressure Derate Threshold
•
Low Coolant Warning Threshold
SECTION 4 – ENGINE OPERATION
Page 43
Operation (cont.)
ENGINE MANUFACTURER DIAGNOSTICS (EMD) OVERVIEW
The EMD system uses many individual pre-programmed
“monitors” to ensure the vehicle is meeting emissions
standards. An EMD monitor is a strategy to evaluate the
performance of an emissions related system or component. All
monitors are designed for execution in a prescribed frequency;
the monitors run automatically during every run cycle.
The operator will be alerted to emissions system problems
the Malfunction Indicator Lamp (MIL) illuminates. Nonemissions faults will illuminate the Amber Warning lamp. When
the MIL illuminates, bring the vehicle in for service at the next
available opportunity. The EMD system does not change the
way the vehicle should be driven, the recommended driving
style, or the way you use the vehicle.
The EMD is capable of causing an engine derate, in this case
the engine STOP lamp will illuminate to notify the driver. The
EMD system will not cause an automatic engine shutdown, it is
up to the driver to turn off the engine as soon as it is safe to do
so. Once the engine is off the driver may attempt to cycle the
key back on to restart the engine. If the engine is restarted and
the STOP lamp remains illuminated, the engine should be shut
off and the driver should seek a tow truck to get the vehicle to a
service center.
when
ROAD SPEED GOVERNOR (RSG)
RSG is the top vehicle speed the ECM allows. RSG can be set
from factory or with the PSI Powerlink using VEPS. A Reverse
Speed Governor will also accompany the RSG settings, this will
allow a limit to be set for vehicle speed while in reverse. The
RSG will have two setting in VEPS:
•
OFF
•
Vehicle speed determined by customer
To have an RSG set, changed or turned off, call an
authorized service provider.
ROAD OPERATION
Correct road operation of your vehicle provides the following:
Satisfactory engine performance
•
•
Maximum fuel economy
•
Long service life
General guidelines for correct road operation:
1.
Accelerate smoothly and evenly to engine's rated speed.
Rapid acceleration causes high fuel consumption.
2.
When approaching a hill, press accelerator smoothly to start
the upgrade at full power. Downshift to maintain maximum
vehicle speed.
Page 44
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Page 45
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Maintenance Schedule
WARNING: The fuel system is under pressure. Do not service the fuel system until it has been relieved of pressure. Servicing the fuel system, or a component of the fuel system, while it is under pressure may result in injury or death.
Replacement Parts
Key Replacement Parts
Engine Oil (7.5 quarts)
Industry Standard
Engine Oil Filter
Engine Coolant
LP Fill Filter
Spark Plug
Spark Plug Wire
DEXOS 5W-30
DEX-COOL 50/50
*or any PSI approved
coolant.
PSI Part Number
DEXOS 5W-30
PSI - 80000983
DEX-COOL 50/50
PSI - 32502612
PSI - 80000808
PSI - 80000064
Page 46
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Maintenance Schedule
Service Procedure
Change Oil and Filter
Perform Coolant Quality Check (including Freeze Point)
Inspect Fuel System (including 80% level gauge)(1)
Inspect/Replace Belts, Tensioners, Air Intake Piping, Clamps
Replace internal and external Fuel Filters (more often if poor fuel
quality)
Inspect Electrical System
Flush Coolant System / Replace Coolant (2)
Inspect/Replace Spark Plugs and Plug Wires (3)
Replace Air Filter
1
- Follow the recommended inspection instructions in the NFPA 58 Standard.
2
- Test coolant quality for proper chemical balance and replace if outside manufacturers specification.
3 - For heavier duty service, inspect/replace spark plugs at 45,000 miles (72,000 Km).
NOTE: When performing these service procedures, the interval should be decided by whichever increment comes first.
Power Solutions International, Inc. - 8.8L LP Engine
Miles (Kilometers)
5,000 (8,000)
Perform Annual Inspection
Perform Annual Inspection
15,000 (24,000)
70,000 (112,000)
35,000 (56,000)
60,000 (97,000)
60,000 (97,000)
Contact your Dealer
Maintenance Schedule (cont.)
Service Procedures
Hours
200
600
1,400
1,400
2,400
2,400
Months
6
18
42
42
72
72
Page 47
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
WARNING: To prevent personal injury or death, shift
transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures.
WARNING: To prevent personal injury or death, do not
let engine fluid stay on your skin. Clean skin and nails
using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids.
OIL LEVEL
Recommended to check before engine operation.
NOTE: Do not check oil level if engine is running or immediately after engine shutdown. Oil level should be checked within 10 minutes of engine shutdown.
2.
Shut down the engine and check oil level within 10 minutes.
3.
Remove the dipstick from the dipstick tube.
Figure 16 - Oil Level Gauge (typical)
CAUTION: To prevent engine damage, do the following:
•
Make sure oil level readings are within the crosshatched
operating range on the oil level gauge.
•
Do not overfill the engine with oil.
•
Do not operate engine if oil level is above or below the
operating range.
4.
If oil level is below operating range, fill with recommended
oil until the level is correct.
5. If oil level is above operating range, drain oil until the level is
correct.
1.
Park vehicle on level ground.
Page 48
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
COOLANT LEVEL
Recommended to check before engine operation.
NOTE: Be sure to use a 50/50 blend of DEX-COOL and distilled water.
WARNING: To prevent personal injury or death, shift
transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures.
WARNING: To prevent personal injury or death, do not
let engine fluid stay on your skin. Clean skin and nails
using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids
1.
Park vehicle on level ground, set the parking brake, and shut
down the engine.
2.
Check coolant level in the coolant tank.
•
For cold engine check, coolant level should be between
the COLD MIN and COLD MAX marks.
•
For hot engine check, coolant level should be at the
COLD MAX mark (top of coolant tank).
•
If coolant level is below the COLD MIN mark on a cold
engine or below the COLD MAX mark on a hot engine,
continue with steps 3 and 4.
Figure 17 - Typical Coolant Tank (for reference only)
Page 49
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
COOLANT LEVEL (cont.)
EXTERNAL LEAKAGE
Service Interval: Before Engine Operation
WARNING: To prevent personal injury or death, do the
following when removing the radiator cap or coolant tank
cap:
•
Allow the engine to cool for 15 minutes or more.
•
Wrap a thick cloth around the radiator cap or coolant tank
cap.
•
Loosen cap slowly a quarter to half turn to vent pressure.
•
Pause for a moment until all pressure has escaped to avoid
being scalded by steam.
•
Continue to turn cap counter clockwise to remove.
3.
Remove coolant tank cap.
•
If engine is cold, add coolant up to the COLD MAX mark.
•
If engine is hot, add coolant up to the bottom of the
coolant tank fill neck.
4.
Install and tighten coolant tank cap.
WARNING: To prevent personal injury or death, shut
down engine, set parking brake, and block wheels before
inspecting for external leakage.
1.
Check for the following conditions:
•
2.
Cracked hoses
•
Loose hose connections
•
Coolant stains
•
Oil stains
•
Fuel stains
•
Leakage at water pump
Correct problems.
Page 50
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
BELT, AIR INTAKE PIPING AND CLAMPS
Service Interval: Check every 15,000 miles (24,000 km), 18
months, or 600 hours. Whichever comes first.
Inspect condition of all drive belts (Figure 18). Install a new
belt if any of the following conditions exist:
•
Excessive wear
•
Missing material
•
Grease or oil contamination
•
Over three cracks per inch in a belt rib
Removing the Belt Main Drive Belt
1.
Insert a 3/8–inch drive ratchet into the machined hole on
the belt tensioner.
2.
Rotate the auto tensioner in the clockwise direction to relieve
tension from the belt and remove the belt from the
tensioner pulley and other pulleys as required.
3.
Slowly release the ratchet; the auto tensioner
auto
automatically adjusts.
4.
Figure 18 - Belt Condition
1.
Belt in good condition
2.
Belt ready for replacement
3.
Belt ribs
4.
Cracks in belt
Remove the ratchet from the tensioner.
Page 51
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
BELT, AIR INTAKE PIPING AND CLAMPS (cont.)
Removing the Belt
Air Compressor Belt
1.
Attach a 3/8–inch drive ratchet and a 15mm socket to
the tensioner.
2.
Rotate the auto tensioner in the counter clockwise direction
to relieve tension from the belt and remove the belt from the
auto tensioner pulley and other pulleys as required.
3.
Slowly release the ratchet; the auto tensioner
automatically adjusts.
4.
Remove the ratchet from the tensioner.
Installing the Belt Main Drive Belt
1.
Insert a 3/8–inch drive ratchet into the machined hole on the
belt tensioner.
2.
Rotate the auto tensioner in the clockwise direction to relieve
tension from the pulley and install the belt on the
tensioner pulley and other pulleys as required.
auto
Installing the Belt Air Compressor Belt
1.
Attach a 3/8–inch drive ratchet and a 15mm socket to the
tensioner.
2.
Rotate the auto tensioner in the counter clockwise direction
to relieve tension from the pulley and install the belt on the
auto tensioner pulley and other pulleys as required.
Slowly release the ratchet; the auto tensioner
3.
automatically adjusts. Ensure the belt is routed properly.
4.
Remove the ratchet and socket.
NOTE: See Figures 19 and 20 for proper belt routing.
AIR INTAKE PIPING AND CLAMPS
Inspect hoses, pipes, and clamps for any of the following
conditions, install new parts when needed:
•
Loose hoses or clamps, tighten or replace as required
•
Ruptured hoses
•
Cracked air cleaner housing
Slowly release the ratchet; the auto tensioner
3.
automatically adjusts. Ensure the belt is routed properly.
4.
Remove the ratchet and socket.
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
BELT, AIR INTAKE PIPING AND CLAMPS (cont.)
Figure 19 - Typical Main Drive Belt Routing
Page 52
Figure 20 - Typical Air Compressor Belt Routing
Page 53
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
ENGINE OIL AND FILTER
COOLANT FREEZE POINT
Check freeze point with a refractometer.
1.
Put drop of coolant on refractometer window.
2.
Look through eyepiece and focus.
3.
Record freeze point.
4.
Adjust coolant concentration as necessary to achieve
desired freeze point protection.
Service Interval: Check annually.
NOTE: Be sure that the antifreeze mix is 50% distilled water
and 50% DEX-COOL.
WARNING: To prevent personal injury or death, wear
safety glasses and avoid moving components such as fans,
pulleys, and belts when taking an engine oil sample.
50/50 Mixture Freeze Point: -34°F (-37°C).
WARNING: To prevent personal injury or death, wear
protective clothing when draining hot oil.
WARNING: To prevent personal injury or death, do not
let engine fluid stay on your skin. Clean skin and nails
using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids.
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
ENGINE OIL AND FILTER (cont.)
1.
Park the vehicle on level ground. Set the parking brake and
shift the transmission to park or neutral.
2.
Run the engine until operating temperature is reached, then
shut down the engine.
3.
Remove the oil filter. (Make sure the filter seal is still on the
filter.)
4.
Dispose of the oil filter according to local regulations.
5.
Using clean engine oil, lubricate the circumference of the
new oil filter O-ring.
6.
Install new oil filter into oil filter housing and tighten to 25 ft·lb
(34 N·m).
7.
Put a drain pan under the oil pan drain plug, remove the oil
pan drain plug, and drain the oil.
8.
Inspect the oil pan drain plug O-ring. If it is free of defects,
it can be reused. Replace if required.
13.
Check the oil level gauge. Oil level must be within the
crosshatched operating range.
14.
Start the engine and run at low idle.
15.
Run the engine at various speeds for 2 minutes to fill the oil
passages. Shut off the engine. Check for leaks, especially
around the oil filter and the oil pan drain plug.
16.
Shut down the engine for 5 minutes to allow the oil to return
to the oil pan.
CAUTION: To prevent engine damage, do not overfill with oil.
17.
Recheck oil level and add oil as needed.
Lubricate the oil pan drain plug O-ring with clean engine oil
9.
and put the O-ring onto the drain plug.
10.
Install the oil pan drain plug and tighten to 21 ft·lb (28 N·m).
11.
Dispose of oil according to applicable local regulations.
CAUTION: To prevent engine damage, do not overfill with oil.
12.
Add engine oil with the correct oil viscosity and formulation.
DEXOS 5W-30 must be used.
Page 54
Figure 21 - Oil Filter Replacement
Page 55
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Service Procedures (cont.)
ELECTRICAL SYSTEM
Service Interval: Annually
1.
Check wiring harness for cracks, rubbing, and loose
connections.
2.
Check sensors for loose connections, corrosion, or cracks.
3.
Check battery cables for the following conditions:
•
Broken insulation
•
Rubbing or chaffin
•
Corroded or loose connections
4.
Repair items identified
SECTION 6 – LONG TERM STORAGE
Page 56
Page 57
SECTION 6 – LONG TERM STORAGE
General Information
If the engine or machine is to be placed in storage for a period
of one to six months, it is recommended that the following steps
be followed:
Store indoors with consistent temperature and low humidity
•
if possible.
•
Protect the air cleaner inlet from water entry.
•
Protect the exhaust outlet or muffler outlet from water entry.
•
Check the coolant freeze point and top off radiator.
•
Use a weather proof storage bag, with desiccant bag inside,
for extra protection.
At the end of each and every three-month storage period:
Carefully check all drive belts, paying particular attention to
•
the point where the straight run of the belt starts to bend
around the pulley. Check grooves in the pulley for
corrosion.
•
Check the level of coolant.
•
Check the level of oil in the sump on the dipstick.
•
Rotate crankshaft by hand to re-distribute load on the valve
train and to keep seals from becoming stuck. Be sure engine
rests in a different position (~180 degrees).
Storing an engine over six months:
(Follow all previous procedures in addition to the following.)
Drain the engine crankcase and refill with recommended
•
oil.
•
Change the oil filter.
•
Disconnect and remove the battery.
•
Clean exterior surface of the engine.
•
If the engine is equipped with an automotive type clutch
or PTO clutch, make sure that the clutch is disengaged.
At the end of each and every six-month storage period:
Check that existing preservation of all external surfaces
•
is sound and complete, paying particular attention to
crankshaft lip seal surfaces, re-preserve as necessary.
•
Ensure that all aperture covers (air intake, exhaust
manifolds, etc.) are securely positioned.
•
Perform all 3 month inspections listed.
NOTE: The lubricating oil and fully primed filter must be
replaced with oil to the listed specification every twelve
months, even though the oil has not been used. Oil left
standing in an engine will oxidize and can be contaminated
by condensation within the crankcase.
•
If battery is still installed in unit, slowly recharge battery. This
can be done every month to extend the service life of the
battery.
SECTION 6 – LONG TERM STORAGE
General Information (cont.)
Removing an Engine from Storage
When removing an engine or machine from storage, the
steps should be taken to be sure the engine is in
condition:
Remove all protective storage coverings from engine /
•
machine.
•
Check engine oil level. If engine has been dormant for over
12 months change engine oil and filter.
•
Check coolant level and strength, add and adjust as
necessary.
•
Inspect drive belt system. Check for cracks in belt and
corrosion on pulleys. Replace and clean as needed. If
applicable grease pulley bearings.
•
Install a new or fully charged battery. If installing a used
battery check electrolyte levels.
proper operating
following
•
Allow engine to run at idle for approximately 5 minutes, then raise
engine to a 'high idle', 1000-1500 rpm and bring to full operating
temperature. Watch all gauges closely, if any system is out of
specification shut down engine immediately and find cause.
After engine has successfully reached operating temperature
•
shut down and re-check all fluid levels and systems.
Inspect all engine systems thoroughly for leaks, tears,
•
broken wires, etc.
•
Rotate engine by hand at least 360 degrees before
attempting to start to be sure engine rotates smoothly.
•
When starting engine watch all gauges closely. Be sure
engine oil pressure rises within 10 seconds of engine run
time. If no oil pressure shut down engine.
Page 58
SECTION 7 – SERVICE RECORDS
Page 59
SECTION 7 – SERVICE RECORDS
Page 60
Maintenance Service Record
WARNING: To prevent personal injury or death, read
all safety instructions in the “Safety Information” section of
this manual.
WARNING: To prevent personal injury or death, shift
transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures.
Save scheduled maintenance work orders and receipts for proof
of correct maintenance. Failure to maintain work orders and
receipts may affect your warranty coverage.
SECTION 7 – SERVICE RECORDS
Page 61
Maintenance Service Record (cont.)
Maintenance Service Record
Date Service Month Service Hours Miles (Km) Item Serviced
SECTION 7 – SERVICE RECORDS
Page 62
Maintenance Service Record (cont.)
Maintenance Service Record
Date Service Month Service Hours Miles (Km) Item Serviced
SECTION 7 – SERVICE RECORDS
Maintenance Service Record (cont.)
Maintenance Service Record
Date Service Month Service Hours Miles (Km) Item Serviced
Page 63
SECTION 7 – SERVICE RECORDS
Page 64
Daily Care and Report
WARNING: To prevent personal injury or death, read
all safety instructions in the “Safety Information” section of
this manual.
WARNING: To prevent personal injury or death, put
transmission in neutral or park, set parking brake, and block
wheels before doing diagnostic or service procedures.
Check the following before engine operation to prevent engine
failure. Report all problems for immediate service.
•
Oil level
•
Oil, air, fuel or coolant leaks
•
Coolant system level
•
Excessive consumption of crankcase lubricating oil, coolant
or fuel
•
Unusual engine noise
Do the following before engine operation to prevent engine
failure.
•
Add coolant if necessary. Make sure fill cap seal is in good
condition and the cap is installed tightly.
•
Fill the fuel tank with correct fuel.
•
Inspect external surfaces of the engine, around and on the
radiators, and accessories. Clean as necessary.
SECTION 7 – SERVICE RECORDS
Page 65
Daily Care and Report (cont.)
Daily Care and Report
Date Miles Fuel Lube
Qty Cost Parts Cost Time Cost
Oil
Model
Serial No.
Parts Labor Service Performed
SECTION 7 – SERVICE RECORDS
Page 66
Daily Care and Report (cont.)
Daily Care and Report
Date Miles Fuel
Qty Cost Parts Cost Time Cost
Lube
Oil
Model
Serial No.
Parts Labor Service Performed
Appendix
Page 67
Appendix
Page 68
Engine Specifications
Power Solutions International, Inc. - 8.8L LP Engine
General Specifications
Engine Type
Displacement
Compression Ratio
Stroke
Bore
Firing Order
Aspiration
RPM Range (Min & Max)
Low Speed Governor
Cold
Hot
High Speed Governor
Throttle (neutral)
Throttle (in-gear)
Item
Big Block V-8
535 (8.767)
10.1:1
4.500 (114.3)
4.350 (110.5)
1-8-7-2-6-5-4-3
Natural
700 / 2,800
850
750
2,600
2,700
Unit
In³ (L)
In (mm)
In (mm)
min / max
rpm
rpm
rpm
rpm
Appendix
Page 69
Engine Specifications
Lubrication Specifications
Minimum Pressure @ Idle
Engine Oil Capacity
Minimum
Maximum
Power Solutions International, Inc. - 8.8L LP Engine
Item
8 (55.1)
7.0 (6.62)
7.5 (7.10)
Unit
psi (kPa)
qts (L)
qts (L)
Cooling System Specifications
Standard Thermostat Range
Full Open
Closed
Item
214 (101.1)
190 (87.2)
Unit
F° (C°)
F° (C°)
Appendix
Power Solutions International, Inc.
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