PSI 8.8L LP Operation And Maintenance Manual
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PSI 8.8L LP Operation And Maintenance Manual

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Power Solutions International, Inc.
8.8L LP Engine Operation and Maintenance Manual
201 Mittel Dr.
Wood Dale, IL 60191
Power Solutions International, Inc.
36100015 - Rev 4
US EPA & CARB HD-SI Certification
May 2019

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  • Page 1 Power Solutions International, Inc. 8.8L LP Engine Operation and Maintenance Manual 201 Mittel Dr. Wood Dale, IL 60191 Power Solutions International, Inc. 36100015 - Rev 4 US EPA & CARB HD-SI Certification May 2019...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS FOREWORD SAFETY INFORMATION WARRANTY EPA and CARB Emission System Warranty Manufacturer's Warranty Coverage Owner's Warranty Responsibilities Warranty Exclusions SECTION 1 – ENGINE SYSTEMS Engine Serial Number Engine Emission Label Engine Accessories Engine Specification Engine Description Engine Features Engine Related Optional Features Component Location –...
  • Page 4 TABLE OF CONTENTS Engine Oil Engine Oil Quality and Service Categories SAE Oil Viscosity Grade Coolant Coolant Mixtures Contamination of Coolant 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)
  • Page 5 TABLE OF CONTENTS Operation Idle Speed Cold Weather Operation Hot Weather Operation Engine Shutdown Engine Warning Protection System (EWPS) EMD Overview Road Speed Governor (RSG) Road Operation SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Maintenance Schedule Service Procedures Oil Level Coolant Level External Leakage Belt, Air Intake Piping and Clamps...
  • Page 6 FOREWORD...

  • Page 7: Foreword

    Service Literature noted in this manual. This This manual includes necessary information and specifications for operators to operate and maintain the PSI 8.8L LP engine. manual does not cover vehicle or equipment maintenance Contact your dealer for more information.
  • Page 8 SAFETY INFORMATION Page 2...

  • Page 9: Safety Information

    SAFETY INFORMATION Safety Information Safety Instructions Work Area This manual provides general and specific maintenance procedures essential for reliable engine operation and your • Keep work area clean, dry, and organized. safety. Since many variations in procedures, tools, and service •...
  • Page 10 Install all shields, guards, and access covers before • Use an OSHA approved blow gun. Limit blow gun air operating engine. pressure to 30 psi (207 kPa). • Do not run engine with unprotected air inlets or exhaust • Wear safety glasses or goggles.
  • Page 11 SAFETY INFORMATION Tools Propane Safety Instructions • Make sure all tools are in good condition. Warnings: • Make sure all standard electrical tools are grounded. • Never loosen fittings or vent any propane. Escaping propane • Check for frayed power cords before using power tools. can cause frostbite and severe freeze burns.
  • Page 12 SAFETY INFORMATION First Respondent and Operator Warning Material ID Number: 1075 Guide Number: 115 NOTE: Please refer to Cautions and Warnings in the PHMSA Emergency Response Guidebook. (Pipeline and Hazardous 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.
  • Page 13 SAFETY INFORMATION Propane Safety Specifications Item Unit Specification Initial Boiling Point @ 14.7 psi -44° (-42.2°) °F (°C) lbs/gal (kg/L) 4.24 (7.28) Weight per 1gal of liquid @ 60°F. °F (°C) Ignition Temperature in Air 920°-1,120° (493.3°-604.4°) 15.6:1 Air/Fuel Ratio by Volume...
  • Page 14 WARRANTY Page 8...

  • Page 15: Warranty

    Solutions International, Inc. are pleased to explain the emission control EPA and CARB Emission System Warranty system warranty on your PSI 8.8L LP engine. In California, new WARRANTY PERIOD motor vehicles must be designated, built and equipped to meet the State's stringent anti-smog standards. Power Solutions...

  • Page 16: Owner's Warranty Responsibilities

    WARRANTY Federal Emission System Warranty (cont.) All receipts and failed parts must be kept in order to receive compensation for warranted repairs reimbursable due to an Owner's Warranty Responsibilities emergency. As the truck owner, you are responsible for the performance of If you have any questions regarding your warranty rights and the required maintenance listed in your Operation and responsibilities,...

  • Page 17: Warranty Exclusions

    • Repairs to engines used for re-powering on-road vehicles. • PSI may deny any claims that in their sole discretion are the • All consequential expenses, including, but not limited to, those result of misapplication of the engine or part.

  • Page 18: Section 1 - Engine Systems

    SECTION 1 – ENGINE SYSTEMS Page 12...

  • Page 19: Engine Serial Number

    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.

  • Page 20: Engine Emission Label

    SECTION 1 – ENGINE SYSTEMS Engine Accessories Engine Emission Label The following engine parts may have manufacturer's labels or The U.S. Environmental Protection Agency (EPA) exhaust emission label is attached to the plate on top of the intake identification plates: manifold as shown in figure 6.

  • Page 21: Engine Specification

    EPA emissions requirements. The PSI 8.8L LP engine uses a naturally aspirated air intake system that utilizes an electronically controlled throttle body to The ECM monitors the engine and exhaust systems to verify control air flow.
  • Page 22 The PSI 8.8L LP engine is equipped with a BiPhase LPEFI® the fuel rails that are mounted on each side of the PSI 8.8L LP (Liquid Propane Electronic Fuel Injection) fuel system. This engine.
  • Page 23 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...
  • Page 24 SECTION 1 – ENGINE SYSTEMS Engine Description (cont.) Secondary Tank (if applicable) Figure 7 - Fuel System Layout (For Reference Only) Page 18...

  • Page 25: Engine Features

    Engine Component Protection System final drive ratio, and tire size revolutions per minute. The PSI The PSI 8.8L is designed to protect all systems from damage by PowerLink tool can be used to modify any changes that occur to monitoring data such as engine temperature, oil temperature, oil these systems.

  • Page 26: Engine Related Optional Features

    Programming System (VEPS) in order to allow specific ECM The ECM will log any DTC's that occur during engine operation. parameters to be modified when necessary. These modifications can be made with the PSI PowerLink tool or by a Cold Idle Kick certified service center.
  • Page 27 Cold Start Assist • Stationary Variable Speed - Permits the operator to select The PSI 8.8L LP engine will have an optional cold start assist any engine speed within the PTO boundaries. system. This system can be supplied as a plug-in block heater, •...
  • Page 28 SECTION 1 – ENGINE SYSTEMS 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).

  • Page 29: Component Location - Top

    SECTION 1 – ENGINE SYSTEMS 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.

  • Page 30: Component Location - Front

    SECTION 1 – ENGINE SYSTEMS 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.

  • Page 31: Component Location - Left

    SECTION 1 – ENGINE SYSTEMS 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.

  • Page 32: Component Location - Right

    SECTION 1 – ENGINE SYSTEMS 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.

  • Page 33: Component Location - Rear

    SECTION 1 – ENGINE SYSTEMS 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 7. Right Side Knock Sensor 8.

  • Page 34: Section 2 - Requirements For Fuel, Engine Oil, And Coolant

    SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Page 28...

  • Page 35: Fuel

    SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT Fuel UNSAFE PRACTICES 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 WARNING: Keep propane gas and containers away odorized.

  • Page 36: Engine Oil

    Coolant Mixtures ENGINE OIL QUALITY AND SERVICE CATEGORIES The PSI 8.8L LP engine requires the use of synthetic blend oil It is required that the PSI 8.8L LP engine uses DEX-COOL® that meets Dexos1® standards. This requirement will provide a...

  • Page 37: Section 3 - Instruments, Indicators, And Switches

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES Instrument Panel Gauge Cluster Wait to Start Lamp During engine starts and engine operation, gauges and indicator lamps should be checked periodically. The Wait to Start lamp will illuminate during the fuel system purge.

  • Page 38: Red Stop Lamp (Rsl)

    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.

  • Page 39: Gauges

    SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES GAUGES Oil Pressure Gauge Typical Water Temperature Gauge The engine oil pressure gauge indicates operating oil pressure. The engine oil pressure indicator lamp and alarm will be The water temperature gauge indicates the temperature of activated at critical low oil pressures during various engine coolant in the cooling system.

  • Page 40: Section 4 - Engine Operation

    SECTION 4 – ENGINE OPERATION Page 34...

  • Page 41: Preoperation Checklist

    SECTION 4 – ENGINE OPERATION Preoperation Checklist 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 WARNING: To prevent personal injury or death, correct oil level.

  • Page 42: Preparing The Fuel System

    SECTION 4 – ENGINE OPERATION Preparing the Fuel System Purging the Fuel System 1. Roll the key on as you would to start the vehicle normally. 2. The Wait to Start lamp will illuminate while the fuel system performs the purging procedure. (this will take 5-30 seconds depending on engine heat and engine off time) 3.
  • Page 43 SECTION 4 – ENGINE OPERATION Starting the Engine 1. Set parking brake and shift transmission to park or neutral. CAUTION: To prevent damage to the engine, do not depress the accelerator pedal. WARNING: To prevent personal injury or death, do not use ether, gasoline, gasohol, or other starting aids.
  • Page 44 SECTION 4 – ENGINE OPERATION Starting the Engine (cont.) NOTE: If engine starts and then stops, repeat engine starting procedure. If more than three attempts are CAUTION: To prevent damage to the engine, if the engine fails required, determine the cause of the no-start and correct. to start after 20 seconds of cranking, do the following: •...

  • Page 45: Emergency Starting

    SECTION 4 – ENGINE OPERATION Emergency Starting WARNING: To prevent personal injury or death, always connect jumper cable for positive battery terminals first. 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 not attach jumper cable to a negative (-) dead battery terminal.

  • Page 46: Operation

    SECTION 4 – ENGINE OPERATION Operation 1. Before operating the engine at 32°F (0°C) or lower, follow preoperation checks and check or service the following: IDLE SPEED • Correct battery size • Full battery charge and charging system operation WARNING: To prevent personal injury or death, •...

  • Page 47: Hot Weather Operation

    SECTION 4 – ENGINE OPERATION 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 •...

  • Page 48: Engine Warning Protection System (Ewps)

    SECTION 4 – ENGINE OPERATION Operation (cont.) • Coolant Temp Warning Threshold ENGINE WARNING PROTECTION SYSTEM (EWPS) EWPS warns the operator of engine conditions that can damage the engine. Optional engine shutdown is available, contact your • Coolant Temp Critical Threshold dealer for information.

  • Page 49: Emd Overview

    RSG is the top vehicle speed the ECM allows. RSG can be set ENGINE MANUFACTURER DIAGNOSTICS (EMD) OVERVIEW from factory or with the PSI Powerlink using VEPS. A Reverse Speed Governor will also accompany the RSG settings, this will The EMD system uses many individual pre-programmed allow a limit to be set for vehicle speed while in reverse.

  • Page 50: Section 5 - Maintenance Schedule And Service Procedures

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Page 44...

  • Page 51: Maintenance Schedule

    Engine Oil (7.5 quarts) DEXOS 5W-30 DEXOS 5W-30 Engine Oil Filter PSI - 80000983 Engine Coolant DEX-COOL 50/50 DEX-COOL 50/50 *or any PSI approved LP Fill Filter PSI - 32502612 coolant. Spark Plug PSI - 80000808 Spark Plug Wire PSI - 80000064...

  • Page 52: Service Procedures

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Power Solutions International, Inc. - 8.8L LP Engine Maintenance Schedule Miles (Kilometers) Hours Months Service Procedure 5,000 (8,000) Change Oil and Filter Perform Coolant Quality Check (including Freeze Point) Perform Annual Inspection...

  • Page 53: Oil Level

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES 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.

  • Page 54: Coolant Level

    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.

  • Page 55: External Leakage

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) EXTERNAL LEAKAGE Service Interval: Before Engine Operation COOLANT LEVEL (cont.) WARNING: To prevent personal injury or death, shut WARNING: To prevent personal injury or death, do the down engine, set parking brake, and block wheels before following when removing the radiator cap or coolant tank inspecting for external leakage.

  • Page 56: Belt, Air Intake Piping And Clamps

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) Inspect condition of all drive belts (Figure 18). Install a new belt if any of the following conditions exist: BELT, AIR INTAKE PIPING AND CLAMPS • Excessive wear Service Interval: Check every 15,000 miles (24,000 km), 18 •...
  • Page 57 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) Installing the Belt Air Compressor Belt BELT, AIR INTAKE PIPING AND CLAMPS (cont.) 1. Attach a 3/8–inch drive ratchet and a 15mm socket to the Removing the Belt tensioner. Air Compressor Belt 2.
  • Page 58 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) BELT, AIR INTAKE PIPING AND CLAMPS (cont.) Figure 19 - Typical Main Drive Belt Routing Figure 20 - Typical Air Compressor Belt Routing Page 52...

  • Page 59: Coolant Freeze Point

    SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) ENGINE OIL AND FILTER COOLANT FREEZE POINT WARNING: To prevent personal injury or death, wear safety glasses and avoid moving components such as fans, Check freeze point with a refractometer. pulleys, and belts when taking an engine oil sample.
  • Page 60 SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES Service Procedures (cont.) 13. Check the oil level gauge. Oil level must be within the crosshatched operating range. ENGINE OIL AND FILTER (cont.) 14. Start the engine and run at low idle. 1.

  • Page 61: Electrical System

    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: •...

  • Page 62: Section 6 - Long Term Storage

    SECTION 6 – LONG TERM STORAGE Page 56...

  • Page 63: General Information

    SECTION 6 – LONG TERM STORAGE General Information Storing an engine over six months: (Follow all previous procedures in addition to the following.) If the engine or machine is to be placed in storage for a period Drain the engine crankcase and refill with recommended •...
  • Page 64 SECTION 6 – LONG TERM STORAGE General Information (cont.) • 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 Removing an Engine from Storage temperature. Watch all gauges closely, if any system is out of When removing an engine or machine from storage, the following specification shut down engine immediately and find cause.

  • Page 65: Section 7 - Service Records

    SECTION 7 – SERVICE RECORDS Page 59...

  • Page 66: Maintenance Service Record

    SECTION 7 – SERVICE RECORDS 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.
  • Page 67 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced Page 61...
  • Page 68 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced Page 62...
  • Page 69 SECTION 7 – SERVICE RECORDS Maintenance Service Record (cont.) Maintenance Service Record Date Service Month Service Hours Miles (Km) Item Serviced Page 63...

  • Page 70: Daily Care And Report

    SECTION 7 – SERVICE RECORDS 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, transmission in neutral or park, set parking brake, and block wheels before doing diagnostic or service procedures.
  • Page 71 SECTION 7 – SERVICE RECORDS Daily Care and Report (cont.) Daily Care and Report Model Serial No. Date Miles Fuel Lube Parts Labor Service Performed Cost Parts Cost Time Cost Page 65...
  • Page 72 SECTION 7 – SERVICE RECORDS Daily Care and Report (cont.) Daily Care and Report Model Serial No. Lube Date Miles Fuel Parts Labor Service Performed Cost Parts Cost Time Cost Page 66...

  • Page 73: Appendix

    Appendix Page 67...
  • Page 74 Appendix Power Solutions International, Inc. - 8.8L LP Engine Engine Specifications Item Unit General Specifications Engine Type Big Block V-8 Displacement 535 (8.767) In³ (L) Compression Ratio 10.1:1 Stroke 4.500 (114.3) In (mm) Bore 4.350 (110.5) In (mm) Firing Order...
  • Page 75 Appendix Power Solutions International, Inc. - 8.8L LP Engine Engine Specifications Lubrication Specifications Item Unit psi (kPa) Minimum Pressure @ Idle 8 (55.1) Engine Oil Capacity qts (L) Minimum 7.0 (6.62) qts (L) Maximum 7.5 (7.10) Cooling System Specifications Item...
  • Page 76 Appendix Power Solutions International, Inc.

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