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Summary of Contents for Engine distributors CSG 637
- Page 1 OPERATOR HANDBOOK LIQUEFIED PETROLEUM GAS (LPG) GASOLINE (EFI) & NATURAL GAS (NG) ENGINES EDI 1030230 Powertrain Assemblies & Components February 2022 Provided By Ford Component Sales...
- Page 3 Reproduction in any manner, in whole or in part, is prohibited without the express permission in writing from Engine Distributors, Inc. (EDI) EDI policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects, the right to change prices, specifications and equipment at any time without notice is reserved.
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Page 4: Table Of Contents
CONTENTS HEALTH & SAFETY ..................... 6 General Guidelines: ..................6 Important Safety Notice................. 6 Notes, Cautions, and Warnings ...............7 FORWARD ....................... 8 ENGINE IDENTIFICATION..................8 U.S.A. Engine Identification Decal ..............8 Federal Emissions Warranty Statement............9 California Emission Control Warranty Statement..........9 What Is Covered? .................. - Page 5 CONTENTS STARTING THE ENGINE..................17 Initial Start-up ....................17 To Start From cold ..................18 STOPPING THE ENGINE ..................19 Normal Conditions...................19 Abnormal Conditions..................19 RUNNING-IN PROCEDURE ..................19 FUEL RECOMMENDATION..................20 Fuel Quality ....................20 Alcohol Gasoline Blends (Gasohol) ............... 20 LUBRICATION AND MAINTENANCE ..............
- Page 6 CONTENTS GENERAL MAINTENANCE INFORMATION ............30 Cooling System ..................... 30 Draining, Flushing and Filling the Cooling System…........32 Engine Lubrication System ................32 Electrical System.................... 33 Generator ...................... 33 Storage......................34 ENGINE SYSTEM CHECK..................35 SPECIFICATIONS ....................38 General Specifications ................38 Fuel System ....................
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Page 7: Health & Safety
HEALTH & SAFETY WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED. Carrying out certain operations and handling some substances can be dangerous or harmful to the operator if the correct safety precautions are not observed. Some such precautions are recommended at the appropriate points in this book. While it is important that these recommended safety precautions are observed, care near machinery is always necessary, and no list can be exhaustive. -
Page 8: Notes, Cautions, And Warnings
manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that neither personal safety nor equipment integrity are compromised by the choice of methods, tools or parts. Notes, Cautions, and Warnings As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. -
Page 9: Forward
FORWARD This book contains operating and maintenance instructions for the engine(s) listed on the title page. The life of your engine unit and the delivery of the high performance built into it will depend on the care it receives throughout its life. It is the operator’s responsibility to ensure that the engine is correctly operated and that the maintenance operations outlined in this book are carried out regularly after the specified hours of operation have been reached. -
Page 10: Federal Emissions Warranty Statement
2000 hours of service for the base engine non-emissions related parts. Three years or 2500 hours of service if any emission-related part on the engine is defective, the part will be repaired or replaced by Engine Distributors, Inc. This is your General Emissions Warranty. -
Page 11: What Is Covered
If you have any questions regarding your warranty rights and responsibilities, you should contact Engine Distributors, Inc. at (800) 220-2700 or via email at klick@edi-dist.com. What is Covered Below is a list of the systems that affect emissions on your engine. Emission control components on these systems are covered by the emissions warranties as applicable. - Page 12 General Emissions Warranty Parts List – 3 years or 2,500 hours, whichever comes first • Fuel Metering System Fuel injection system. Air/fuel ratio feedback and control system. Carburetor system (internal parts and/or pressure regulator or fuel mixer or injection system). •...
- Page 13 High Priced Emissions Warranty Parts List – 5 years or 3,500 hours, whichever comes first: • • Intake Manifold • Muffler assembly with Catalyst...
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Page 14: Parts And Service
PARTS AND SERVICE Replacement parts can be obtained through your local EDI Distributors listed on www.EDI-DIST.com. They also may be found in the yellow pages under “Engines” or contact EDI at: 1-800-220-2700. On new engines received it is the customer’s responsibility to report any missing parts to EDI within 30 days of receiving the engine. -
Page 15: Before Operating The Engine
BEFORE OPERATING THE ENGINE 1. Before operating a new engine it should be thoroughly inspected to ensure that during transit and installation it has not suffered damage likely to affect its subsequent operation. Controls and instruments should be studied carefully in order that their functions are thoroughly understood. -
Page 16: Safety Switch (Where Fitted)
4. Start - In this position, the starter solenoid is energized and the starter motor cranks the engine. The switch, when released, automatically returns to the RUN position. Safety Switch (where fitted) A low oil pressure/high water temperature safety switch may be fitted. This automatically shuts off the ignition when the oil pressure drops below a pre-set value, or when the water temperature rises above a pre-set value. -
Page 17: Instruments
INSTRUMENTS Your Engine Distributors, Inc. (EDI) Powered Equipment will have been fitted with instruments selected by the manufacturer. The types of instruments most likely to be encountered are detailed here. A typical instrument panel is shown below. Ammeter (Where Fitted) This instrument registers the charging current which is being passed to the battery from the alternator. -
Page 18: Temperature Gauge (Where Fitted)
Temperature Gauge (Where Fitted) The temperature gauge enables a close check to be kept on the coolant temperatures. Malfunction Indicator Light (Where Fitted) Used on all industrial engines. This light will illuminate whenever there is an engine malfunction such as low oil pressure, high engine temperature, fuel injection system fault. -
Page 19: To Start From Cold
To Start From cold 1. Where possible, disconnect the driven equipment, eg, fully depress the clutch where a manual transmission is fitted. If your unit is equipped with the engine warning light system, always turn the ignition switch to the ON position to make sure that each warning light is operating before starting engine. -
Page 20: Stopping The Engine
STOPPING THE ENGINE Normal Conditions Following normal operating conditions, lower the engine speed to idle, disengage the clutch, and then turn the ignition switch to the OFF position. If the engine has been running under high power, let it run at fast idle speed a few minutes to cool the engine down. -
Page 21: Fuel Recommendation
FUEL RECOMMENDATION This engine is designed to operate on dry fuel such as LPG Grade HD5 or NG (1050 BTU/ft. CAUTION: Use of commercial and non-commercial fuels rated lower than the grades specified above may cause persistent, heavy spark knock, which can lead to engine damage. - Page 22 Methanol (CH30H) is also an alcohol based fuel. It can be produced in several ways. One is from natural gas. This process is an inefficient nonviable method of production. Another method is from coal. The problem with methanol produced from coal is that it yields a higher carbon dioxide emission.
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Page 23: Lubrication And Maintenance
LUBRICATION AND MAINTENANCE The importance of correct lubrication, periodic inspection and adjustment cannot be over-emphasized. It will determine, to a very large extent, the service the engine will give. Detailed instructions regarding this maintenance are given in the following pages. Your Authorized EDI Distributor listed www.EDI-DIST.com, will be pleased to carry out this regular maintenance for you. -
Page 24: Recommended Maintenance Schedules
RECOMMENDED MAINTENANCE SCHEDULES Check engine oil level and top up if necessary Check engine coolant level and top up if necessary with correct mixture Check visually for oil, fuel or coolant leaks Check all instruments, controls and warning lights. Check hot and cold start functions Check coolant, oil, fuel, exhaust and vacuum hoses/pipes for leaks, damage,... -
Page 25: Recommended Maintenance Operations
RECOMMENDED MAINTENANCE OPERATIONS Recommended Lubricants CAUTION: Do not use supplemental oil additives or other engine treatments. They are unnecessary and could, under certain conditions, lead to engine damage which is not covered by EDI warranty. Lubricating oil cleanliness is vital for the successful operation of your engine. The oil should be stored under the cleanest possible conditions. -
Page 26: Used Engine Oils
Used Engine Oils WARNING: PROLONGED AND REPEATED CONTACT MAY CAUSE SERIOUS SKIN DISORDERS INCLUDING DERMATITIS AND SKIN CANCER. WARNING: AVOID EXCESSIVE CONTACT—WASH THOROUGHLY AFTER CONTACT. KEEP OUT OF THE REACH OF CHILDREN. WARNING: PROTECT THE ENVIRONMENT: IT IS ILLEGAL TO POLLUTE DRAINS, WATER COURSES OR SOIL. -
Page 27: Change Engine Oil
Check Engine Oil Level 1. Make sure the equipment is standing level and that the engine is stopped. 2. Pull out the dipstick and wipe it with a clean rag. 3. Insert the dipstick fully and again remove it. At no time should the level of the oil fall below the lower mark on the dipstick. -
Page 28: Fuel Filter - Efi
Fuel Filter - EFI The fuel filter is located between the fuel tank and the fuel pump. Ignition System - DIS The Distributorless Ignition System (DIS) used on this engine does not have a distributor or vacuum advance mechanism. Ignition timing is set by design and cannot be readily changed. -
Page 29: Check Condition Of Ancillary Drive Belts
Check Condition of Ancillary Drive Belts WARNING: ENGINE SHOULD BE STOPPED AND ANY REMOTE STARTER DISABLED BEFORE CHECKING BELTS. The serpentine ancillary belt used to drive the generator and water pump, is tensioned automatically and does not require adjustment. If the fan is driven by a separate belt and pulley then it may need to be adjusted. -
Page 30: Renew Air Cleaner Element
Renew Air Cleaner Element Your air cleaner filters air entering the engine induction system and acts as a silencer and a flame arrester. Air that contains dirt and grit produces an abrasive fuel mixture, and can cause severe damage to the cylinder walls and piston rings. -
Page 31: General Maintenance Information
GENERAL MAINTENANCE INFORMATION The following section outlines some aspects of general maintenance which will be of value to the operator. Cooling System To obtain maximum engine service life, its operating temperature must be maintained by an efficient cooling system. CAUTION: Under no circumstances should the engine be started without liq- uid in the cooling system. - Page 32 Motorcraft Premium Gold coolant, or equivalent, has long life characteristics and if the concentration is kept to a maximum of 50% it will provide adequate frost protection and inhibiting for the life of the engine. NOTE: If a major component of the cooling system is renewed such as the radiator, water pump etc., the system should be flushed and re-filled with a 50% solution of Motorcraft Premium Gold engine coolant, or equivalent, and clean water.
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Page 33: Draining, Flushing And Filling The Cooling System
Draining, Flushing and Filling the Cooling System WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE. TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF... -
Page 34: Electrical System
Electrical System A NEGATIVE EARTH (NEGATIVE GROUND) SYSTEM IS USED. GCP - Power Distribution Box Part of Wiring Harness Generator This is mounted on a bracket at the front of the engine and is driven from the crankshaft by a serpentine belt. The charging rate is adjusted automatically by the built-in regulator to provide sufficient electric current to keep the battery fully charged under normal operating conditions. -
Page 35: Storage
Storage NOTE: It is highly recommended that a fuel stabilizer, Ford Part Number E8AZ- 19C544-A or an equivalent additive be used for any length of storage. It is imperative in any application where the fuel will not be consumed within thirty days. Ford Fuel stabilizer comes in an 8 fl.oz. -
Page 36: Engine System Check
ENGINE SYSTEM CHECK GCP System Check NOTE: Items listed in the possible cause column generally do not set a diagnostic trouble code (DTC) or illuminate the MIL light. NOTE: EDI engines are used in many different applications and equipment. When performing any system diagnosis be aware of any OEM inputs or equipment monitoring devices that may have an effect on the engine’s performance or any of the engine’s operating systems. - Page 37 SYMPTOM POSSIBLE CAUSE • Engine Does Not Crank Dead Battery • Ground Loss • Ancillary Components Binding or Seized • OEM Shutdown - Oil Level Safety • Starter Lockout Relay Failure • Ignition Switch Failure • Bad Starter Crank Control Wire Failure •...
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Page 38: Fuel System
SYMPTOM POSSIBLE CAUSE • Lack of Power Ancillary Components Binding • Intake Air Restriction • Crossed Spark Plug Wires • Spark Plugs Fouled • Fuel System Failure • Low Fuel Pressure • Low Cylinder Compression • Spark Knock Poor Quality or Contaminated Fuel •... -
Page 39: Specifications
SPECIFICATIONS General Specifications Engine Type: V-6 cylinder 4 stroke spark ignition. Liter/CID: 3.7 / 225.7 Bore: mm (inch) 95.5 mm (3.76 in.) Stroke: mm (inch) 86.6 mm (3.41 in.) Number of cylinders: Compression Ratio: 10.5:1 Fuel System LPG Type: Fuel Liquefied Petroleum Gas Fumigation EN589 (European) HD5 (USA) Specification: NG Type: Fuel Specification:... -
Page 40: Cooling System
Cooling System Thermostat: Type: Wax element Commences opening: 188°F (86.7°C) Fully open: 210°F (98.9°C) Coolant 50% Motorcraft Premium Gold engine coolant plus 50% clear water Ford specification: WSS-M97B51-A1 Drive Belts Front end accessory drive Serpentine belt with automatic tension control. belt &... -
Page 41: Conversion Table
CONVERSION TABLE... - Page 42 Engine Distributors, Inc. 400 University Court Blackwood, NJ 08012 1-856-228-7298 1-800-220-2700 1-856-228-5657(fax parts) 1-856-228-5531(fax sales)
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