Summary of Contents for PSI 4.5L
- Page 1 4.5L OPERATIONS & MAINTENANCE MANUAL POWER GENERATION PRODUCT LINE 7610038-2 02/17 ©2023 Power Solutions International A Product by Power Solutions International Wood Dale, IL...
- Page 2 This publication may not be reproduced without written permission of Power Solutions International (PSI). At date of publication, all information included in this manual is accurate to the best of our knowledge. PSI cannot be held responsible for information that has changed after publication date.
- Page 3 REVISION CONTROL INFORMATION Revision Release Change Level Date Description (s) 04/21/2021 Initial Release 02/17/2023 Added additional information to clarify coolant specification & engine oil specification.
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Page 4: Table Of Contents
Engine Introduction and Performance Parameters ......................... 7 Introduction of Engine Model ..........................7 Engine Main Performance Parameters ......................7 4.5L Gas Engine Data ............................8 U.S. EPA Legal Requirements ..............................9 Emission Related Installation Instructions ..........................9 Personal Safety ..................................10 Fuel Information ................................... - Page 5 Inspect Belts, Pipes, Clamps and Hoses ....................25 Inspect Ignition System ..........................25 Check Coolant Conditioner ........................... 25 Inspect Water Pump ............................25 Test and/or Replace Batteries ........................25 Maintenance for Long-Term Storage ............................ 26 Engine Fastener Torque Specifications ..........................27 Torque Head Bolts ............................
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Page 6: Description Of The Illustration Marks
Description of the Illustration Marks Dismounting (assembly parts) Oil Coating Fitting (assembly parts) Special Tools Marking (do before disassembling, Pay attention to assembly adjust when assemble) direction Filling – full charge (such as Deflating lubricating oil, cooling water, etc.) Draining off (lubricating oil or Unloosing (such as: unloose cooling water) clamping equipment) -
Page 7: Engine Introduction And Performance Parameters
Engine Introduction and Performance Parameters 1. Introduction of Engine Model 4.5L TA/NA NA: Natural aspirated TA: Turbocharged G: Gas engine WPxx: Engine series 2. Engine Main Performance Parameters nameplate Illustration 1- Engine nameplate... -
Page 8: Gas Engine Data
See engine nameplate to find engine model, series number, rated power, rated speed and weight. More data as following table: 3. 4.5L Gas Engine Data Item Unit Content Engine type 4.5L naturally aspirated Number of cylinders Displacement Cylinder bore * stroke... -
Page 9: Epa Legal Requirements
U.S. EPA Legal Requirements This engine has been certified by the U.S. Environmental Protection Agency (EPA) as a Non-road and stationary constant-speed engine. It is illegal to operate this engine in a variable-speed (foot pedal speed control) application. A maintenance plan and log provided within this manual are for you to record your engine maintenance. -
Page 10: Personal Safety
Personal Safety WARNING Improper operation of this machine could result in death or serious injury. Before operating any equipment, ensure every operator: Is instructed on safe operation and use of all equipment • Fully understands all manuals and safety measures for all equipment before use •... -
Page 11: Fuel Information
55ppm. Wellhead Gas (Non-Emergency Only) Your 4.5L naturally aspirated engine is certified to run on "wellhead-quality natural gas". It must have a heating value of 700-2362 BTU (a fuel switch should be used if above 1800BTU) per standard cubic foot (LHV). Maximum allowable H2S is 55ppm. -
Page 12: New Engine Break-In Procedures
The engines moving parts are closely fitted for long service, and even though all Power Solutions International, Inc. 4.5L Gas Engines are run before they leave the factory, an additional period may be required before uniform oil films are established between all mating parts. -
Page 13: Rating Definition For Power Generation
Rating Definition for Power Generation Continuous Power (COP) is defined as being the maximum power which the generating set is capable of delivering continuously whilst supplying a constant electrical load when operated for an unlimited number of hours per year. No overload capability is available for this rating. -
Page 14: Engine Hoist
Engine Hoist While lifting, the centerline of the crankshaft of the engine must be kept level; no tilt or single-point lifting. Lift and lower slowly (See Illustration 1) Illustration 2- Engine Installation Diagram Extreme Operating Conditions 1. Engine Speed This engine is designed to operate at constant speed (1000 to 2200 RPM) and should not exceed 2400 RPM for any length of time. -
Page 15: Engine Operation
Engine Operation 1. Engine Starting With the controls in the idle position, start engine. To prevent damage to the starter, do not engage the starter motor for more than fifteen (15) seconds. Wait two (2) minutes between each start attempt to allow the starter motor to cool. If oil pressure reading does not indicate normal oil pressure(≥120kPa) within fifteen seconds of engine start, immediately shut down the engine to avoid damage to the engine. -
Page 16: Service Intervals
Service Intervals NOTE Non-critical emission-related maintenance is not necessary to keep the emission- related warranty valid. CAUTION Failure to follow these scheduled maintenance intervals could cause engine damage or decreased engine life. NOTE Valve lash adjustments will be accomplished every 500 hours (1000, 1500, etc.) engine operating time on non-emergency. -
Page 17: Maintenance Intervals - Emergency
Maintenance Intervals – Emergency Preventative Maintenance Schedule – Emergency Interval Every Event Maintenance Event Weekly The first 250 hrs or Number Years months 1 year 50 hours Check Engine Oil Level Check Engine Coolant Level Check Oil Pressure Check Overall Operating Condition (hose/clamp/pipe/belt/harness/connector) Change Oil and Oil Filter * (Sample)# Valve Lash (Inspect/Adjust) -
Page 18: Maintenance Intervals- Non-Emergency
Maintenance Intervals– Non-emergency Preventative Maintenance Schedule – Non-Emergency Interval Interval Event (Hours) Maintenance Event Weekly Number The first 1500 6 months 50hours Check Engine Oil Level Check Engine Coolant Level Check Oil Pressure Check Overall Operating Condition (hose/clamp/pipe/belt/harness/connector) Change Oil and Oil Filter * (Sample)# Valve Lash (Inspect/Adjust)## Spark Plugs (Check/Adjust/Replace) Check Air Filter (Inspect/Replace) -
Page 19: L Gas Engine Maintenance Procedures
4.5L Gas Engine Maintenance Procedures 1. Check Engine Oil A. Ensure engine is level. B. Pull dipstick after the engine stop running at least 5 minutes. C. Ensure oil level is between high and low marks. Illustration 3 D. If the oil level is below the low mark, add additional oil as necessary. -
Page 20: Check Oil Pressure
3. Check Oil Pressure When engine is running and at normal operating temperature, check oil pressure gauge. Some engines will have an analog gauge and others will have an electronic gauge from the ECU. Ensure oil pressure is in the range of the table below both at idle and rated speed and operating temperature. - Page 21 Drain plug Illustration 5 B. Inspect drain plug washer (replace if necessary) and clean plug seating surface. C. Inspect magnetic plug for iron and ferrous material. If this exists, consider an oil analysis to determine source of debris. D. Reinstall drain plug and tighten securely. E.
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Page 22: Engine Valve Lash Inspection/Adjustment
6. Engine Valve Lash Inspection/Adjustment NOTE: Required every 500 hours (1000, 1500, etc.) on non-emergency. NOTE Confirm that #1 piston is on the compression stroke by turning both pushrods by hand to verify that both valves are closed. The valves are closed when the push rods are loose and can be turned easily. - Page 23 Install gasket onto the valve cover and align the cover and gasket onto the cylinder head. Tighten the valve cover mounting bolts to 36 in/lbs. Ensure valve cover gasket is aligned before tightening. With #1 piston at “TDC”, adjust these valves to: 4.5L Exhaust 0.4mm/0.016” / Intake 0.2mm/0.008”; #1@TDC Illustration 11...
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Page 24: Inspect Spark Plugs
With #4 piston at “TDC” adjust these valves to: 4.5L Exhaust 0.4mm/0.016” / Intake 0.2mm/0.008”; #4@TDC Illustration 12 7. Inspect Spark Plugs Inspect high tension leads from coils for shorts, cracking and damage. (if used) Remove/blow out any debris from the cylinder head spark plug hole before removing the spark plug to prevent any debris falling into the combustion chamber. -
Page 25: Replace Engine Breather Filter
9. Replace Engine Breather Filter Unscrew breather housing top counterclockwise. Pull top of filter element up and remove filter. Install new filter element and breather housing top. 10. Inspect Belts, Pipes, Clamps and Hoses Inspect hoses, pipes, clamps, for loose connections, aging, corrosion, or leaks. Check the belt for fraying or damage. -
Page 26: Maintenance For Long-Term Storage
Maintenance for Long-Term Storage Power Solutions International, Inc. runs all completed engines prior to shipping to customers. Your engine was hot tested and calibrated using fully formulated coolant in the cooling system and Mobil Pegasus 805 40W Natural Gas Engine Oil prior to being drained and shipped to you. -
Page 27: Engine Fastener Torque Specifications
Engine Fastener Torque Specifications Tightening torque (N ) + further Permissible times ·m Fastener’s Name Bolt Specification turned angle (°) of repeat used 70N·m + (90±4°), required sequence of Main bearing* M14-10.9 tightening (See illustration13) 30N·m + (120±5°), (Reach 67 to 107N·m at Connecting rod* the same time) 30N·m +2x (120±4°), required sequence of... -
Page 28: Torque Head Bolts
Illustration 13 15. Torque Head Bolts NOTE: Cylinder head bolts are allowed to be reused and torqued only three (3) times. Discard these bolts after the third torque because they lose their elasticity and strength and should not be torqued for a fourth time. Remove cylinder head covers. - Page 29 0.125 (Galvanized) 0.14 (Bright) Strength 10.9 12.9 10.9 12.9 Class Bolt Specs Recommended Torque (N·m) 13.0 16.0 14.0 1100 1000 1200 1400 1650 1050 1500 1800 1100 1350 1850 2250 1200 1450 2000 2400 M8x1 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5...
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Page 30: Engine Service Schedule Log
Engine Service Schedule Log Service Service Start Complete Hour Comments Initial Interval (hr.) Date Time Time Meter 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000... -
Page 31: Engine Identification
Engine Identification Engine Part Number: Engine Serial Number: Engine Application: Purchased From: In-Service Date: Engine Hours at Delivery:... - Page 32 PM INSPECTION Performed by: UNIT # DATE: HOURS: WORK ORDER# ENGINE COMPARTMENT INSPECTION CHECK ENGINE OIL LEVEL REPLACE BREATHER FILTER CHECK ENGINE COOLANT LEVEL INSPECT BELTS, PIPES, CLAMPS & HOSES CHECK OIL PRESSURE IGNITION SYSTEM (PLUG WIRES/COILS/COP) CHECK OVERALL OPERATING CONDITION CHECK COOLANT CONDITIONER (SAMPLE) REPLACE COOLANT AS REQUIRED CHANGE OIL &...
- Page 34 Power Solutions International, Inc (PSI) 201 Mittel Drive Wood Dale, IL 60191 USA 630-350-9400 02/16 ©2023 Power Solutions International...
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