PSL 8.8l Propane Service Manual

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
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.
NOTICE
Be advised that this motor vehicle may be equipped with
computer / recording devices. Their function is to allow an
authorized individual to download data or information relating
to the operation or performance of this vehicle.
The stored data or information may be neither downloaded
nor retrieved except by the vehicle’s registered owner, or, in
the alternative, by another individual or entity authorized
by the registered owner, (e.g., Certified Service Dealer)
who may need this data or information to properly service
or diagnose this vehicle for repair or following an accident.
Any access to this information without the owner’s consent
may be in violation of law and may subject that person or
entity to criminal penalties.
TABLE OF CONTENTS
FOREWORD 1
SAFETY INFORMATION 3
WARRANTY 9
EPA and CARB Emission System Warranty 9

Manufacturer's Warranty Coverage 9
Owner's Warranty Responsibilities 10
Warranty Exclusions 11
SECTION 1 – ENGINE SYSTEMS

Engine Serial Number 13
Engine Emission Label 14
Engine Accessories 14
Engine Specification 15
Engine Description 15
Engine Features 19
Engine Related Optional Features 20
Component Location – Top 23
Component Location – Front 24
Component Location – Left 25
Component Location – Right 26
Component Location – Rear 27
SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT
Fuel 29
Acceptable Fuel Blends 29
Unacceptable Fuel and Blends 29
Unsafe Practices 29
TABLE OF CONTENTS
Engine Oil
Engine Oil Quality and Service Categories 30
30
SAE Oil Viscosity Grade
30
Coolant 30
Coolant Mixtures 30
Contamination of Coolant 30
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES
Instrument Panel Gauge Cluster
Warning Lamps 31
31
Wait to Start Lamp
31
Maintenance Lamp
31
Amber Warning Lamp (AWL) 31
RED Stop Lamp (RSL) 32
Malfunction Indicator Lamp (MIL) 32
Gauges 33
Typical Water Temperature Gauge 33
Oil Temperature Gauge 33
Oil Pressure Gauge 33
SECTION 4 – ENGINE OPERATION

Preoperation Checklist 35
Preparing the Fuel System 36
Starting the Engine 37
Emergency Starting 39
TABLE OF CONTENTS
Operation 40
Idle Speed 40
Cold Weather Operation 40
Hot Weather Operation 41
Engine Shutdown 41
Engine Warning Protection System (EWPS) 42
EMD Overview 43
Road Speed Governor (RSG) 43
Road Operation 43
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Maintenance Schedule 45
Service Procedures 47
Oil Level 47
Coolant Level 48
External Leakage 49
Belt, Air Intake Piping and Clamps 50
Coolant Freeze Point 53
Engine Oil and Filter 53
Electrical System 55
SECTION 6 – LONG TERM STORAGE

General Information 57
SECTION 7 – SERVICE RECORDS

Maintenance Service Record 60
Daily Care and Report 61
APPENDIX 67
FOREWORD
FOREWORD
Foreword About the Manual

Power Solutions International, Inc. is committed to continuous This manual contains information needed to correctly operate
research and development to improve products and introduce and maintain your engine as recommended by PSI. Numerous
technological advances. Procedures, specifications, and illustrations, symbols and feature descriptions are used to aid in
parts defined in published technical service literature may be understanding the meaning of the text. The illustrations,
altered. symbols or feature descriptions may not be available for all
NOTE: Photo illustrations identify specific parts applications, please contact your dealer for complete
or assemblies that support text and procedures; other information. Both metric and U.S. customary values are listed
areas in a photo illustration may not be exact. in this manual. The U.S. Customary value is listed first,
followed by the metric value in brackets. For additional service
This manual includes necessary information and specifications literature refer to Service Literature noted in this manual. This
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. procedures.
Refer to the applicable technical service literature 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)
Engine Service & Diagnostic Manual
Warranty Policy and Procedures Manual Consult the original vehicle or equipment manufacturer for
specific maintenance recommendations.
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.
Page 1
SAFETY INFORMATION
Page 2
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
parts exist, advice for all possible safety conditions and • Keep tools and parts off the floor.
hazards cannot be stated. • Make sure the work area is ventilated and well lit.
Read safety instructions before doing any service and test • Make sure a First Aid Kit is available.
procedures for the engine. See related manuals for more
Safety Equipment
information.
• Use correct lifting devices.
Obey Safety Instructions, Warnings, Cautions, and Notes in this
manual. Not following Warnings, Cautions, and Notes can lead • Use safety blocks and stands.
to injury, death, or damage to the engine or vehicle.
Protective Measures
Safety Terminology • Wear protective safety glasses and shoes.
Three terms are used to stress your safety and safe operation of • Wear correct hearing protection.
the engine: Warning, Caution, and Note.
• Wear cotton work clothing.
Warning: A warning describes actions necessary to prevent or
• Wear sleeved heat protective gloves.
eliminate conditions, hazards, and unsafe practices that can
cause personal injury or death. • Do not wear rings, watches or other jewelry.
Caution: A caution describes actions necessary to prevent or • Restrain long hair.
eliminate conditions that can cause damage to the engine or
vehicle.
Note: A note describes actions necessary for correct, efficient
engine operation.
Page 3
SAFETY INFORMATION
Vehicle 2. Type B — Flammable liquids

• Shift transmission to park or neutral, set parking brake, and 3. Type C — Electrical equipment
block wheels before doing diagnostic or service procedures.
Batteries
• Clear the area before starting the engine.
• Always disconnect the main negative battery cable first.
Engine
• Always connect the main negative battery cable last.
• The engine should be operated or serviced only by
• Avoid leaning over batteries.
qualified individuals.
• Protect your eyes.
• Provide necessary ventilation when operating engine in a
closed area. • Do not expose batteries to flame or sparks.
• Keep combustible material away from engine exhaust • Do not smoke in workplace.
system and exhaust manifolds.
Compressed Air
• 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.
openings. If unavoidable for service reasons, put protective
screens over all openings before servicing engine. • Wear hearing protection.
• If an engine is not safe to operate, tag the engine and ignition • Use shielding to protect others in the work area.
key.
• Do not direct compressed air at body or clothing.
Fire Prevention
• 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 4
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. Wear insulated
Fluids Under Pressure PVC rubber gloves resistant to propane, goggles for
protection against accidental release of pressurized
• Use extreme caution when working on systems under products, and thermal protective clothing when handling
pressure. Pay close attention when working with the fuel refrigerated liquids.
system.
• Do not remove any valves, bulkheads, or fittings from a tank
• Follow approved procedures only. unless the tank has been drained completely. The pressure
Fuel inside a propane tank can push a loosened bulkhead or
valve out with enough force to cause injury or death.
• Do not smoke in the work area.
• Keep all sources of ignition away from propane vehicles
• Do not refuel the tank when the engine is running. while the fuel system is being serviced. Even if the tank and
fuel lines are empty, there may still be flammable vapors
Removal of Tools, Parts, and Equipment
near the vehicle.
• Reinstall all safety guards, shields, and covers after
• Do not disconnect any propane hoses unless they have
servicing the engine.
been completely drained using the proper procedure.
• Make sure all tools, parts, and service equipment are • Do not vent or release propane indoors or near sewers, pits
removed from the engine and vehicle after all work is done. 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 5
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.
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.
Figure 1 - 1/4 Turn Safety Shut-Off Valve
Page 6
SAFETY INFORMATION
Propane Safety Specifications
Specification Item Unit
Initial Boiling Point @ 14.7 psi -44° (-42.2°) °F (°C)
Weight per 1gal of liquid @ 60°F. 4.24 (7.28) lbs/gal (kg/L)
Ignition Temperature in Air 920°-1,120° (493.3°-604.4°) °F (°C)
Air/Fuel Ratio by Volume 15.6:1
Air/Fuel Ratio by Weight 24:1
Chemical Formula: C3H8
Page 7
WARRANTY
Page 8
WARRANTY
Warranty The California Air Resources Board, United States

Environmental Protection Agency and Power Solutions
EPA and CARB Emission System Warranty International, Inc. are pleased to explain the emission control
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
Government agencies including the United States International, Inc. warrants the emission control system on your
Environmental Protection Agency (EPA) and the California Air engine for the periods of time listed, provided there has been
Resources Board (CARB) require Power Solutions International, no abuse, neglect or improper maintenance of your vehicle.
Inc. to provide emissions warranty to end users. PSI must
warrant the engine is designed, built and equipped so as to Your emission control system includes parts such as the LPG
conform at the time of sale with applicable regulations and be fuel-injection system, the ignition system, catalytic converter, and
free from defects in materials and workmanship for a defined engine computer. Also included may be hoses, belts, connectors
period of years or miles, whichever occurs first (Emissions and other emission-related assemblies.
Warranty). PSI will provide emissions warranty coverage as Where a warrantable condition exists, Power Solutions
required by the EPA and CARB regulatory agencies. Emissions International, Inc. will repair your truck at no cost to you including
Warranty does not cover, remanufactured, dealer rebuilt or diagnosis, parts and labor.
dealer exchange engines.
• 5 years Manufacturer's Warranty Coverage
• 50,000 miles (80,467 km) 5 years or 50,000 miles (whichever first occurs):
• Or if covered by any basic or extended warranty (if greater 1) If your truck fails a Smog Check inspection, all necessary
than above) repairs and adjustments will be made by Power Solutions
International, Inc. to ensure that your emission control system is
Your 8.8L LP engine conforms to U.S. Environmental
working properly. This is your Emission Control System
Protection Agency (EPA) regulations for emission systems. 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 9
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, you should contact Power Solutions
Maintenance manual. Power Solutions International, Inc. International, Inc. at 888-331-5764 or the California Air
recommends that you retain all receipts covering maintenance Resource Board at 9528 Telstar Avenue, El Monte, CA 91731.
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 dealer
as soon as a problem exists. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30
days.
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 10
WARRANTY
Federal Emission System Warranty (cont.) • Use of other than genuine OEM parts, unless in an
emergency situation.
WARRANTY EXCLUSIONS
• Any failure that is a result of the application and not a defect
The following items are not reimbursable under the PSI warranty in the materials or workmanship from PSI as deemed by PSI.
terms.
• Repairs to parts that, upon analysis, are found not to
• Any repair on an engine that has exceeded the hour or time be defective.
limitation of the stated warranty.
• Repairs to engines used for re-powering on-road vehicles.
• PSI may deny any claims that in their sole discretion are the
result of misapplication of the engine or part. • All consequential expenses, including, but not limited to, those
resulting from equipment failure such as lodging, food,
• Units that are under development (i.e. prototype projects, downtime or replacement equipment rental.
engineering projects).
• Any misapplication or misuse of the product as deemed
• Any repair on an engine where the hours of operation or in-
by PSI.
service date has been misrepresented.
• Towing or transportation expense for moving an engine or
• Any repair on an engine if the hour meter has been altered engine-powered equipment from the customer location to the
so that the true hours on the engine cannot be determined. repair location.
• Any repair on an engine where the date of service has been • Repairs caused by damage due to poor workmanship.
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. For additional warranty information please refer to the "Power
Solutions International Warranty Policy and Procedures
• Adjustments made to improve performance beyond PSI
estimated normal standards. Manual".
Page 11
Page 12
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 3 - Serial Number Label Location
Figure 2 - Serial Number Label Example
Figure 4 - Stamped Location of Serial Number
Page 13
Engine Emission Label Engine Accessories

The U.S. Environmental Protection Agency (EPA) exhaust The following engine parts may have manufacturer's labels or
emission label is attached to the plate on top of the intake identification plates:
manifold as shown in figure 6. The EPA label typically includes
the following: • Alternator
• Model year • Compressor
• Engine family and displacement • Engine Control Module
• 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.
Figure 6 - Engine Spec Label
Page 14
Engine Specification Cylinder Head

Engine Description The cylinder head has two valves per cylinder for controlled air
flow. The push rod driven valve train uses hydraulic roller lifters
The PSI 8.8L LP engine has been designed to produce and individual rocker arms. There is a port in the cylinder head
greener emissions while providing reliability and power through where the fuel injectors are located and the cam gear is driven
the use of a liquid propane fuel injection system.
by the timing chain.
For additional information on engine specifications please refer Electronic Control System
to the Appendix section of the manual.
An Engine Control Module (ECM) will monitor and control
Air Management System
engine performance in order to ensure maximum performance
The PSI 8.8L LP engine uses a naturally aspirated air intake and compliance with EPA emissions requirements.
system that utilizes an electronically controlled throttle body to The ECM monitors the engine and exhaust systems to verify
control air flow. that operation remains within emissions limits. If emissions
Crankcase Assembly parameters are not met an emissions fault will be logged, the
Malfunction Indicator Lamp (MIL) will illuminate, and one or
The crankcase is designed to withstand high-pressure loads more fault codes will be present. This may result in a derate in
during operation. It is a single piece crankcase with parent bore engine performance.
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.
Page 15
Engine Description (cont.) The LPEFI® system utilizes three main components: a fuel
tank, the fuel lines, and the fuel injectors. The tank is located
Fuel System
near the back of the vehicle and the lines run from the tank to
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.
system utilizes liquid fuel injection to improve power, efficiency
and operating characteristics. Fuel System - Fuel Lines
Fuel will be drawn from an LP fuel tank via a supply pump. The Fuel lines in the LPEFI® system are composed of two different
fuel will then pass through a supply lock-off valve, excess flow hoses, one inside of the other. The inner nylon hose supplies
valve, and past the fuel pressure and fuel temperature sensors. LP to the fuel injector while the space between the outside of
The pressurized fuel is then fed to the two fuel rails mounted the inner hose and the inside of the larger outer hose is utilized
on each side of the engine. The liquid fuel is vaporized as it is as the fuel return passage. There will be two fuel lines coming
being injected into the cylinders and ignited. Excess out of the fuel tank. One is used as the supply and return line for
pressurized fuel is returned from the fuel rail via a fuel return the left side fuel rail while the other line is used for the supply
line, the fuel will pass through an excess flow valve and a and return to the right side fuel rail.
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.
Page 16
Engine Description (cont.) In order to counter this, the LPEFI® system will go through a
5-30 second system purge at every startup attempt to rid the
Fuel System - Tanks
system of any vapor.
The tank is the most complex portion of the LPEFI® system.
Fuel System - Injectors and Fuel Rails
The primary tank includes the following components:
The fuel injectors in the LPEFI® system are specifically
Internal Electric Fuel Pump
Fuel Filter designed for use with liquid propane. Electronically the function
Fuel Supply Valve will be similar to a gasoline fuel injector, holding a resistance
Fuel Return Valve value between 13 and 15 ohms.
Fuel Pump Baffle (used to keep pump submerged in LP) The fuel rails use the same concentric design as the fuel lines
Fuel Level Float and each injector has a supply and return passage. These
Pressure Relief Valve passages in the injectors are separated by the cooling bushing,
Overfill Prevention Device which is used to cause a pressure reduction resulting in the fuel
Liquid Service Valves being vaporized. The vaporization of the fuel will help keep the
Vapor Service Valves supply side of the system cool, which in turn helps the fuel
Fuel Supply Lock-Off Valve remain in a liquid state while in the supply side of the fuel lines.
Fuel Return Lock-Off Valve The fuel is immediately turned to a vapor when it exits the
A secondary tank can be used to increase fuel capacity in the injector into the intake port. This can cool the intake air allowing
system. The secondary fuel tank will simply supply additional for additional power and reduced emissions.
fuel to the primary tank once the fuel level begins to deplete.
The tank levels are monitored and controlled by the Engine
Control Module.
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.
Page 17
Engine Description (cont.)
Secondary Tank (if applicable)
Figure 7 - Fuel System Layout

(For Reference Only)
Page 18
Engine Features Engine Electronic Governor Control

The engine governor controls will limit engine rpm to ensure
Coolant Temperature Control
that it remains within a safe operating range.
The ECM will begin to derate the engine if the coolant The low speed governor prevents engine rpm from dropping
temperature surpasses the allowable range. below a certain limit when hot or cold. This is done to avoid any
Prior to activation of the standard warning system, the ECM will chance of engine stall when various loads are demanded on the
derate the engine once temperatures exceed above a certain engine. For low speed governor limits refer to the Appendix
limit. Derates will occur according to vehicle manufacturer section.
specifications. For thermostat temperature limits please 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
Electronic Speedometer and Tachometer possibility of engine damage due to excessively high rpm. For
The PSI 8.8L LP engine system will calculate vehicle speed. high speed governor limits refer to the Appendix Section
The calculated speed will be a function of transmission speed, Engine Component Protection System
final drive ratio, and tire size revolutions per minute. The PSI
PowerLink tool can be used to modify any changes that occur to The PSI 8.8L is designed to protect all systems from damage by
these systems. monitoring data such as engine temperature, oil temperature, oil
The in-dash tachometer uses a signal generated from the pressure, coolant level, and engine speed. If critical engine
engines crank sensor. parameters are exceeded this system will alert the driver by
using a series of warning lamps and derating the engine if
Engine Starter Engagement Limitations necessary.
The ECM will prevent starter engagement when the To make any modification to the Engine Protection System you
transmission is in gear. must contact the vehicle Manufacturer or a certified service
dealer.
Air Compressor
An air compressor is standard for all applications with air brakes
or air suspension.
Page 19
Engine Features (cont.) VEPS (Vehicle Equipment Programming System)

ECM Logging System The PSI 8.8L LP engine will use the Vehicle Equipment
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
Cold Idle Kick modifications can be made with the PSI PowerLink tool or by a
certified service center.
If the ECM senses the engine temperature is below a certain
limit the Cold Idle Kick (CIK) will begin to increase (kick) engine Engine Crank Inhibit (ECI)
idle rpm. Once the engine temperature is at or above operating ECI prevents starter engagement once the vehicle has been
temperature the ECM will allow the engine to idle at the normal started and the engine is running.
idle speed. For idle speeds and temperatures
refer to the Appendix section.
PSI Power Link Password Protection
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.
Page 20
Engine Related Optional Features (cont.) Power Take Off (PTO) — Remote
Power Take Off (PTO) — In Cab When control over engine speed is required from outside the
The in cab engine speed control feature, commonly referred to vehicle’s cab, remote mounted switches must be used to turn
as PTO, allows the operator to set and maintain a constant on PTO engine speed control and select the desired engine
engine speed without using the accelerator pedal. It is speed. This functionality is referred to as Remote Engine Speed
commonly used for powering auxiliary devices. Control (RESC). The system provides for two preset rpm
The in-cab engine speed control feature provides 3 conditions positions. Customer programmable parameters within the ECM
in which the operator may select PTO speeds: provide RESC related options that can be adjusted to suit the
customer’s needs. Choosing the rpm set point or presets is one
• Stationary Preset - Permits the operator to select up to four example.
preset speeds while the vehicle is stationary.
Cold Start Assist
• Stationary Variable Speed - Permits the operator to select
any engine speed within the PTO boundaries. 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,
• Mobile Variable Speed - Permits the operator to select a a plug-in oil heater, or a combination of both.
desired variable speed for moving or stationary PTO The heating option is required if the vehicle routinely operates in
operations. temperatures below the normal operating range. For other
Customer programmable parameters within the ECM provide temperature requirements refer to the Appendix section or Cold
in-cab engine speed control related options that can be Weather Operation section.
adjusted to suit the customer's needs. The accelerator pedal is A block coolant heater and oil heater is required
disabled for all mobile variable speed modes. Choosing the at temperatures below -20°F (-28.9°C).
rpm set points or presets is one example.
Page 21
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 22
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
Front
Page 23
Component Location – Front
Figure 9 - Typical Front View

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
Page 24
Component Location – Left
Figure 10 - Typical Left View
1. Compressor

3. Ignition Coils
4. Oil Cooler
5. Leads to Post-Cat O2 Sensors
6. Crank Position Sensor
7. Oil Filter
8. Exhaust Manifold
Front
Page 25
Component Location – Right
Figure 11 - Typical Right View
1. Oil Cooler
2. Right Rear Lifting Eye
3. MAP Sensor

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
Page 26
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. O2 Sensors (in Exhaust)
9. Oil Drain Plug
10. Flywheel / Flex Plate
11. Crank Position Sensor
12. Left Side Knock Sensor
Page 27
Page 28
Fuel
HD-5 Consumer Grade Propane is required for the PSI 8.8L LP UNSAFE PRACTICES
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. from heat, sparks, and open flames. Avoid contact
with eyes, skin, and clothing.
ACCEPTABLE FUEL AND BLENDS
• HD-5 Commercial Propane Caution: To prevent engine damage, do not mix any other fuel
forms with propane. This can cause an unexpected reaction that
• More than 90% Propane may damage the engine and those around it.
• 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 Figure 13 - NFPA 704 Hazard Class
Page 29
Engine Oil Coolant
ENGINE OIL QUALITY AND SERVICE CATEGORIES Coolant Mixtures
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 Coolant in the cooling system, or any PSI approved alternative
reduction in volatility and oil consumption, significant wear coolant. DEX-COOL® is a nitrite-, nitrate-, phosphate-, silicate-,
protection, and improved piston cleanliness. Meeting the borate and amine-free formulation that uses a patented
Dexos1® standard can also enhanced aeration control for carboxylate technology to provide maximum protection. DEX-
improved fuel efficiency while providing better oxidation COOL® meets ASTM D 3306 standards and is recommended for
properties. use in automotive applications.
All oil used in the PSI 8.8L LP engine must meet the The PSI 8.8L LP engine requires the use of a 50/50 mixture
Dexos1® specification and display the green Dexos1® logo. of DEX-COOL® and distilled water. This mixture will not
(Shown Below) vary depending on ambient temperature, the mixture will
always remain 50% DEX-COOL® and 50% distilled water.
Contamination of Coolant
Coolant color can help indicate the condition of the coolant.
• Coolant color should be orange (clear - not cloudy).

Oil Recommendation
• Coolant must not have floating debris or visible oil.
SAE Oil Viscosity Grades
• At times, DEX-COOL® may begin to change to a pink color
It is required that the Dexos1® oil meet SAE 5W-30 viscosity tone. This is normal and should not be a concern as long as
standards. This oil weight will be used regardless of ambient it has remained clear.
temperature.
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 30
Instrument Panel Gauge Cluster

During engine starts and engine operation, gauges and
Wait to Start Lamp
indicator lamps should be checked periodically. The Wait to Start lamp will illuminate during the fuel system
Gauges may vary with vehicle applications. Warning purge. This will take 5-40 seconds before the engine should
and indicator lamps show conditions not indicated by the be started (see Fuel System section for details). When the Wait
gauges. to Start lamp is extinguished, start the engine. See Starting
the Engine section for further information.
See the Vehicle Operator Manual for description of If the operator does not wait for the lamp to extinguish, the result
indicator lamps for the drivetrain, chassis components, and may be a hard start or no start condition.
cabin.
WARNING LAMPS Maintenance Lamp
Warning lights signal when a reading is outside preset The Maintenance lamp will illuminate in conjunction with other
limits. warning lights or general text and warning messages. It may be
accompanied by an audible alarm to indicate an alert condition
• Warning lamps indicate situations that must be to the operator.
inspected before operating the vehicle.
Amber Warning Lamp (AWL)
NOTE: Please reference the vehicle operation manual for
visual representations of the Instrument Panel Gauge The Amber Warning Lamp (AWL) may illuminate by itself, or in
Cluster. 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 drive the
vehicle. However, if the lamp continues to light or remains on,
contact an authorized service provider to have the problem
corrected at the first opportunity.
Page 31
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.
Page 32
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. The gauge operates only when speeds. Shut down the engine immediately if the lamp and alarm
the ignition switch is turned to ON. For normal operating are activated. For detailed oil pressure parameters please see
temperatures refer to the Appendix section. the Appendix section.
CAUTION: To prevent engine damage, do not operate engine CAUTION: To prevent engine damage, shut down engine
above the maximum allowable temperature; this may cause immediately if the oil pressure indicator lamp and alarm are
internal damage. If the engine reaches maximum temperature, act
a derate will occur.
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 33
Page 34
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.
provide ventilation when operating an engine in a closed
area. Inhalation of exhaust gas can be fatal. 3. Inspect for coolant, fuel or oil leaks.
This engine has been given predelivery and delivery service by 4. Inspect air cleaner and piping for tightness and correct
your dealer and is ready for operation. The operator should fully installation of filter element.
understand the use and function of all controls and instruments. 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 35
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. Once the fuel system purge is complete, the Wait to Start
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 been
drained and the engine will not start, contact your local
dealer.
WARNING: To prevent personal injury or death, shift CAUTION: To prevent engine damage, if engine fails to start
transmission to park or neutral, set parking brake, and block after 20 seconds of cranking, stop cranking engine and wait 2
wheels before doing diagnostic or service procedures. minutes to allow the starter motor to cool.
WARNING: To prevent personal injury or death, do

not smoke while in or around the vehicle. Keep fuel away
from flames and sparks.
Page 36
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
WARNING: To prevent personal injury or death, do not accelerator pedal.
use ether, gasoline, gasohol, or other starting aids. 2. Depress clutch pedal if equipped.
3. Turn ignition switch to ON. The Wait to Start lamp will
WARNING: To prevent personal injury or death, do not illuminate continuously. Do not crank engine while lamp is
install ether start equipment, if an engine has a cold starting on continuously.
device or other cold climate starting aid.
4. When the Wait to Start lamp is extinguished turn ignition
switch to START. If the vehicle has pushbutton starting,
press and hold starter button.
WARNING: To prevent personal injury or death, do not
use ether starting fluid to start the engine. 5. When the engine starts, release the ignition switch or starter
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 37
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:
• 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.
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 38
Emergency Starting
WARNING: To prevent personal injury or death,
always connect jumper cable for positive battery terminals
WARNING: To prevent personal injury or death, do not first.
use ether starting fluid to start the engine.
WARNING: To prevent personal injury or death, do the attach jumper cable to a negative (-) dead battery terminal.
following when jump starting an engine: This can cause sparks and an explosion.
• Wear eye protection. 5. Connect one end of the second jumper cable to the negative
(-) terminal of the charged battery and the other end to
• Do not smoke. chassis frame of the vehicle with the dead battery.
• Keep flame and sparks away from battery. 6. Start the engine in the vehicle that has the charged battery.
• The starting system may require a 12V or 24V system. The 7. Start the engine in the vehicle that has the dead battery.
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 always disconnect jumper cable from negative contacts
to contact positive terminal of battery. first.
1. Set parking brake and shift transmission to park or neutral. 8. Disconnect the jumper cable from negative terminal and
2. Shut off lights, heater, air conditioner, and other electrical chassis frame.
loads in both vehicles. 9. Disconnect the jumper cable from positive battery terminals
3. Make sure vehicles are not touching. or one terminal and jump start stud.
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 positive
(+) terminal of the charged battery.
Page 39
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
provide ventilation when operating an engine in a closed • Condition of other electrical equipment
area. Inhalation of exhaust gas can be fatal. • Cooling system leaks
Idle speed will vary depending on engine temperature. The • Correct coolant and cooling system level
engine will utilize the Cold Idle Kick when engine temperature is
below a certain degree. This will allow rpm to be increased, 2. At the end of each day of operation, perform the following:
providing a quicker engine warmup. During this time, engine • Fill the fuel tank with the correct fuel.
rpm may fluctuate. For normal idle speed please refer to the
Appendix section. • Check oil level.
• Clean external surfaces of the engine and accessories to
COLD WEATHER OPERATION prevent dirt or snow buildup.
• Clean the outside of the radiator to prevent dirt or snow
WARNING: To prevent personal injury or death, do not build up.
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.
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. Use
of a Winter Front can lead to overheating and possible
engine damage.
Page 40
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.
Page 41
Operation (cont.)
ENGINE WARNING PROTECTION SYSTEM (EWPS) • Coolant Temp Warning Threshold
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.
The EWPS is the base system in which all engines are equipped.
If one or more faults are detected, the ECM will illuminate the
RED Stop Lamp, and set a corresponding Diagnostic Trouble • Oil Temp Warning Threshold
Code (DTC).
Coolant temperature, coolant level, oil temperature, and oil
• Oil Temp Critical Threshold
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 • Oil Pressure Warning Threshold
turned off. A derate may also occur.
If a Warning Threshold is exceeded, the amber warning lamp
• Oil Pressure Derate Threshold
will illuminate. If a Critical Threshold is exceeded, the red STOP
lamp will illuminate.
Depending on vehicle configuration options and emissions • Low Coolant Warning Threshold
certification level, the MIL may also be illuminated when a
derate condition is achieved.
NOTE: These images are for reference only. Refer to the
vehicle operation manual for visual representation of the
warning lamps.
Page 42
Operation (cont.) ROAD SPEED GOVERNOR (RSG)
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. The
“monitors” to ensure the vehicle is meeting emissions
RSG will have two setting in VEPS:
standards. An EMD monitor is a strategy to evaluate the
performance of an emissions related system or component. All • OFF
monitors are designed for execution in a prescribed frequency;
• Vehicle speed determined by customer
the monitors run automatically during every run cycle.
The operator will be alerted to emissions system problems when
To have an RSG set, changed or turned off, call an
the Malfunction Indicator Lamp (MIL) illuminates. Non-
authorized service provider.
emissions 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 ROAD OPERATION
way the vehicle should be driven, the recommended driving Correct road operation of your vehicle provides the following:
style, or the way you use the vehicle.
• Satisfactory engine performance
The EMD is capable of causing an engine derate, in this case
the engine STOP lamp will illuminate to notify the driver. The • Maximum fuel economy
EMD system will not cause an automatic engine shutdown, it is • Long service life
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 General guidelines for correct road operation:
key back on to restart the engine. If the engine is restarted and 1. Accelerate smoothly and evenly to engine's rated speed.
the STOP lamp remains illuminated, the engine should be shut Rapid acceleration causes high fuel consumption.
off and the driver should seek a tow truck to get the vehicle to a
service center. 2. When approaching a hill, press accelerator smoothly to start
the upgrade at full power. Downshift to maintain maximum
vehicle speed.
Page 43
Page 44
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 Industry Standard PSI Part Number

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 coolant. PSI - 32502612
Spark Plug PSI - 80000808
Spark Plug Wire PSI - 80000064
Page 45
Maintenance Schedule Power Solutions International, Inc. - 8.8L LP Engine
Service Procedure Miles (Kilometers) Hours Months
5,000 (8,000)
Change Oil and Filter 200 6
Perform Coolant Quality Check (including Freeze Point) Perform Annual Inspection
Inspect Fuel System (including 80% level gauge)(1) Perform Annual Inspection
Inspect/Replace Belts, Tensioners, Air Intake Piping, Clamps 15,000 (24,000) 600 18
Replace internal and external Fuel Filters (more often if poor fuel 70,000 (112,000) 1,400 42
quality)
Inspect Electrical System 35,000 (56,000) 1,400 42
Flush Coolant System / Replace Coolant (2) 60,000 (97,000) 2,400 72
Inspect/Replace Spark Plugs and Plug Wires (3) 60,000 (97,000) 2,400 72
Replace Air Filter Contact your Dealer
1 - Follow the recommended inspection instructions in the NFPA 58 Standard. Maintenance Schedule (cont.)
2 - Test coolant quality for proper chemical balance and replace if outside manufacturers
Servicespecification.
Procedures
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.
Page 46
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:

WARNING: To prevent personal injury or death, shift
transmission to park or neutral, set parking brake, and block • Make sure oil level readings are within the crosshatched
wheels before doing diagnostic or service procedures. operating range on the oil level gauge.
• Do not overfill the engine with oil.
WARNING: To prevent personal injury or death, do not • Do not operate engine if oil level is above or below the
let engine fluid stay on your skin. Clean skin and nails operating range.
using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids. 4. If oil level is below operating range, fill with recommended
oil until the level is correct.
OIL LEVEL 5. If oil level is above operating range, drain oil until the level is
correct.
Recommended to check before engine operation.
1. Park vehicle on level ground.
Page 47
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.

transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures.

let engine fluid stay on your skin. Clean skin and nails
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). Figure 17 - Typical Coolant Tank (for reference only)
• 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.
Page 48
Service Procedures (cont.) EXTERNAL LEAKAGE
COOLANT LEVEL (cont.) Service Interval: Before Engine Operation
WARNING: To prevent personal injury or death, do the WARNING: To prevent personal injury or death, shut
following when removing the radiator cap or coolant tank down engine, set parking brake, and block wheels before
cap: inspecting for external leakage.
• Allow the engine to cool for 15 minutes or more. 1. Check for the following conditions:
• Wrap a thick cloth around the radiator cap or coolant tank • Cracked hoses
cap. • Loose hose connections
• Loosen cap slowly a quarter to half turn to vent pressure. • Coolant stains
• Pause for a moment until all pressure has escaped to avoid • Oil stains
being scalded by steam.
• Fuel stains
• Continue to turn cap counter clockwise to remove.
• Leakage at water pump
3. Remove coolant tank cap. 2. Correct problems.
• 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.
Page 49
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 • Missing material
months, or 600 hours. Whichever comes first.
• 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 auto
tensioner pulley and other pulleys as required.
3. Slowly release the ratchet; the auto tensioner
automatically adjusts.
Figure 18 - Belt Condition 4. Remove the ratchet from the tensioner.
1. Belt in good condition
2. Belt ready for replacement
3. Belt ribs
4. Cracks in belt
Page 50
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. Rotate the auto tensioner in the counter clockwise direction
1. Attach a 3/8–inch drive ratchet and a 15mm socket to to relieve tension from the pulley and install the belt on the
the tensioner. auto tensioner pulley and other pulleys as required.
2. Rotate the auto tensioner in the counter clockwise direction 3. Slowly release the ratchet; the auto tensioner
to relieve tension from the belt and remove the belt from the automatically adjusts. Ensure the belt is routed properly.
auto tensioner pulley and other pulleys as required.
4. Remove the ratchet and socket.
automatically adjusts. NOTE: See Figures 19 and 20 for proper belt routing.
4. Remove the ratchet from the tensioner. AIR INTAKE PIPING AND CLAMPS
Installing the Belt Inspect hoses, pipes, and clamps for any of the following
Main Drive Belt conditions, install new parts when needed:
1. Insert a 3/8–inch drive ratchet into the machined hole on the • Loose hoses or clamps, tighten or replace as required
belt tensioner. • Ruptured hoses
2. Rotate the auto tensioner in the clockwise direction to relieve • Cracked air cleaner housing
tension from the pulley and install the belt on the auto
tensioner pulley and other pulleys as required.
automatically adjusts. Ensure the belt is routed properly.
4. Remove the ratchet and socket.
Page 51

BELT, AIR INTAKE PIPING AND CLAMPS (cont.)
Figure 19 - Typical Main Drive Belt Routing Figure 20 - Typical Air Compressor Belt Routing
Page 52
Service Procedures (cont.) ENGINE OIL AND FILTER
COOLANT FREEZE POINT

WARNING: To prevent personal injury or death, wear
Check freeze point with a refractometer. safety glasses and avoid moving components such as fans,
pulleys, and belts when taking an engine oil sample.
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.
50/50 Mixture Freeze Point: -34°F (-37°C).
WARNING: To prevent personal injury or death, wear

protective clothing when draining hot oil.

let engine fluid stay on your skin. Clean skin and nails
discard clothing and rags contaminated with engine fluids.
Page 53
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. Park the vehicle on level ground. Set the parking brake and
15. Run the engine at various speeds for 2 minutes to fill the oil
shift the transmission to park or neutral.
passages. Shut off the engine. Check for leaks, especially
2. Run the engine until operating temperature is reached, then around the oil filter and the oil pan drain plug.
shut down the engine.
16. Shut down the engine for 5 minutes to allow the oil to return
3. Remove the oil filter. (Make sure the filter seal is still on the to the oil pan.
filter.)
4. Dispose of the oil filter according to local regulations.
17. Recheck oil level and add oil as needed.
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.
9. Lubricate the oil pan drain plug O-ring with clean engine oil
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.

12. Add engine oil with the correct oil viscosity and formulation.
DEXOS 5W-30 must be used. Figure 21 - Oil Filter Replacement
Page 54

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
Page 55
Page 56
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
of one to six months, it is recommended that the following steps • Drain the engine crankcase and refill with recommended
be followed: oil.
Store indoors with consistent temperature and low humidity • Change the oil filter.
•
if possible. • Disconnect and remove the battery.
• Protect the air cleaner inlet from water entry. • Clean exterior surface of the engine.
• Protect the exhaust outlet or muffler outlet from water entry. • If the engine is equipped with an automotive type clutch
• Check the coolant freeze point and top off radiator. or PTO clutch, make sure that the clutch is disengaged.
• Use a weather proof storage bag, with desiccant bag inside, At the end of each and every six-month storage period:
for extra protection. • Check that existing preservation of all external surfaces
At the end of each and every three-month storage period: is sound and complete, paying particular attention to
crankshaft lip seal surfaces, re-preserve as necessary.
• Carefully check all drive belts, paying particular attention to
• Ensure that all aperture covers (air intake, exhaust
the point where the straight run of the belt starts to bend
manifolds, etc.) are securely positioned.
around the pulley. Check grooves in the pulley for
corrosion. • Perform all 3 month inspections listed.
• Check the level of coolant. NOTE: The lubricating oil and fully primed filter must be
• Check the level of oil in the sump on the dipstick. replaced with oil to the listed specification every twelve
months, even though the oil has not been used. Oil left
• Rotate crankshaft by hand to re-distribute load on the valve standing in an engine will oxidize and can be contaminated
train and to keep seals from becoming stuck. Be sure engine by condensation within the crankcase.
rests in a different position (~180 degrees).
• If battery is still installed in unit, slowly recharge battery. This
can be done every month to extend the service life of the
battery.
Page 57
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.
steps should be taken to be sure the engine is in proper operating
• After engine has successfully reached operating temperature
condition:
shut down and re-check all fluid levels and systems.
• 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.
• 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
Page 59
Maintenance Service Record
WARNING: To prevent personal injury or death, read

all safety instructions in the “Safety Information” section of
this manual.

transmission to park or neutral, set parking brake, and block
Save scheduled maintenance work orders and receipts for proof
of correct maintenance. Failure to maintain work orders and
receipts may affect your warranty coverage.
Page 60
Maintenance Service Record (cont.)

Date Service Month Service Hours Miles (Km) Item Serviced
Page 61

Page 62

Page 63
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
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.
Page 64
Daily Care and Report (cont.)

Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost
Page 65
Daily Care and Report (cont.)

Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost
Page 66
Appendix
Page 67
Appendix
Engine Specifications Power Solutions International, Inc. - 8.8L LP Engine
General Specifications Item Unit

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 1-8-7-2-6-5-4-3
Aspiration Natural
RPM Range (Min & Max) 700 / 2,800 min / max
Low Speed Governor
Cold 850 rpm
Hot 750 rpm
High Speed Governor
Throttle (neutral) 2,600 rpm
Throttle (in-gear) 2,700 rpm
Page 68
Appendix
Engine Specifications Power Solutions International, Inc. - 8.8L LP Engine
Lubrication Specifications Item Unit

Minimum Pressure @ Idle 8 (55.1) psi (kPa)
Engine Oil Capacity
Minimum 7.0 (6.62) qts (L)
Maximum 7.5 (7.10) qts (L)
Cooling System Specifications Item Unit

Standard Thermostat Range
Full Open 214 (101.1) F° (C°)
Closed 190 (87.2) F° (C°)
Page 69
Appendix
Power Solutions International, Inc.

PSL 8.8l Propane Service Manual

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Power Solutions International, Inc.

8.8L LP Engine Operation and Maintenance Manual

201 Mittel Dr.

Power Solutions International, Inc. 36100015 - Rev 4

EPA and CARB Emission System Warranty 9

SECTION 1 – ENGINE SYSTEMS

SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT

SECTION 4 – ENGINE OPERATION

SECTION 6 – LONG TERM STORAGE

SECTION 7 – SERVICE RECORDS

Foreword About the Manual

Technical Service Literature is revised periodically. Use only

Safety Information Safety Instructions

Vehicle 2. Type B — Flammable liquids

NOTE: Check the classification of each fire extinguisher

Tools Propane Safety Instructions

NOTE: It is recommended that you obtain and read the

First Respondent and Operator Warning

Material ID Number: 1075

NOTE: Please refer to Cautions and Warnings in the PHMSA

1/4 Turn Safety Shut-Off Valve

The fuel system utilizes a manual shut-off valve to be used in

Propane Safety Specifications

Specification Item Unit

Initial Boiling Point @ 14.7 psi -44° (-42.2°) °F (°C)

Weight per 1gal of liquid @ 60°F. 4.24 (7.28) lbs/gal (kg/L)

Ignition Temperature in Air 920°-1,120° (493.3°-604.4°) °F (°C)

Air/Fuel Ratio by Volume 15.6:1

Air/Fuel Ratio by Weight 24:1

Chemical Formula: C3H8

Warranty The California Air Resources Board, United States

• Engines damaged by an Act of God or force majeure.

Engine Serial Number

Figure 2 - Serial Number Label Example

Figure 4 - Stamped Location of Serial Number

Engine Emission Label Engine Accessories

• Engine family and displacement • Engine Control Module

• Advertised horsepower rating

Figure 5 - Emission Label Example

Engine Spec Label

Figure 6 - Engine Spec Label

Engine Specification Cylinder Head

Engine Description (cont.)

Secondary Tank (if applicable)

Figure 7 - Fuel System Layout

Engine Features Engine Electronic Governor Control

Engine Features (cont.) VEPS (Vehicle Equipment Programming System)

Engine Related Optional Features (cont.)

Component Location – Top

Figure 8 - Typical Top View

6. Oil Fill Cap

7. Dipstick and Tube

8. Engine Control Module

10. MAP Sensor

Component Location – Front

Figure 9 - Typical Front View

1. Engine Control Module

4. Power Steering Pump and Pulley

6. Cam Position Sensor