Powertrain 8.0L LPG V8, Operator'S Manual

Page 1: ...OPERATOR S MANUAL 8 0L LPG V8 ENGINE ...

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Page 3: ...INFORMATION 8 PERFORMING SERVICE WORK 8 ENGINE OIL 8 ENGINE OIL ADDITIVES 9 ENGINE OIL FLUSHES 9 CHECKING ENGINE OIL 9 CHANGING THE ENGINE OIL 9 OIL CONSUMPTION 9 ENGINE AIR CLEANER FILTER 9 INSPECTING THE ENGINE AIR CLEANER FILTER 9 COOLING SYSTEM ENGINE COOLANT 9 CHECKING COOLANT 10 ENGINE OVERHEATING 10 EMISSION CONTROL EQUIPMENT 11 SECTION IV MAINTENANCE SCHEDULE 11 RECOMMENDED FLUIDS AND LUBR...

Page 4: ...ARTING 22 TOWING YOUR VEHICLE 22 STORING YOUR VEHICLE 22 RETURING TO SERVICE 23 LIFTING YOUR VEHICLE 23 PAINTING THE VEHICLE 23 SECTION III SERVICE AND MAINTENANCE 24 MAINTAINING YOUR VEHICLE 24 MAINTENANCE SCHEDULE 24 SECTION IV TECHNICAL INFORMATION 24 FUEL TANK CAPACITIES 24 PROPANE DIAMOND STICKER 24 SIDE MOUNTED TANK SHUT OFF LOCATION 25 BETWEEN FRAME RAIL MOUNTED TANK SHUT OFF LOCATION 26 SE...

Page 5: ...3 copyright 2014 11290 Rev B OPERATOR S MANUAL 8 0 L V8 ENGINE LPG ...

Page 6: ...epared as a supplement to the OEM operator manual to inform the operator of the specific items regarding the engine USING THIS MANUAL This manual contains information which is unique to the Powertrain Integration 8 0L LPG engine It should be used in conjunction with the OEM Opera tor Manual If after reviewing the information con tained in this manual there are questions about the information pleas...

Page 7: ...will illuminate for a brief time Ignoring the Wait to Start lamp may result in a backfire through the intake manifold rough idle slow run up or hesitation on first tip in Do not crank the engine for more than 30 seconds at a time Wait two minutes after each try to allow the starter to cool Failure to do so may cause starter damage 3 When the Wait to Start lamp goes out do the following 4 Rotate th...

Page 8: ...as possible Failure to maintain the engine operating system could void the warran ty CHECK ENGINE LAMP Flashing A flashing CHECK ENGINE LAMP is an indication of an engine misfire Misfires occur when the combus tion process in one or more cylinders is not properly completed This could lead to fuel passing through the engine and into the exhaust system which could damage catalytic converters Individ...

Page 9: ...down period may be required before restarting 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 trans ported to an OEM authorized service facility FUEL IMPORTANT Using the recommended fuel pro pane is an important part of the proper mainte nance of this vehicle This engine is power...

Page 10: ...rts from your dealer PERFORMING SERVICE WORK Some maintenance work can be dangerous and cause serious injury Perform maintenance work only if the required information proper tools and equipment are available If the information tools are not available seek out a trained technician to perform the work If performing service on engine use the proper ser vice manual The service manual provides in depth...

Page 11: ...GING THE ENGINE OIL The engine oil and filter must be changed every 5 000 miles 8 064 km or less depending on operat ing conditions The crankcase capacity is 8 quarts 9 with the filter Refer to the OEM Operator Manual for oil change instructions OIL CONSUMPTION All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls pistons and...

Page 12: ... and coolant conditions i e rust cloudy dirt other contaminants ENGINE OVERHEATING Steam from an overheated engine can cause burns Stay away from the engine and vehicle hood if steam is seen or heard Turn off the engine and move away from the vehicle until the engine cools down Wait until there is no sign of steam or cool ant before opening the vehicle s hood If driving continues when the engine i...

Page 13: ...ft of the steering wheel The vehicle may not pass inspection if The malfunction indicator lamp is on with the engine running or If the light does not come on when the ig nition is turned to ON RUN while the en gine is off SECTION IV MAINTENANCE SCHEDULE AT EACH FUEL STOP Check engine oil level Check engine coolant level AT EVERY ENGINE OIL CHANGE Change engine oil and filter Perform visual inspect...

Page 14: ...12 copyright 2014 11290 Rev B ...

Page 15: ... Spec 48 254961 Detroit Diesel Spec 93K217 ASTM D6210 Organic Acid Technology with Nitrite Additive NOAT Extended Life Coolant ELC 600 000 mile minimum service life guarantee Ethylene Glycol based Silicate and phosphate free MAINTENANCE REPLACEMENT COMPONENTS PART POWERTRAIN INTEGRATION PART NUMBER GM AC Delco PART NUMBER if applicable Engine Oil Filter 11020 PF1218 Spark Plugs 11309 41 963 Plug W...

Page 16: ...ved rebuilt remanufactured or Like Kind and Quality LKQ parts Powertrain Integration is not responsible for failures resulting from the use of parts not approved by Powertrain Integration New and or approved Powertrain Integration part s used in repairing a warranted claim those parts then assume the remaining eligible time and mileage of the remaining warranty term Powertrain Integration is not r...

Page 17: ... the Engine and or vehicle caused by collision misuse lack of mainte nance lubrication cooling and or intake systems unauthorized modifications of the Engine over fueling road conditions negli gence overloading fires floods riots acts of war acts of God commission of any crime k A gradual reduction in operating perfor mance due to normal wear and tear such as but not limited to valve guides valves...

Page 18: ... Manual Powertrain Integration recommends that you retain all receipts covering maintenance on your engine but Powertrain Integration cannot deny warranty solely for the lack of receipts or for your failure to substantiate the performance of all scheduled maintenance You are responsible for presenting your engine to a Powertrain Integration authorized service location as soon as a problem exists T...

Page 19: ...e Seal Piston Pins Pistons Rear Crankshaft Oil Seal Rocker Arm Assembly Rocker Arm Stud Timing Chain Assembly Timing Cover Gasket Upper Intake Manifold O Ring Valve Cover Gaskets Valve Guide Valve Lifters Valve Push Rods Valve Retainers Valve Springs Water Pump 8 0L LPG WARRANTY COVERED PARTS 2 Years 24 000 miles 38 500 km School Bus and Delivery Vehicle Whichever occurs first Air Brake Compressor...

Page 20: ...5 305 1500 WARRANTY CLAIMS Upon initial discovery of an engine needing repair please call Powertrain Integration Warranty Services at 855 305 1500 COMPONENT ORDERS For component orders or pricing contact Powertrain Integration at sales ptintegration com or 855 305 1500 POWERTRAIN INTEGRATION SERVICE WEB SITE www service powertrainintegration com ...

Page 21: ...19 copyright 2014 11290 Rev B OPERATOR S MANUAL 8 0 L V8 ENGINE DEDICATED ...

Page 22: ... warnings la beled WARNING These warnings are extremely important Failure to follow them could result in property damage personal injury or death Please read this manual thoroughly and familiarize yourself with the warnings Propane is extremely flammable Keep sparks and open flames away from propane Do not smoke while refueling your vehicle Liquid propane can cause serious burns to skin or eyes Pr...

Page 23: ...systems use a fuel tank design different from the traditional LPG engine systems The LPI tank typically has a higher operating pressure than a LPG Vapor system tank resulting in a slower fill rate than experienced with older LPG Systems While there are many places which sell LPG as an engine fuel it is recommended that you fill your LPG powered vehicle at filling stations capable of filling autoga...

Page 24: ...is normal You should not be able to smell propane at any oth er time If you do or if you hear a constant hissing sound the fuel system may have a leak If you smell propane or a constant hissing sound is audible 1 Park the vehicle in a well ventilated area and ap ply the parking brake Keep heat sparks and flames away Open all doors for ventilation Note Do not lower your windows 2 Turn the ignition ...

Page 25: ...age to the LPI system components tank or tank mounting may result Lifting on the tank struc ture valves or mounting attachments can result in fuel leaks or damage to the tank mounting devices See Tire Changing in the OEM operator manual for proper jacking instructions Use only the jacking points recommended in the owner s manual Always inspect the jacking point to make sure there is no contact to ...

Page 26: ...intervals and fluid spec ifications In addition the LPI system has required mainte nance service internals See your dealer for required service and maintenance Your dealer has the neces sary training and parts to repair the vehicle SECTION IV TECHNICAL INFORMATION LPI FUEL TANK CAPACITY PROPANE DIAMOND STICKER If not purchased with a body some vehicle applica tions may not have a propane diamond s...

Page 27: ...eed to be closed Note Be sure to open both valves before starting the vehicle Failure to turn both valves on will cause fuel pump failure 1 Locate the supply valve Figure 1 2 To shut off the supply valve turn the valve handle clockwise until it reaches its stop Roughly three and a half turns NOTE Damage may occur if the valve is over tightened 3 Locate the return valve Figure 2 4 To shut off the r...

Page 28: ... 3A 3B 2 To shut off the supply valve turn the valve handle clockwise until it reaches its stop Roughly three and a half turns NOTE Damage may occur if the valve is over tightened 3 Locate the return valve Figure 3C 4 To shut off the return valve turn the valve handle clockwise until it reaches its stop Roughly two and a quarter turns NOTE Damage may occur if the valve is over tightened 5 To turn ...

Page 29: ...27 copyright 2014 11290 Rev B Figure 3B between the Frame Rail Mounted Tank Valve Location Figure 3C Thomas Built SAF T Liner C2 Valve Location ...

Page 30: ... LPG not meeting the specifications of HD 5 propane See LPI Owner s Manual Supplement for more info about HD 5 PROPANE Costs of scheduled maintenance or failures due to lack of scheduled maintenance as identified in the 8 0L Engine Owner s Manual Supplement Any failure resulting from abuse or neglect A repair due to accidents or comprehensive losses CFUSA is not responsible for incidental or conse...

Page 31: ...y Evaporative Pump Evaporative System Housing Fuel Injectors Fuel Regulator Knock Sensor Mass Air Flow Sensor Positive Crankcase Ventilation Valve Propane Fuel Tank Throttle Body Torque Security Module LIQUID PROPANE INJECTION WARRANTY COVERED PARTS School Bus 5 Years 100 000 miles 160 000 km Whichever occurs first Delivery Vehicle 2 Years Unlimited miles or 2 000 hours Whichever occurs first 80 M...

Page 32: ...hnical service please contact CleanFUEL USA at 1 855 305 1500 WARRANTY CLAIMS Upon initial discovery of an engine needing repair please call Powertrain Integration Warranty Services at 1 805 305 1500 COMPONENT ORDERS For component orders or pricing contact CleanFUEL USA at 1 805 305 1500 ...

Page 33: ...NGINE OVERHEATING 10 ENGINE WARNING LAMPS 6 EMISSION COMPONENTS 28 EMISSION COMPONENTS FOR 8 0L V8 LPG FUELED ENGINES 29 EVAPORATIVE SYSTEM PUMP 20 FILLING YOUR LPI FUEL TANK 20 FUEL CFUSA 20 FUEL PI 7 FUEL SYSTEM LEAK 21 FUEL TANK CAPACITIES 23 GENERAL INFORMATION PI 8 INTRODUCTION CFUSA 19 INTRODUCTION PI 4 INSPECTING THE ENGINE AIR CLEANER FILTER 9 JUMP STARTING 21 LIFTING YOUR VEHICLE 22 LIMIT...

Page 34: ...9 STARTING A LPI ENGINE 19 STARTING PROCEDURE CFUSA 19 STARTING THE ENGINE PI 5 STOP ENGINE LAMP 7 STORING YOUR VEHICLE 21 TANK SHUT OFF VALVE LOCATION BETWEEN FRAME MOUNTED 25 TANK SHUT OFF VALVE LOCATION SIDE MOUNTED 24 TECHNICAL SERVICE CFUSA 29 TECHNICAL SERVICE PI 17 TOWING YOUR VEHICLE 21 USING THIS MANUAL CFUSA 19 USING THIS MANUAL PI 4 WAIT TO START LAMP 6 WARNINGS CAUTIONS AND NOTES 4 WAR...

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Page 36: ...Copyright 2014 Powertrain Integration All rights reserved Part Number 11290 B BY ...