OPERATOR HANDBOOK - EDI Ford Industrial Engine Documentation
Contents
1. DISTRIBUTORS INC OPERATOR HANDBOOK WSG 1068 LIQUEFIED PETROLEUM GAS LPG NATURAL GAS NG ENGINES Part 1080050 EDI Revision F March 2011 WARNING WARNING ENGINE EXHAUST SOME OF ITS CONSTITUENTS AND CERTAIN VEHICLE COMPONENTS CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM IN ADDITION CERTAIN FLUIDS CONTAINED IN VEHICLES AND CERTAIN PRODUCTS OF COMPONENT WEAR CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM FORD WSG 1068 ENGINES Gasoline LIQUEFIED PETROLEUM GAS LPG NATURAL GAS NG Reproduction any manner in whole or in part is prohibited without the express permission in writing from Engine Distributors Incorporated Engine Distributors policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects the right to change prices specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as a final description of any individual engine CONTENTS HEALTH amp SAFETY General Guidelines Important Safety Notice Notes Cautions and Warnings FORWARD ENGINE IDENTIFICATION U S A Engine Identification Decal Non Certified Engine Decal Federal Emissions Warranty Statement California Emission Control Warran2. S designates gasoline and designates diesel The second letter in the system designates the level of the classification It should be noted that alternative fuel engines fall into the gasoline API category Gasoline engines that are converted for LPG or Natural Gas applications must use oils labeled SH and or SJ Do not use oils that are specifically formulated for Diesel Engines only CC or CD classification even when labeled Heavy Duty or for Natural Gas Engines are not acceptable The use of SAE 5W 20 is recommended for all temperatures Used Engine Oils X A WARNING AVOID EXCESSIVE CONTACT WASH THOROUGHLY AFTER CONTACT KEEP OUT OF THE REACH OF CHILDREN WARNING PROTECT THE ENVIRONMENT IT IS ILLEGAL TO POLLUTE DRAINS WATER COURSES OR SOIL USE AUTHORIZED FACILITIES FOR DISPOSAL IF IN DOUBT CONTACT YOUR LOCAL AUTHORITY FOR ADVICE WARNING DO NOT HANDLE A HOT OIL FILTER WITH BARE HANDS CONTINUOUS CONTACT WITH USED MOTOR OIL HAS CAUSED SKIN CANCER IN LABORATORY MICE PROTECT YOUR SKIN BY WASHING WITH SOAP AND WATER IMMEDIATELY AFTER CONTACT Change Engine 1 Warm the engine to normal operating temperature 2 Make sure that the equipment is standing level and that the engine is stopped 3 Obtain a sufficiently large draining pan to accommodate the engine Refer to Service Oil fll capacity including filler on page 38 4 Remove the filer cap from the rocker cover remove the drain
3. Under abnormally overheated conditions the engine may continue to run after the ignition switch is turned off I this case is ever encountered tum on the ignition switch immediately and allow the engine to idle until it has cooled enough to stop If the engine is overheated due to loss of coolant itis best to stop the engine immediately if necessary by applying the load Add engine oi if necessary then after the engine has returned to a normal temperature add coolant slowly until the radiator is full WARNING TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT ENGINE COVER THE RADIATOR CAP IN A THICK CLOTH AND TURN IT SLOWLY COUNTERCLOCKWISE TO THE FIRST STOP AFTER THE PRESSURE HAS BEEN COMPLETELY RELEASED PRESS THE CAP DOWNWARD AND FINISH REMOVING THE CAP The above instructions also apply to engines that stop due to operation of the low oil pressure high water temperature safety switch However if the engine stops due to low oil pressure do not restart until the cause has been determined and corrected Refer to Recommended Lubricants page 21 RUNNING IN PROCEDURE new or reconditioned engine must not be run at high speeds or on full load for the first 25 hours The load and speed may be increased to a maximum over this period After the first 50 hours running carry out the maintenance operations listed Refer to RECOMMENDED MAINTENANCE SCHEDULES on page 20 Check the instruments frequently and keep the coolant
4. KANSAS Kansas City Power 50 South James 7 913 321 7040 Broducts ine Kansas Ci KS 66118 1 800 488 5217 1 813 321 7341 KENTUCKY Engine Power Ine 1830 Executive Drive 1 262 567 8575 Western Oconomowoc WI 53066 1 800 242 2289 12625672552 E Pit Auto 1241 Freedom Road 1 724 778 8200 Cranberry Twp PA 16066 05 1 800 367 3463 industria Engine 157287788208 Divsion LOUISIANA Lightboum 13649 Beta Ra 197223551581 Equipment Co Dallas TX 75244 15722811738 Lightboum 5272 EI Rio Suite 110 4 713 741 2003 Equipment Co Heuston TX 77054 171387411809 MAINE Engine 400 University Court 1 856 228 7298 Distributors Inc Blackwood NJ 08012 1 800 220 2700 1 856 228 5657 Parts 1 856 228 5531 Sales MARYLAND Engine 400 University Court 1 856 228 7298 Distributors Inc Blackwood NJ 08012 1 800 220 2700 1 856 228 5657 Parts 1 856 228 5531 Sales MASSACHUSETTS Engine 200 University Court 1 856 228 7298 Distributors Blackwood NJ 08012 1 800 220 2700 1 856 228 5657 Parts 1 856 228 5531 Sales MICHIGAN Engine Center nc 2351 Hiton Road 1 248 399 0002 Lover Peninsula Ferndale MI 48220 1 800 726 8870 1 248 399 3142 Engine Power Inc 1830 Executive Drive 1 262 567 8575 usper Perna 279 Oconomowoc Wi 53066 1 800 242 2289 1 262 567 2556 MINNESOTA Northem Power 2859 Lexington Avenue S 1 851 452 8900 Products In Eagan MN 88
5. Spark Plugs 842 715 71 108 Filter 14 17 1 12 Coil Hold Down bolts 57 44 62 CONVERSION TABLE Distance at ST CEIC Te aT Ta a ACCELERATION POWER SPECIFIC FUEL CONSUMPTIO EDI Distributors AUSTRALIA Lees Industries 1224 Lytton Road 617 3390 5522 Australia PTY Ltd Hemmant Brisbane 61 7 3390 7571 Wynnum Central Queensland 4178 Australia Europe FINLAND Mesino OY Karkikuja 3 FIN 01740 358 9 476 800 Vantaa Finland 358 9476 80300 FRANCE Fomaut S A 45 Rue Charles Nodier 33 148 450 394 93310 Le Pre St Gervais 33 148 457 504 France GERMANY H D Westring 41 49 5202 987 510 Groeschler GmbH 0 33818 Leopoldshoehe 48 5202 987 515 Groschier 8 Sonn Gross Zimmerer Strasse 51 49 607 1 206 330 Sauer 05 64807 Dieburg Germany 48 6071 206 219 ystems GREAT BRITAIN Dalton Power Unit Autumn Park Industrial 44 1476 576 066 Products Ltd Estate 44 1476 577 127 Main Office Dysart Road Grantham Lincolnshire England Damon Power Suite 3 Concord House 44 191 416 1922 Products Ltd Concord 44 191 415 3682 Washington Tyne amp Wear 1AS England Dalton Power Ellesmere Street Manchester 44 161 833 2932 Products Ltd M184LP England 22 441618328465 Hendy Power School Lane 744 2380 579 800 Chandlers Ford Industrial 44 2380 271 471 Estate Eastleigh Hamp
6. USING ANTIFREEZE ARE RECOMMENDED TO ADHERE TO THE FOLLOWING PRECAUTIONS ANTIFREEZE MUST NEVER BE TAKEN INTERNALLY IF ANTIFREEZE IS SWALLOWED ACCIDENTALLY MEDICAL ADVICE SHOULD BE SOUGHT IMMEDIATELY PRECAUTIONS SHOULD BE TAKEN TO AVOID SKIN CONTACT WITH ANTIFREEZE IN THE EVENT OF ACCIDENTAL SPILLAGE ONTO THE SKIN ANTIFREEZE SHOULD BE WASHED OFF AS SOON AS PRACTICABLE IF CLOTHING IS SPLASHED WITH ANTIFREEZE IT SHOULD BE REMOVED AND WASHED BEFORE BEING WORN AGAIN TO AVOID PROLONGED SKIN CONTACT FOR REGULAR AND FREQUENT HANDLING OF ANTIFREEZE PROTECTIVE CLOTHING PLASTIC OR RUBBER GLOVES BOOTS AND IMPERVIOUS OVERALLS OR APRONS MUST BE USED TO MINIMIZE SKIN CONTACT Draining Flushing and Filling the Cooling System WARNING NEVER REMOVE THE PRESSURE Radiator Drain Cock RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO AT LEAST 40 C 110 1 Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system 2 When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap 3 Remove
7. Where a safety switch is filed the override button must be depressed while the engine is being cranked 3 Set the throttle to give a fast idle speed until normal operating temperature is reached where fitted CAUTION If the engine stalls or falters in starting wait 3 4 seconds before re engaging starter This will prevent possible damage to the starter or engine The starter should not operate for periods longer than 30 seconds at a time An interval of at least two minutes should be observed between such cranking periods to protect the starter from overheating To Re start When Warm Switch on the ignition and operate the starter motor until the engine starts NOTE Safety shut down incorporated in the Ignition Performance Module IPM Oil pressure below 6 psi and or coolant temperature goes above 250 F will shutdown the ignition system NOTE The IPM will also shut the engine off when engine speed reaches 2250 rpm for Gen Set and 4000 rpm for all other applications Key must be recycled to restart NOTE Where a safety switch is fitted the override button must be depressed while the engine is being cranked STOPPING THE ENGINE Normal Conditions Following normal operating conditions lower the engine speed to idle disengage the clutch and then turn the ignition switch to the OFF position If the engine has been running under high power let it run at fast idle speed a few minutes to cool the engine down Abnormal Conditions
8. distributors for a distributor in your area You can obtain a standard parts listing describing the parts It remains a distributor function to identify the part number The key to identifying the engine is the identification decal mounted on the engine rocker cover That decal provides not only the engine serial number but also the exact model or type configuration code and customer name The combination of that data permits you to isolate the precise engine build level and customer so you can determine the correct replacement parts EDI Engine Identification Decal An identification Decal is affixed to the valve cover of the engine The decal contains the engine serial number which identities this unit rom all others Use all numbers when seeking information or ordering replacement parts for this engine DISTRIBUTORS INC Model No WSG 1068 For handy reference transfer the data recorded on this decal to a safe place Your Warranty Rights and Obligations The California Air Resources Board U S EPA and Engine Distributors Inc are pleased to explain the emission control system warranty on your new 2010 and subsequent model year emission certified engine or brand equipment New off road large spark igntion LSI engines must be designed built and equipped to stringent Federal and State anti smog standards Engine Distributors Inc warrants that the emission control system on your engine for the p
9. illuminate the MIL light NOTE EDI engines are used in many different applications and equipment When performing any system diagnosis be aware of any OEM inputs or equipment monitoring devices that may have an effect on the engine s performance or any of the engine s operating systems Engine Performance No Load SYMPTOM POSSIBLE CAUSE Engine Runs Briefly and Loss of Spark Shuts Down um Frozen Fuel Regulator Dry Fuel Low Fuel Pressure Air Inlet Restriction Wiring Failure IPM Failure Coll Power Loss IPM Ground Loss IPM Power Loss Severe Vacuum Leak Dry Fuel Air Inlet Restriction Air Inlet Leak Dry Fuel Fuel Lock Off Inoperative Dry Fuel Wiring Failure Low Fuel Pressure Ancillary Components Binding Engine Cranks But No Start Engine Runs Poorly High Fuel Pressure Low Fuel Pressure Contaminated Fuel Incorrect Fuel Select Table Selected Wrong IPM installed Actuator Air Blockage TMAP Sensor Leak Fuel Contaminated Noise Suppression Capacitor Failure Improper PCV Routing Valve Timing Low Cylinder Compression Engine Cranks Slowly Excessive Engine Load Hydraulic Pump Failing Binding Ancillary Drive Components Low Battery Voltage Incorrect Battery Specifications incorrect Battery Cable Size Starter Relay Starter Failure Excessive Drain SYMPTOM POSSIBLE CAUSE Engine Does Not Crank Dead Battery Ground Loss Coll Power Loss An
10. is 55 lbf 245 N for the over centre type and 25 Ibf 110 N for the spring loaded type Throttle Control where fitted The throttle control adjusts engine speed Initial engine speed adjustment is obtained by pressing the throttle control release button while pulling the throttle knob out to increase the engine speed or pushing it in to decrease the engine speed A final fine speed adjustment is obtained by turning the throttle control counterclockwise to increase engine speed or clockwise to decrease engine speed INSTRUMENTS Your Ford Powered Equipment will have been fitted with instruments selected by the manufacturer The types of instruments most likely to be encountered are detailed here A typical instrument panel is shown below Ammeter _ Oil Pressure Gauge Qe Combined _ C Tach Hour Meter f Z Temp Gauge Charge Indicator Light Safety Switch Override Button Engine Management System Warning Light Malfunction Indicator Lamp MIL Fuel Select Switch Ignition or isolation Switch Ammeter Where Fitted This instrument registers the charging current which is being passed to the battery from the alternator It also registers a discharge equivalent to the amount of current being used by the electrical equipment when the alternator is not charging Battery Condition Indicator Where Fitted This is sometimes fitted instead of an ammeter and measures the battery voltage
11. lead as this could cause the wire connection inside the boot to become separated 5 Coil Ignition Connector Plug Coll Spark Plug Boot 3 it p Down Bolt B Upper Intake Manifold Sages Front of Engine ue NOTE To remove spark plugs you must first remove coils 1 Disconnect the ignition coil wire connectors 2 Remove the hold down screw then the coil NOTE For fuel rail clearance rotate coils 45 clockwise and lift out 3 Alter loosening each spark plug one or two turns with a proper spark plug spanner clean the area around each spark plug port with compressed air then remove the spark plugs Ae WARNING PROTECTIVE GOGGLES MUST BE WORN TO PROTECT THE EYES WHEN USING COMPRESSED AIR 4 Check the gaps of the new spark plugs with a feeler gauge and where necessary bend the outer ground extension to achieve the specified gap 5 Use a proper spark plug spanner to avoid damaging the insulators screw the new spark plugs into the cylinder head and tighten them to the specified torque value listed under specification of this manual NOTE Do not over tighten spark plugs as the gap may change considerably due to the distortion of the plug outer shell 6 Coat the inside of each spark plug boot with silicone dielectric compound D7AZ 1 9A33 1 A USA or equivalent using a small nscrewdriver blade Firing Order 1 6 5 10 2 7 3 8 4 9 7 Install the plug coils and
12. previously and the alternator is given initial excitation via the battery 4 Start In this position the starter solenoid is energized and the starter motor cranks the engine The switch when released automatically returns to the RUN position Safety Switch where fitted A low oil pressure high water temperature safety switch may be fitted This automatically shuts off the ignition when the oil pressure drops below a pre set value or when the water temperature rises above a pre set value A button on the instrument panel is used to override the safety switch when starting the engine The safety switch override button must be depressed to start the engine NOTE With EDI GCP safety shut down incorporated oil pressure below 6 psi or coolant temperature goes above 250 F will shut down ignition system Corrective action must be taken and key recycled to restart Power Take off where fitted The power take off control handle allows engagement and disengagement of the power take off clutch Moving the lever towards the engine engages the clutch and moving the lever away from the engine disengages the clutch When moving the handle to engage the clutch and pick up the load do so in a smooth manner Moving the clutch handle too slowly will cause slippage and wear while moving it too fast will cause quick engagement and possible damage to the power take off engine or driven equipment normal force required to engage the clutch
13. the radiator expansion degas tank filer cap then open the radiator drain cock where fitted or detach the bottom radiator hose 4 Flush the system with water using a hose until clean water emerges and allow all water to drain Close the drain cock or replace the bottom radiator hose Recover all old antifreeze and dispose of properly Contact your local municipal government for the proper disposal 5 Fill the system with the correct coolant mixture via the expansion degas tank filler neck Fill the system slowly to avoid air locks up to the maximum mark on the degas tank 6 Run engine and check hose connections for leaks Check and if necessary top up the coolant in the radiator or degas tank Engine Lubrication System lubrication system should be maintained Dipstick regularly Refer to RECOMMENDED x MAINTENANCE SCHEDULES on page 20 with the correct grade of lubricant as specified the maintenance summary Refer to Recommended Lubricants on page 21 The system is of the force feed type the lubricating being circulated to the engine bearings under pressure by an oil pump driven from the camshaft drive chain belt The dipstick provides some guide to the condition of the oil An additive type of oil keeps soot in suspension and even a small amount of soot causes the to darken rapidly However if the dipstick is found to be heavily coated with sludge then obviously the oil should
14. 1 251 626 2744 ALASKA Power 6051 5 194th Street 1 253 872 7011 Systems Kent WA 98032 1 800 247 5899 1 253 872 6947 ARIZONA Power 8360 E Via de Ventura Blvd 1 480 905 5585 Sysiems Suite L 200 1 503 224 3907 Scottsdale AZ 85258 ARKANSAS Kansas City Power 80 South James 1 913 321 7040 Products Inc City KS 66118 1 800 486 5277 Northern 1 813 321 7341 Extreme Lightboum 13649 Beta Road 1 972 233 5151 Southern EquipmentCo Dallas TX 75244 1 972 661 0738 Territory CALIFORNIA Powertech 2933 E Hamilton Avenue 1 559 264 1776 Engines Inc Fresno CA 93721 1 800 891 1776 Main Office 1 559 264 2933 Powertech 2003 Leghom Street 1 650 968 2434 Engines Inc Mountainview CA 94043 1 650 969 1267 Powertech 1410 South Acacia Avenue 1 714 635 1774 Engines Inc Suite B 1 800 784 1776 Fullerton CA 92831 1 714 635 1771 COLORADO Industrial Power 3233 Oakland Street 1 303 360 7110 Systems Inc Aurora CO 80010 1 800 678 3673 Engine Division 1 303 360 7513 CONNECTICUT Engine 200 University Court 1 856 228 7298 Distributors Inc Blackwood NJ 08012 1 800 220 2700 1 856 228 5657 Parts 1 856 228 5531 Sales DELAWARE Engine 400 University Court 1 856 228 7298 Distributors Inc Blackwood NJ 08012 1 800 220 2700 1 856 228 5657 Parts 1 856 228 5531 Sales North America United States Continued DISTRIETGF Engin
15. 121 1 800 284 5247 17651 452 8182 Sales 17651 452 8047 Parts MISSISSIPPI Kansas City Power 80 South James 191 Norther Products Inc Kansas City KS 66118 1 800 486 5277 191232127341 Lightbourn 8272 EI Rio Suite 110 4 718 741 2008 foem EquipmentCo Houston TX 77054 17137417909 MISSOURI Kansas City Power 80 South James 1 913 321 7040 Products Inc Kansas City KS 66118 1 800 486 5277 191223217341 MONTANA industrial Power 3233 Oakland Street 4 303 360 7110 Eastern Systems Aurora CO 20010 1 800 678 3673 Central Engine Division 4 803 360 7515 Power 4498 Market Street 1 208 342 6541 Systems Boise ID 83705 1 800 354 6767 1 208 345 4308 NEBRASKA Anderson 5552 Center Street 1 402 558 8700 industrial Engines Omaha 68106 1 800 747 1438 1 402 558 8249 NEVADA Powertech 2933 E Hamilton Avenue 1 559 264 1776 Engines Inc Fresno 93721 12002511776 1 559 264 2933 NEW HAMPSHIRE Engine 400 University Court 1 856 228 7298 Distnbutors Ine Blackwood NU 08012 1 8007220 2700 1 856 228 5657 Parts 1 856 228 5551 Sales NEW JERSEY Engine Distributors Inc 200 University Court Blackwood NJ 08012 1 856 228 7298 20 2700 228 5657 Parts 1 856 228 5531 Sales NEW MEXICO EC Power 8360 E Via de Ventura Bivd 1 480 905 5585 Southern Systems Suite 1200 1 503 224 3907 Scottsdale AZ 85258 North Industrial P
16. 15 Liter CID 90215 mm Bore mm inch 105 8 mm Stroke mm inch 10 Number of cylinders FUEL SYSTEM LPG Liquefied Petroleum Gas Type Fumigation Fuel Specification EN589 European HD 5 USA NG Natural Gas Type Fumigation Fuel Specification 38 7 UK 39 0 MJ m USA LUBRICATION SYSTEM Max Pressure Hot 2500 rpm 275 79 413 69 kPa 40 60 psi Oil Type Super Premium SAESW20 WSS M2C153 G Service Oil fil capacity including filter 6 0 qt 5 681 5 5 qt Pan 0 5 qt fiter Oil fiter Ford Service Part Number F1AZ 6731 BD Motorcraft FL820 S COOLING SYSTEM Thermostat Wax element Commences opening 85 C Fully 99 Coolant 50 Motorcraft Super Plus 2000 plus 50 clear water Ford Specification WSS MS7B44 D ESE M97B44 A DRIVE BELT Generator Belt Length Tension 6 Groove 1055mm 5mm in length ELECTRICAL SYSTEM Polarity Negative to earth ground Generator Drive Belt Tension 8K Poly Belt Tension is within specification if the tensioner is within the indicator markings Generator Output 100 Amp 3400 RPM IGNITION Spark Plug Type Dedicated LPG amp NG Motorcraft AGSF 22F M1 Gap 1 12mm 044 in Firing Order TIGHTENING TORQUES ITEM Nm FT LB LB IN Oil Pan Drain Plug 20 34 15 25 98 143
17. IONS Recommended Lubricants CAUTION Do not use supplemental oil additives or other engine treatments They are unnecessary and could under certain conditions lead to engine damage which is not covered by Ford warranty Lubricating oil cleanliness is vital for the successful operation of your engine The oil should be stored under the cleanest possible conditions When changing or topping up engine oil use only clean receptacles Do not allow the oil to come into contact with rubber hoses on the engine 45 9907 407 T sewo gt T sewo gt e swo e SAE 10W30 9 1040 e CAUTION Use Ford Motorcraft Formula E SAE 5W 20 engine oil or equivalent that meets Ford Specification ESEM2C153 C API Classification SJ If SJ oils are not available SH oils are acceptable Use only engine oil displaying the American Petroleum Institute Certification Mark on the front of the container or API specification SH or SJ NOTE Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current API classification should be used API classifications are broken into two categories gasoline and diesel engines API s classification is designated by a two letter system The first letter the prefix designates gasoline or diesel An
18. N Power 1805 NW 21st Avenue 1 503 224 3623 Systems Portland OR 97210 1 800 452 1511 1 503 224 3907 PENNSYLVANIA Engine 400 University Court Eastern Distributors Blackwood NJ 08012 26 5657 Parts 228 5631 Sales Westem itt Auto Electric 1241 Freedom Road 1 724 776 8200 Co Cranberry Twp PA 16066 06 1 800 367 3463 Industrial Engine 1 724 778 8206 Division RHODE ISLAND Engine Distributors Inc 400 University Court Blackwood NJ 08012 1 856 228 7298 1 800 220 2700 1 856 228 5657 Parts 1 856 228 5531 Sales SOUTH Engine 303 Interstate Drive 13364346616 CAROLINA Distributors Inc lArchdale NC 27263 1 800 220 7080 1 336 434 6612 SOUTH DAKOTA Northem Power 2859 Lexington Avenue S 1 651 452 8900 Products inc MN 55121 1 800 284 6247 1 651 452 9182 Sales 1 851452 9047 TENNESSEE M amp iEngne 30762 Highway 181 1 251 626 8080 Central Company Inc Daphne AL 36525 1 800 633 1834 Eastern 12518262744 Western Kansas City Power 80 South James 1 913 321 7040 Products Inc Kansas City KS 66118 1 800 486 5277 128133217341 TEXAS Lightbourn 13649 Beta Rd 4 972 233 5151 Equipment _ Dallas TX 75244 128725610738 Lightbourn 8272 EI Rio Suite 110 11137412003 Equipment Houston TX 77054 1 713 741 1808 UTAH Industrial Power 2492 W Custer Road 1 801 908 8099 No
19. RS INC Engine Distributors Inc 400 University Court Blackwood NJ 08012 1 856 228 7298 1 800 220 2700 1 856 228 5657 fax parts 1 856 228 5531 fax sales
20. am of water in the opposite direction to normal airflow Check all hoses and connections for leaks If any of the hoses are cracked frayed or feel spongy they should be replaced CAUTION Never use a cold coolant mixture to top up the radiator or degas tank of a hot engine if the coolant level is very low this could cause serious engine damage The radiator or degas tank is equipped with a pressure cap It is dangerous to remove this when the system is very hot AN WARNING NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO AT LEAST 40 C 110 1 Wrap a thick cloth around the pressure relief cap and turn it slowly one half turn counterclockwise Stepping back while the pressure is released from the cooling system 2 When you are sure all the pressure has been released still with a cloth turn counterclockwise and remove the pressure relief cap In territories where freezing conditions may occur the coolant should consist of a mixture of 50 plain water and 50 Motorcraft Super Plus 2000 coolant This antifreeze contains additional corrosion inhibitors designed to provide lasting protection for the engine Only this antifreeze or proprietary antifr
21. and oil filed to their recommended levels FUEL RECOMMENDATION This engine is designed to operate on dry fuel such as LPG Grade HDS or NG 1050 BTU f 3 CAUTION Use of fuels rated lower than the grades specified above may cause persistent heavy spark knock which can lead to engine damage If your engine knocks heavily or if you hear continuous spark knock while maintaining constant operating speeds consult your distributor or another qualified technician LUBRICATION AND MAINTENANCE The importance of correct lubrication periodic inspection and adjustment cannot be over emphasized It will determine to a very large extent the service the engine will give Detailed instructions regarding this maintenance are given in the following pages Your Authorized EDI Distributor listed in the back section of this manual will be pleased to carry out this regular maintenance for you The various maintenance operations are listed Refer to RECOMMENDED MAINTENANCE SCHEDULES on page 20 When carrying out any of the following maintenance operations any fault or malfunction should be reported immediately to the supervisor or person responsible for engine overhaul or repair following Maintenance Schedules give the maximum recommended service periods Since operating conditions can vary it may be advisable to carry out some operations for example changing the engine oil at an interim period Your operating experience is the best guid
22. be changed Electrical System ANEGATIVE EARTH NEGATIVE GROUND SYSTEM IS USED GCP Power Distribution Box Starter pid empty AL 2 28 m g2 l z i2 Fu Amps Circuits protected 70 Bariery Volgo to EPR 2 5 Ignion Votage to GGP and Relays 3 Battery Vatage to GCP 4 Fuel pump 5 E Battery Vatago out of Power Relay s Alerator Generator This is mounted on a bracket at the front of the engine and is driven from the crankshaft by serpentine belt The charging rate is adjusted automatically by the built in regulator to provide sufficient electric current to keep the battery fully charged under normal operating conditions The generator requires no lubrication or maintenance WARNING IT IS ESSENTIAL THAT THE WIRING CONNECTIONS TO THE GENERATOR ARE NOT REMOVED WHILE THE ENGINE IS RUNNING AS THIS WILL RESULT IN DAMAGE TO THE REGULATOR OR PERSONAL INJURY Storage Storage One Month While the engine is running treat upper cylinders by spraying engine fogging agent from your local aftermarket supplier into the air intake for about two minutes Open throttle for short burst of speed shut off engine and allow it to come to a stop while continuing to spray into air intake Leave spark plugs in holes or seal spark plug holes with suita
23. ble threaded metal plugs and cover all openings into engine with dust proof caps or shields suitable non hygroscopic material If engine is less transmission spray flywheel and ring gear with mixture of one part recommended engine oil and one part Stoddard Solvent or equivalent Check coolant protection Store indoors in dry area Storage Indefinite Period Drain crankcase completely and refill with recommended engine oil SAE 10 or equivalent Run engine and treat upper cylinders by spraying fogging agent into the air intake for about two minutes Open throttle for short burst of speed shut off engine and allow it to come to a stop while continuing to spray into air intake Check coolant protection Disconnect and remove battery Clean exterior surface of engine Leave spark plugs in holes or seal spark plug holes with suitable threaded metal plugs Seal all openings in engine and accessories with non hygroscopic material Mask off all areas to be used for electrical contacts Make sure all surfaces are dry then spray all taped openings all engine accessories including ignition wiring and all exterior surfaces of engine with Insulation Compound 1 engines are equipped with automotive type clutch block clutch in slightly disengaged position so that lining and pressure plates are not in contact ENGINE SYSTEM CHECK GCP System Check NOTE Most items listed in the possible cause column may not set a diagnostic fault indicator or
24. cillary Components Binding or Seized Shutdown Oil Level Safety Starter Lockout Relay Failure Ignition Switch Failure Bad Starter Crank Control Wire Failure Loose Connection or Corrosion Engine Performance While Under Load SYMPTOM POSSIBLE CAUSE Engine Stalls Quits Faulty OEM Drivers Safety Shut off Seat Switch Low Battery Voltage Low Fuel Pressure Safety Shutdowns Bad TMAP Sensor Air Restriction Coll Failure Fuel Mixer Binding Dry Fuel Runs Rough Ground Loss Misrouted Spark Plug Wires Fuel System Failure Vacuum Leak Wiring Failure Coil Power Loss Low Fuel Pressure Spark Plugs Fouled Incorrect Valve Timing Misses Fuel System Failure Misrouted Spark Plug Wires Spark Plug Gap Too High Spark Plugs Fouled Cracked Spark Plug Insulator Coil Power Loss Incorrect Valve Timing Compression Loss Hesitation Stumble Low Fuel Pressure Spark Plugs Fouled Sensor Vacuum Signal Loss Surge Low Fuel Pressure Sensor Failure Application or Ancillary System Momentarily Binding During Load or Unload SYMPTOM POSSIBLE CAUSE Backfires Faulty OEM Drivers Safety Shut off Seat Switch Fouled Spark Plugs Spark Plug Wire Broke IPM Momentary Ground Loss Excess Lean Condition Coil Failure Fuel Lock Off Leaking Dry Fuel Intake Manifold Leak Bad Intake Valve Lack of Power Ancillary Components Binding Intak
25. e 400 University Court 1 856 228 7298 COLUMBIA Distributors Blackwood Nv 08012 15902202700 1 856 228 5657 1 856 228 5531 Sales FLORIDA Engine 259 Ells Ra 7 886 228 7208 Distributors Ine Jacksonville FL 32254 12902202700 1 856 228 5657 1 856 228 5531 Sales GEORGIA Engine 303 Interstate Drive 1 336 454 6016 Distributors inc Archdale NC 27263 18002207080 E Centrai 1 336 434 6612 Southeastem Engine 259 Ra So 1 856 228 7208 anes ime Jaeksonvile FL 32254 15902202100 1 856 228 5657 Parts 1 856 228 5531 Sales Hawan Powertech 2933 Hamilton Avenue 1 559 264 1778 Engines Inc Fresno 93721 18002011776 Main 1 550 264 2933 IDAHO Power 4499 Market Street 1 208 342 6541 Sysiems Boise D 83705 3 800 354 6707 12032454505 ILLINOIS Engine Power inc 1830 Executive Drive 1 262 567 8575 central Oconomowoe WI 1 800 242 2289 C Nonh Centrai 53008 1 282 567 2558 C Northeastern Southern Kansas City Power 50 South James 1 913 321 7040 Products Inc Kansas City KS 66118 18002865277 819221751 Anderson 5532 Center Street 1 402 558 8700 Northwestern Engines Omaha NE 68109 18097471458 1 402 568 8249 INDIANA Engine Power inc 1850 Executive Drive 4 262 567 8575 JOconomewoe WI 53065 1 800 242 2289 1 252 567 2556 IOWA Anderson 5532 Center Street 1 402 558 6709 industrial Engines Omana NE 68106 1 800 747 1438 12025504245
26. e Air Restriction Crossed Spark Plug Wires Spark Plugs Fouled Fuel System Failure Low Fuel Pressure Low Cylinder Compression Spark Knock Poor Quality or Contaminated Fuel Carbon Build up Wrong Spark Plugs Too High Heat Range Fuel Delivery System PCV System Fuel Selection Timing Cylinder Hot Spots Engine Concerns SYMPTOM POSSIBLE CAUSE Oil System Concerns High Oil Consumption Positive Crankcase Ventilation PCV System Oil Viscosity External Leaks Improper Oil Dipstick Valve Seals Cylinder Wall Taper Excessive Wom Piston Rings Cooling System Concerns Trapped Air Worn Drive Belt Wom Water Pump Stuck Thermostat Plugged Radiator Internal amp External Dry Fuel System Running Rich Exhaust System Concerns visible smoke Black Smoke Blue Smoke Ignition System Fuel Delivery System Sticking Fuel injector High Fuel Pressure PCV System Wom Piston Rings Wom Valve Guides SYMPTOM POSSIBLE CAUSE Fuel System Concerns Leaky Lines Contaminated Fuel Excessive Alcohol in Fuel Incorrect Octane Rating Engine Noise Low Oil Pressure Oil Filter Restriction SPECIFICATIONS GENERAL SPECIFICATIONS V 10 4 stroke spark ignition 90 Overhead Valve OHV chain driven camshaft operating the valves via roller cam followers and hydraulic lash adjusters Compression Ratio Engine Type 68 4
27. e for determining this time RECOMMENDED MAINTENANCE Hours Running Or Wies Diven EE ICI ILE aaa y V TREN a e necessary wth coret mitre Check visualy for of fuel er coolant Teak PTO release bearing Theckal nsmuments contig and wanting Talis Check hot ane cote aeo hunch Check coolant of usi exhaust ane Vacuum hoses ipee aka came fetenoration ard comer routing Check all Voti electra yung lor secur cored ik and se tag at Tosca PTO bearing Check condition and adjust tension of dive Satie Check fal Wer element and renew a5 par plugs Clean adjust or repiace TCheck si Aust PTO release amp shaft bears Renew PCV valve lean PCY and Wings deteriorated It is recommended that this operation is carried by an authorized Ford Distributor Depending upon the quality of the fuel used it may be necessary to renew the filter element more frequently PCV Valve inspection and Spark Plug replacement are recommended at the interval s described Spark plug cleaningireplacement at these intervals will ensure maximum engine performance fuel economy and emissions Failure to complete recommended maintenance does disqualify your engine from any emissions related warranty coverage s RECOMMENDED MAINTENANCE OPERAT
28. eeze meeting Ford specification WSSM97B44 D or Ford specification ESE M97B44 A should be used when topping up or re filing the cooling system Motorcraft Super Plus 2000 coolant has long life characteristics and if the concentration is kept to a maximum of 50 it will provide adequate frost protection and inhibiting for the of the engine NOTE If a major component of the cooling system is renewed such as the radiator water pump etc the system should be flushed and re filed with 50 solution of Motorcraft Super Plus 2000 coolant and clean water In territories where the ambient temperature is such that no protection against freezing is required itis recommended that a 25 concentration of Motorcraft Super Plus 2000 coolant is used This will protect water pumps core plugs thermostat housings and radiators against corrosion for the of the engine and raise boiling point when used at this concentration See previous Note on renewing cooling system components antifreeze concentration in cooling system can be determined by using a suitable hydrometer lt Areading of 1080 represents a 50 antifreeze concentration lt Areading of 1040 represents a 25 antifreeze concentration lt Areading of 1000 represents plain water A WARNING ANTIFREEZE CONTAINS MONO ETHYLENE GLYCOL AND OTHER CONSTITUENTS WHICH ARE TOXIC IF TAKEN INTERNALLY AND CAN BE ABSORBED IN TOXIC AMOUNTS ON REPEATED OR PROLONGED SKIN CONTACT PERSONS
29. eriods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor regulator fuet injection system ignition system engine computer unit ECM catalytic converter and air induction system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable condition exists Engine Distributors Inc will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage Standard warranty for any non emissions related part is two years or 2000 hours This includes the base engine and ancillary parts such as the starter and alternator The new 2010 model year off road large spark ignition engines are warranted for three years or 2500 hours of service whichever occurs first from the date the equipment is delivered to the first retail purchaser when the equipment is first placed in service If any emission related part on the engine is defective the part will be repaired or replaced by an authorized Engine Distributors Inc dealer This is your General Emissions Warranty For five years or 3500 hours of service whichever occurs first if any emission related part specially noted with coverage for five years or 3500 hours is defective the part will be repaired or replaced by and authorized Engine Distributors Inc dealer This
30. he specified hours of operation have been reached We consider it to be in your interests to enlist the aid of an authorized Ford Power Products Distributor not only when repairs are required but also for regular maintenance Distributors are listed at the back of this handbook Regular maintenance wil result in minimal operating costs Engines manufactured by Ford Motor Company are available through Ford Power Products Distributors When in need of parts or service contact your local Authorized Distributor In overseas territories in the event of difficulties communicate directly with the supervising Ford affliated Company in your area whose address appears at the end of this book Where the terms Right or Left occur in this publication they refer to the respective sides of the engine when viewed from the rear or flywheel end Pistons and valves are numbered from the front or timing cover end of the engine commencing at No 1 You may find that your engine assembly includes optional equipment not specifically covered in the following text Nevertheless the maintenance procedures outlined in this book stil apply to your engine ENGINE IDENTIFICATION Because Engine Distributors has such a wide range of industrial gasoline and diesel engines manufactured both in the U S and overseas itis important that you have as complete identification of the engine as possible in order to provide the correct replacement parts Review the list of
31. ions to prevent engine damage 1 Release the air cleaner lid retaining hardware 2 Lift the air cleaner lid clear of the air cleaner body then remove the air cleaner element and discard it 3 Wipe the inside of the air cleaner body and lid clean using a lint free rag 4 Insert the new element ensuring that it fits properly and install air cleaner lid Renew PCV Valve 1 Detach the hose from the top of the PCV valve located at the top rear of right valve cover and from the intake manifold 2 Withdraw the PCV valve from the valve cover grommet 3 Discard the PCV valve and the O ring 4 Thoroughly clean the inside and outside of the hose 5 Insert the new PCV valve complete with a new O ring 6 Re connect the hose to the PCV valve and to the intake manifold Connector amp Hose GENERAL MAINTENANCE INFORMATION The following section outlines some aspects of general maintenance which will be of value to the operator Cooling System To obtain maximum engine service life its operating temperature must be maintained by an efficient cooling system CAUTION Under no circumstances should the engine be started without liquid in the cooling system This may cause permanent damage to the engine Inspect the exterior of the radiator for obstructions remove all bugs dirt or foreign material with a soft brush or cloth Use care to avoid damaging the fins If available use low pressure compressed air or a stre
32. iques tools and parts for servicing equipment as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that neither personal safety nor equipment integrity are compromised by the choice of methods tools or parts Notes Cautions and Warnings As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES gives you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the equipment WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on the equipment GENERAL WARNINGS Always wear safely glasses for eye protection Use safety stands whenever a procedure requires you to be under the equipment Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Set the parking brake if equipped when working on the equipment If you have automatic transmission set it in PARK REVERSE engine off or NEUTRAL engine on unless instructed otherwise for a specific operation Place wood blocks 4
33. is your High Priced Parts Emission Warranty As the off road LSI engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Engine Distributors Inc recommends that you retain all records covering maintenance on your off road engine but Engine Distributors Inc cannot deny warranty solely forthe lack Cf receipts or for your failure to ensure the performance of all scheduled maintenance Responsi As the off road large spark ignition engine owner you should however be aware that Engine Distributors Inc may deny you warranty coverage if your off road large spark ignition engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications Depending on the model of engine you have purchased your engine may be designed to operate on LPG Gasoline and or Natural Gas fuels Use of any other fuel may result your engine no longer operating in compliance with applicable emissions requirements You are responsible for initiating the warranty process Engine Distributors suggests that you present your off road large spark ignition engine to an Engine Distributors Inc dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible It you have any questions regarding your warranty rights and responsibilities you should contact Engine Distributors Inc at 800 220 2700 What is C
34. lectronic Control Units Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Vacuum Control Diaphragms Control Cables Control Linkages Purge Valves Vapor Hoses Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector High Priced Emissions Warranty Parts List 5 years or 3 500 hours whichever comes first Press Regulator Catalytic Mutfier Engine Control Module ECM Intake Manifold Exhaust Manifold Hamess Throttle SERVICE LITERATURE service manual can be purchased from your EDI distributor This publication will provide the necessary servicing and overhaul information for your Ford Power Products engine WSG1068 SERVICE MANUAL EDI WSG1068 PARTS LIST EDI BEFORE OPERATING THE ENGINE 1 Before operating a new engine it should be thoroughly inspected to ensure that during transit and installation it has not suffered damage likely to affect its subsequent operation Controls and instruments should be studied carefully in order that their functions are thoroughly understood 2 Check that the radiator where applicable is full and top off as necessary Refer to Cooling System on page 28 for recommended coolant mixtures 3 In the case of marine industrial engines ensure that there is coolant in the degas expansion tank where applicable CAUTION Under no circums
35. ngine can result in a cracked block or cylinder head 1 Allow the engine to down to 40 C 110 F 2 Turn the radiator expansion degas tank filler cap through 90 in a counterclockwise direction Pause to allow any pressure to drop then turn cap fully counterclockwise and remove it 3 The quantity of coolant in the expansion degas tank is a direct indication of the coolant level in the complete system The acceptable level of coolant in the expansion degas tank is shown by the level indicators moulded into the tank wall Top up as necessary with a mixture of plain water and antifreeze Refer to Cooling System on page 28 for information on mixing antifreeze solutions NOTE It is essential that only the correct type of antifreeze is used Refer to Cooling System on page 28 4 Replace the filter cap and turn down tightly Renew Air Cleaner Element Your air cleaner filters air entering the engine induction system and acts as a silencer and a flame arrester Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe damage to the cylinder walls and piston rings Damage to the cylinder walls and piston rings will cause high consumption and short engine A restricted or dirty air cleaner will also cause a rich fuel mixture Thus itis extremely important that the air cleaner be serviced at recommended intervals CAUTION Service the air cleaner more frequently under severe dust condit
36. o vital engine parts This filter is especially designed for use in engines built by Ford to give successful operation with the recommended filter change intervals Contact your nearest EDI Distributor Dealer listed in the back section to obtain the correct filter Before commencing place a drain pan beneath the filer to catch any spilt 1 Using a suitable strap wrench unscrew the oil filter canister 2 Thoroughly clean oil filter housing face 3 Partly pre fil the new filler with clean engine of the correct type and grade Apply a thin film of clean engine to the filter sealing ring 4 Screw on new fter canister until sealing ring abuts the filter head and tighten a further 1 2 turn Do NOT use a strap wrench or similar tool to tighten the filter canister 5 Run engine and check for any leaks from filler 6 Stop engine allow to settle and top up as necessary Ignition System The 6 8L engine is equipped with a coi on plug ignition system Rather than a remotely mounted coil with secondary ignition wires this system has a separate ignition coil mounted on each spark plug Operation of the coils is controlled by the engine computer module GCP which computes ignition timing based on inputs from engine sensors Renew Spark Plugs WARNING THE IGNITION SYSTEM COMMONLY CARRIES VOLTAGES IN EXCESS OF 30 000 VOLTS PLEASE USE CAUTION CAUTION Do not pull directly on the
37. overed Below is a list of the systems that affect emissions on your engine Emission control components these systems are covered by the emissions warranties as applicable If failure of one of the components listed below results in failure of another part both will be covered by this warranty For detailed information concerning specific components covered by these emission control systems warranties ask your dealer neral Emissions Warranty Parts List 3 years or 2 500 hours whichever comes first Fuel Metering System Fuel injection system ratio feedback and control system Carburetor system internal parts and or pressure regulator or fuel mixer or injection system Air Induction System Air intake system Catalyst or Thermal Reactor System Positive Grankcase Ventilation PCV System PCV Vale 5 Oil Filler Cap Ignition Control System 2 Ignition module s Spark Plugs Miscellaneous items Used in Above Systems Vacuum temperature and time sensitive valves and switches Sensors used for electronic controls Hoses belts connectors assemblies clamps fittings tubing sealing gaskets or devices and mounting hardware c Pulleys belts and idlers Emission Related Components Only Covered if Your Engine was Sold in California Air Induction System Fuel System Ignition System Exhaust Gas Recirculation Systems fter Treatment Devices Crankcase Ventilation Valves Sensors E
38. ower 3233 Oakland Street 1 303 360 7110 Neer Systems Inc Aurora CO 80010 1 800 678 3673 Engine Division 1 303 360 7518 NEW YORK Engine 200 University Court 1 856 228 7208 New York City Distributors Inc Blackwood NJ 08012 0 Nassau Co Suffolk Upstate Pitt Auto Electric 1241 Freedom Road 4 78 8200 2 Hudson Valley Industrial Engine Division Cranberry Twp PA 16066 05 0 367 3463 4 77 8 8206 NORTH CAROLINA Engine Distributors Inc 303 Interstate Drive Archdale NC 27263 1 336 434 6616 1 800 220 7080 1 336 434 6612 NORTH DAKOTA Northern Power Products Ine 2859 Lexington Avenue 6 Eagan MN 55121 1 651 452 8900 1 800 284 6247 1 651 452 9182 Sales 1 651 452 9047 Parts Graham Ford Inc 707 W Broad Street 1 614 464 6006 Central Columbus OH 43216 0 837 7070 1614 464 6013 North Coast Ford 11885 Bellaire Road 1 216 251 5800 Northern Industrial inc Cleveland OH 44135 1 800 423 1316 1 216 251 8675 Pitt Auto Electric 1241 Freedom Road 1 724 778 8200 ORES Co Cranberry Twp 16066 05 1 800 367 3463 Industrial Engine 1 724 778 8206 Division OKLAHOMA Kansas City Power 7714 Melrose Lane 1 405 491 9491 Except Panhandle Products Oklahoma City OK 73127 1 800 654 3673 1 408 491 8495 Panhandle _ Lightbourn 13649 Beta Road Dallas 1 972 233 5151 Equipment Co T 75244 1 972 661 0738 OREGO
39. plug from the pan and drain the oil into the draining pan NOTE Modern high performance oils have a cleaning action on the engine which may turn the oil dark but does not necessarily indicate inadequate oil changes 5 Replace and tighten the drain plug then fill the engine via the filler neck in the rocker cover with the correct quantity of oil Refer to SPECIFICATIONS on page 38 6 Replace the filer cap and run the engine for no more than 30 seconds 7 Check the oil level as described in the following section Check Engine Oil Level 1 Make sure the equipment is standing level and that the engine is stopped 2 Pull out the dipstick and wipe it with a clean rag 3 Insert the dipstick fully and again remove it At no time should the level of the oil fall below the lower mark on the dipstick 4 If necessary top up to the dipstick higher mark with an approved type and grade of 5 Replace the dipstick ensuring that it is fully inserted into its tube to maintain a sealed crankcase condition Renew Engine Oil Filter CAUTION The original filter is not available for service Use the recommended Motorcraft FL 8205 Your engine is equipped with a Motorcraft filter A filter of this quality should be used throughout the life of the engine It is designed to protect your engine by filtering harmful abrasive and sludgy particles without clogging up or blocking the flow of the oil t
40. rthern Systems inc Sait Lake City UT 84104 17800 678 3673 Engine Division 1 303 360 7519 Southern Power 3683 West 2270 South 1 801 886 1424 Systems Suite A Salt Lake City 1 800 462 3370 UT 84120 1 801 586 1464 VERMONT Engine 400 University Court 1 856 228 7298 Distributors Inc Blackwood NJ 08012 17800 220 2700 1856228 5657 Parts 1 856228 553 Sales VIRGINIA Engine 400 University Court 1 856 228 7298 Central Distributors Inc Blackwood NJ 08012 800 220 2700 Eastern 1 856 228 5657 Parts 1656 28 53 1 Sales Southwestern Pitt Auto Electric 1241 Freedom Road 1 724 778 6200 Cranberry Twp PA 16066 06 1 800 967 3463 Industrial Engine 1 724 778 8206 Division WASHINGTON E C Power 6051 5 194th Street 1 253 872 7014 Systems Kent WA 98032 Us 1 800 247 5899 1 253 872 6947 WEST VIRGINIA Pitt Auto Electric Industrial Engine Division 1241 Freedom Road Cranberry Twp PA 16066 us WISCONSIN Engine Power Inc 1830 Executive Drive 1 262 567 8575 Eastern Oconomowoc Wi 53066 1 800 242 2289 Central 1 262 567 2556 Northem Power 2859 Lexington Avenue S 1 651 452 8900 Products nc MN 55121 1 800 284 6247 Northwestern dE di 1 651 452 WYOMING Industrial Power 3253 Oakland Street 1 303 360 7110 Systems Inc Aurora CO 80010 800 878 2673 Engine Division 1 303 360 7519 ENGINE DISTRIBUTO
41. sed on some installations is actuated automatically when the coolant reaches a specified temperature For this reason care should be taken to ensure that the ignitionvisolating switch is OFF when working in the Vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate 3 Avoid contact with exhaust pipes exhaust manifolds and silencers when an engine is or has recently been running these can be very hot and can cause severe burns 4 Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes In the event of accidentally swallowing gasoline petrol diesel fuel antifreeze battery acid etc DO NOT ENCOURAGE VOMITING AND OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Wear protective goggles when handling liquids which are harmful to the eyes these include ammonia and battery acid If any of these substances are splashed in the eyes wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Important Safety Notice Appropriate service methods and proper repair procedures are essential for the safe reliable operation of all industrial engines as well as the personal safety of the individual doing the work This operator handbook provides general directions for accomplishing service and repair work with tested effective techniques Following them will help assure reliability There are numerous variations in procedures techn
42. shire 5053 406 England Power Torque Herald Way Binley Coventry 44 2476 635 757 Engineering Wanvickshie CV32RA 442476426378 nglan ITALY Compagnia Via Magellano 4 20090 39 02 450 581 Technica Motori Boscone Milano 39 02 450 562 60 62 SpA SWITZERLAND Mineli AG Mattenstr 3 8330 21 1 950 1720 Pf effikon ZH Switzerland 41 1 950 1132 New Zealand NEW ZEALAND Lees Industries 345 Gt South Road Group Takenini Papakura Auckland Delta Centre New Zealand North America Canada BRITISH Industrial Engines 1020 Cliveden Ave 1 604 525 8529 COLUMBIA Delta Annacis Island British 1 877 438 6560 Columbia 1 604 525 0974 Canada 585 ONTARIO M K Power 5841 McAdam Road 1 905 890 5323 QUEBEC Products Corp Mississauga Ontario CAN 1 800 263 5011 MONITOBA Canada 142 189 1 905 890 6660 ALBERTA Industrial Engines 14335 12th Avenue 1 780 484 6213 SASKATCHEWAN Lt Edmonton Alberta Canada CAN 1 866 484 6213 791 2R8 1 780 132 0400 NOVASCOTIA Lunenburg 53 Falkland Street PO 1240 1 902 634 8827 NEW Industrial Foundry Lunenburg Nova Scotia 1 902 634 8886 BRUNSWICK Engineering Canada B03 2C0 FOUNDLAND PRINCEEDWARD ISLAND North America United States ALABAMA Mal Engine 30762 State Highway 181 1 251 626 8080 Company Inc Daphne AL 36526 4 800 633 1834
43. tances may the engine be started without liquid in the cooling system 4 Check the engine oil level and top up or fill as necessary Refer to Check Engine Oil Level on page 23 For the correct type and grade of oil Refer to Recommended Lubricants on page 21 5 Ensure that the battery is fully charged and if necessary top up with distilled water NOTE Ensure that ALL wiring ground connections are properly made to a clean point on the chassis frame 6 The engine must be started in accordance with the starling instructions Refer to STARTING THE ENGINE on page 17 OPERATING CONTROLS Ignition or Isolation Switch An ignition or isolation switch is usually fitted which connects the engine starter motor and other electrical equipment to the battery The switch can be moved to any of the four positions shown by rotating the key These positions are on Run Auxiliary Circuits _ 1 Auxiliary Circuits When moved to this position the auxiliary electrical equipment such as radios and heater fans can be operated without also connecting the starting circuit with the battery 2 Off When set to this position the switch disconnects the auxiliary electrical equipment and the starting circuit from the battery The key can be removed from the switch when itis in this position this will help to prevent unauthorized operation of the engine 3 Run This switch position connects the auxiliary circuits as described
44. tem Generator Storage ENGINE SYSTEM CHECK SPECIFICATIONS TIGHTENING TORQUES CONVERSION TABLE FORD POWER PRODUCTS SERVICE 18 18 18 19 19 38 39 40 HEALTH amp SAFETY WARNING THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED Carrying out certain operations and handling some substances can be dangerous or harmful to the operator if the correct safety precautions are not observed Some such precautions are recommended at the appropriate points in this book While itis important that these recommended safety precautions are observed care near machinery is always necessary and no list can be exhaustive ALWAYS BE ON YOUR GUARD General Guidelines The following recommendations are for general guidance 1 Always wear correctly fitting protective clothing which should be laundered regularly Loose or baggy clothing can be extremely dangerous when working on running q engines or machinery Clothing which becomes impregnated with oll or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing 2 So far as practicable work on or close to engines or machinery only when they are stopped If this is not practicable remember to keep tools test equipment and all parts of the body well away from the moving parts of the engine or equipment fans drive belts and pulleys are particularly dangerous The electric cooling fan u
45. the charge indicator light should cease glowing Safety Switch Override Button Where Fitted This must be depressed when starting the engine as the safety switch operates when the oil pressure falls due to the engine stopping Refer to Safety Switch where fitted on page 14 Ignition or Isolation Switch Refer to Ignition or Isolation Switch on page 13 Fuel Select Switch Where Fitted This switch is incorporated for use with dual fuels Switch must point to selection of fuel being used STARTING THE ENGINE WARNING ALL INTERNAL COMBUSTION ENGINES GIVE OFF VARIOUS FUMES AND GASES WHILE RUNNING DO NOT START OR RUN THE ENGINE IN A CLOSED OR POORLY VENTILATED BUILDING WHERE THE EXHAUST GASES CAN ACCUMULATE AVOID BREATHING THESE GASES AS THEY MAY CONTAIN POISONOUS CARBON MONOXIDE WHICH CAN ENDANGER YOUR HEALTH OR LIFE IF INHALED STEADILY FOR EVEN A FEW MINUTES Initial Start up On initial start up follow the daily regular maintenance schedule illustration Refer to RECOMMENDED MAINTENANCE SCHEDULES on page 20 To Start From cold 1 Where possible disconnect the driven equipment eg fully depress the clutch where manual transmission is fitted If your unit is equipped with the engine warning light system always turn the ignition switch to the ON position to make sure that each warning light is operating before starting engine 2 Switch on the ignition and operate the starter motor until the engine fires NOTE
46. thus indicating the state of charge of the battery Tachometer Where Fitted The tachometer indicates the actual engine running speed in crankshaft revolutions per minute Hourmeter Where Fitted This instrument records the number of hours of operation which the engine has completed at the rated rpm Itis frequently combined with the tachometer and is used to determine when an engine service operation is required If no hourmeter is fitted a log should be kept Oil Pressure Gauge Where Fitted The oil pressure gauge registers the lubricating system pressure in bar kgf cm2 or Ibfiin2 and should be frequently observed to ensure that the system is functioning correctly Temperature Gauge Where Fitted The temperature gauge enables a close check to be kept on the coolant temperatures Malfunction Indicator Light Where Fitted Used on all industrial engines This light will iluminate whenever there is an engine malfunction such as low oil pressure high engine temperature fuel injection system fault The engine can be programmed to shut down in the event of a malfunction Charge Indicator Light Where Fitted alternator is fitted to your engine a charge indicator ight will also be fitted The light will glow when the isolating switch is in the RUN position with the engine stationary and will therefore serve as a reminder either to turn the isolating switch to the OFF position or to start the engine Once the engine has started
47. tighten hold down bolt to 5 7 Nm 44 62 in tb NOTE Coils are interchangeable 8 Reconnect ignition coil wire connectors Electronic Actuator In the event that your engine is equipped with an electronic actuator any necessary adjustment should be made by your Power Products Distributor listed at the back of this manual The adjusting procedure requires the use of tools which are not readily available to consumers Check Condition of Ancillary Drive Belts WARNING ENGINE SHOULD BE STOPPED AND ANY REMOTE STARTER DISABLED BEFORE CHECKING BELTS The serpentine ancillary belt used to drive the generator and water pump is tensioned automatically and does not require adjustment The belts should be visually inspected for signs of wear or damage It should be renewed if necessary Refer to Service Manual NOTE May be purchased from your local Ford Power Product Distributor listed on the back of this handbook Check Engine Coolant Level WARNING TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT ENGINE COVER THE RADIATOR CAP WITH A THICK CLOTH AND TURN IT SLOWLY COUNTER CLOCKWISE TO THE FIRST STOP AFTER THE PRESSURE HAS BEEN COMPLETELY RELEASED PRESS DOWNWARD AND FINISH REMOVING CAP FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND OR PERSONAL INJURY CAUTION Do not add coolant to an engine that has become overheated until the engine cools Adding coolant to an extremely hot e
48. ty Statement What Is Covered European Service Identification Plate PARTS AND SERVICE SERVICE LITERATURE WARRANTY REGISTRATION BEFORE OPERATING THE ENGINE OPERATING CONTROLS Ignition or Isolation Switch Safely Switch where fitted Power Take off where fitted Throttle Control where fitted INSTRUMENTS Ammeter Where Fitted Battery Condition Indicator Where Fitted Tachometer Where Fitted Hourmeter Where Fitted Oil Pressure Gauge Where Fitted Temperature Gauge Where Fitted Malfunction Indicator Light Where Fitted Charge Indicator Light Where Fitted Safely Switch Override Button Where Fitted Ignition or Isolation Switch Fuel Select Switch Where Fitted STARTING THE ENGINE Initial Start up To Start From cold To Re start When Warm Donyo o maaa 12 12 12 CONTENTS STOPPING THE ENGINE Normal Conditions Abnormal Conditions RUNNING IN PROCEDURE FUEL RECOMMENDATION LUBRICATION AND MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULES RECOMMENDED MAINTENANCE OPERATIONS Recommended Lubricants Used Engine Oils Change Engine Oil Check Engine Oil Level Renew Engine Oil Filler Ignition System Renew Spark Plugs Electronic Actuator Check Condition of Ancillary Drive Belts Check Engine Coolant Level Renew Air Cleaner Element Renew PCV Valve GENERAL MAINTENANCE INFORMATION Cooling System Draining Flushing and Filling the Cooling System Engine Lubrication System Electrical Sys
49. x 4 or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent equipment movement Operate the engine only in well ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine is running especially the fan belts To prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler Do not smoke while working on the equipment To reduce the risk of injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on the equipment Tie long hair securely behind the head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures even though the ignition is in the OFF position Therefore care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood FORWARD This book contains operating and maintenance instructions for the engine s listed on the title page The life of your engine unit and the delivery of the high performance built into it will depend on the care it receives throughout its It is the operator s responsibility to ensure that the engine is correctly operated and that the maintenance operations outlined in this book are carried out regularly after t
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