PI Operator`s Manual
Contents
1. Ocopyright 2014 Keep detailed maintenance records List the mileage and the date of any service work performed ENGINE OIL To ensure proper engine performance and long life careful attention must be paid to engine oil Follow ing these simple but important steps will help pro tect the vehicle e Always use engine oil approved to the proper specification and of the proper vis cosity grade e Check the engine oil level at every fuel stop and maintain the proper oil level See Checking Engine Oil on page 12 e Change the engine oil at the appropriate maintenance intervals CAUTION Use engine oil that is identified as American Petro leum Institute API SN or most current stand ard Failure to use the recommended oil can result in engine damage and will void the engine warran ty When determining the type of engine oil to use look for e The API starburst symbol Oils that display the starburst symbol must meet the re quirements of ILSAC GF 2 to display the mark Temperature S Viscosity Ex Low Or const Temperature Viscosity Rated as Energy Conserving e SAE5W 30 The recommended oil for the Powertrain Integration engine SAE 5W 30 has the best viscosity grade for the en gine Do not use other viscosity oils such as SAE 10W 30 10W 40 15VV40 or 20W 50 Conven 11290 Rev B tional oil non synthetic is recommended for the first two oil cha2. 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 17 Ocopyright 2014 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 Bracket Air Brake Compressor Pulley Crankshaft Balancer Crankshaft Pulley Dual A C Engine Harness Front Engine Mount Heater Valve Bracket Idler Pulleys Injector Harness Main Accessory Drive Bracket Molded Air Induction Tube Oil Cooler Bypass Adapter Oil Filter Fitting Oil Pan and Drain Plug Rocker Covers Single and Dual A C Mounting Brackets Tensioners Thermostat Housing Thermostats Upper and Lower Intake 11290 Rev B SECTION VI CUSTOMER ASSISTANCE TECHNICAL SERVICE For technical service please contact Powertrain Inte gration at 855 305 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 Ocopyright 2014 18 11290 Rev B G4 CLEANFUEL USA OPERATOR S MANUAL DEDICATED LI
3. WARNING Never place a jack on the fuel storage tank or fuel system components to raise the vehicle Serious damage 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 the fuel supply lines or storage tanks PAINTING THE VEHICLE In the event if the vehicle requires painting this pro cess should not be cured by heating The LPI fuel tank is equipped with a pressure release device The pressure relief valve will open at 312 PSI 2151KPA if heated to approximately 140 F 60 C Note In the event the vehicle requires a paint pro cess that is cured by heating the tank will need to be removed and reinstalled by an OEM authorized service facility 23 Ocopyright 2014 11290 Rev B SECTION III SERVICE AND MAINTENANCE MAINTAINING YOUR VEHICLE WARNING Never try to service the LPI propane fuel system yourself The LPI fuel system operates under high pressure You could be injured and the vital system Your LPI vehicle is designed for routine mainte nance filters fluids etc See the original specifica tions as provided in the engine owner s ma
4. in the OEM operator manual TOWING YOUR VEHICLE WARNING Towing your vehicle with improperly positioned tow straps hooks or chains can damage LPI com ponents such as the propane tank fuel lines or components Serious damage or injury could result Do not use the propane fuel system components as a towing attachment points See the OEM operator manual for information re garding towing the disabled vehicle STORING THE VEHICLE If you plan on storing your vehicle for an extended period of time 60 days or more refer to the vehi cle storage in your OEM operator manual for infor mation on the base vehicle Also 1 Close the manual shut off valves Refer to Page 32 on closing your manual shut off valves 2 If you suspect a leak get your vehicle inspected by an OEM authorized service facility before putting your vehicle in storage 11290 Rev B RETURNING TO SERVICE 1 Open all manual shut off valves 2 Ensure the battery is fully charged 3 After prolonged storage or periods of not running it may be difficult to start the engine as the fuel system will need to be primed It may be neces sary to operate the Wait to Start prime cycle several times Note It is recommended that any stored vehicle be started once a month to keep all fuel system com ponents lubricated Storing a vehicle for long peri ods may require much more work to return to normal running order LIFTING YOUR VEHICLE
5. CUSTOMER ASSISTANCE TECHNICAL SERVICE WARRANTY CLAIMS COMPONENT ORDERS 30 SECTION VII ALPHABETICAL INDEX rennes 31 Ocopyright 2014 11290 Rev B Powertrain Integration 2 OPERATOR S MANUAL 8 0 L V8 ENGINE LPG Ocopyright 2014 11290 Rev B FOREWARD This manual contains the latest information available at the time of publication Powertrain Integration LLC reserves the right to make future changes in the products or information contained in this manual without prior notice Keep this manual with the vehicle If the vehicle is traded or sold give this manual to the future owner WARNINGS CAUTIONS and NOTES This manual contains several different WARNINGS CAUTIONS and NOTES that must be observed to prevent personal injury and or damage to the en gine fuel system or personal property WARNING A warning statement is used when an operating pro cedure practice etc which if not correctly fol owed could result in serious personal injury or loss of life CAUTION A caution statement is used when an operating pro cedure practice etc which if not correctly fol owed could result in personal injury or damage to or destruction of equipment NOTE A note is used when an operating procedure practice etc is essential to highlight IMPORTANT An important statement generally de notes a situation which requires strict adherence to the assembly tightenin
6. a Warranted claim Parts used in any repair s may be new parts or in dustry approved 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 14 Ocopyright 2014 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 responsible for any modified production components or the addition of aftermarket accessories SERVICE SUPPLIES Powertrain Integration will pay for the applicable replacement of the required fluids and filters in the event of an authorized eligible claim Other compo nents items that have normal manufacturer re placement intervals are non eligible for replacement by Powertrain Integration ENGINE REMOVAL AND REINSTALLATION Powertrain Integration pays reasonable labor costs based on the current Powertrain Integration Labor Time Guide for Engine removal and re installation when necessary to repair a valid Warranted author ized claim TOWING On eligible Warranted authorized claims Powertrain Integration will pay reasonable costs for towing a disabled vehicle up to 450 00 if eligible to the nearest authorized repair location for the first year from the date of delivery of the Engine or to the first owner THIS WAR
7. air ventilation 11290 Rev B E 10302012 19 1511201 1 Maintenance Warning Light 8 Headlight High Beam Indicator 14 Check Transmission Indicator 2 LeftTurn Signal Arrow 8 Wait to Start Warning 15 Stop Transmission Indicator 3 Check Engine Indicator 10 Hydraulic Brake System Warning 16 Right Turn Signal Arrow 4 Stop Engine Waming 11 ABS Indicator 17 Fasten Seat Belt Warning 5 Malfunction Indicator Lamp MIL 12 Traction Control Indicator 18 Parking Brake On Indicator 6 Low Air Pressure Warning 13 Shift Inhibit Indicator 19 Cruise Control Indicator 7 Engine Brake Light not used ENGINE WARNING LAMPS WAIT TO START LAMP The WAIT TO START lamp will illuminate for a brief time after the key is turned to the run position This waiting period allows the fuel rails to be purged of vapor and supplied with liquid propane fuel Engine cranking is possible but not recommended while the lamp is on When the lamp turns off and the key is turned to the start position the engine will start If the engine is not started within 15 seconds after the lamp goes out the key should be cycled back to the off position and then again to the run position to repeat the wait to start process CHECK CHECK ENGINE LAMP Steady A steady illumination of the CHECK ENGINE LAMP indicates that there is a fault with some aspect of the engine operating system Some faults may put the engine into a reduced power mode to pr
8. is over tightened To turn valves on turn both the return and supply valve counter clock wise until you reach valve stop N w A u Front of Vehicle Supply Valve Ocopyright 2014 25 11290 Rev B EL P Front of Vehicle gt Side Mounted Tank BETWEEN THE FRAME RAIL MOUNTED TANK FUEL SHUT OFF To shut off the supply of fuel to the engine both the supply and return valves will need 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 3A amp 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 valves on turn both the return and supply valve counter clock wise until you reach valve stop Figure 3A between the Frame Rail Mounted Tank Valve Location Ocopyright 2014 26 11290 Rev B Figure 3B between the Frame Rail Mounted Tank Valve Location Figure 3C Thomas Built SAF T Liner C2 Valve Location 27 Ocopyright 2014 11290 Rev B SECTION V CleanFUEL USA WARRANT
9. party other than Powertrain Integration b Damage to or from a non covered part c Damage or loss caused in whole or in part by misuse abuse negligence theft abnor mal operation vandalism alteration or modification of the Engine improper instal lation lack of maintenance unauthorized repair s or failure to follow instructions supplied with the Engine d Damage s or loss caused by any operation of the Engine with fuels oils or lubricants that are contaminated lacking or under filled or unsuitable for the Engine including a breakdown caused by the failure to re place seals or gaskets in a timely manner e Damage or loss caused by continued opera tion of an impaired Engine with knowledge or a reason to suspect that a defective condition exists f Damage or loss occurring during shipment claims must be presented to carrier g Damage or loss caused whole or in part by exposure to natural atmospheric elements or corrosive chemicals h Damage or loss caused in whole or in part from a collision or comprehensive loss i Blown head gaskets seals or gaskets fluid leaks cracked heads or block overheating or other engine failures caused by a lack of suitable fluids improper maintenance or continued operation of an impaired vehicle j Damage or loss to the Engine and or vehicle caused by collision misuse lack of mainte nance lubrication cooling and or intake systems unauthorized modifications of the
10. shut off This pump will cycle frequently for up to 72 hours this is normal FUEL This vehicle is designed to operate on Liquefied Pe troleum Gas LPG or Propane Propane vehicles are recognized for their contribution to lower emissions cleaner air and lower operating costs High automotive grade propane is required and must meet the following automotive standards for fuel composition and quality e HD5 grade propane in the United States e HD10 grade propane in California e Grade 1 Propane in Canada Propane that does not meet or exceed the above standards may decrease engine performance dam age vital LPI system components or emission con trols Damage to components resulting from con tamination is NOT covered under warranty LPG is a colorless odorless highly flammable gas A distinctive odorant is added to LPG to alert anyone nearby in the event of a leak The odor smells similar to sulfur or rotten eggs FILLING YOUR LPI FUEL TANK REFUELING STATION INFORMATION A list of public and private LPG filling stations may be found on the following government website http www afdc energy gov locator stations LPI Engine systems use a fuel tank design different 21 Ocopyright 2014 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 plac
11. sold with this Warranty will meet all applicable specifica tions and under normal use and service be free from defect in material or factory workmanship Warrantable Condition This Coverage begins with the in service date of the vehicle and continues for the Terms and Conditions stated herein If the in service date of the vehicle cannot be determined the start of warranty date will be the date the chas sis was manufactured CLAIMS All warrantable conditions eligible for warranty claims for 8 0 LPG engines must be made by calling the toll free number 855 305 1500 upon initial dis covery of an engine needing repair Any repairs made or completed prior to calling and receiving claims or repair authorization will make that repair ineligible for claims coverage Prior to issuing an Au thorization Number or paying the repair cost we reserve the right to review inspect any documenta tion regarding the vehicle including but not limited to maintenance records OEM vehicle analysis soft ware reports and parts in their failed state Defec tive items must be held for inspection or return to Powertrain Integration or its authorized service facil ity within 90 days from the date of repair Additional coverage is outlined in the Emission War ranty Section REPAIRS Powertrain Integration will pay for parts and labor based on the current Powertrain Integration Labor Time Guide needed to repair the damage to the Engine resulting from
12. 11290 Rev B vice as soon as possible Failure to maintain the emissions system could void the warranty MALFUNCTION INDICATOR LAMP MIL CAUTION If the vehicle is continually driven when the MIL is activated the emission controls may not function the vehicle fuel economy may deteriorate and the engine may not run smoothly This could lead to costly repairs that may not be covered by the en gine warranty NOTE Modifications made to the engine transmis sion exhaust intake fuel system of the vehicle or replacing the original tires with tires that do not meet the same tire performance criteria may affect the vehicle s emission controls and can cause the MIL to activate Modifications to these systems could lead to costly repairs not covered by the en gine or vehicle warranty This could also result in a failure to pass required emission inspection and or maintenance tests A MALFUNCTION INDICATOR LAMP indicates that a malfunction has been detected in the vehicle emis sion system The vehicle can continue to be driven normally Diagnosis and service may be required to correct the malfunction The vehicle should be tak en to an OEM authorized service facility for service as soon as possible Failure to maintain the emis sions system could void the warranty STOP STOP ENGINE LAMP The STOP ENGINE LAMP indicates that a severe fault condition exists and the engine should be shut down as soon as it is safe to d
13. Engine over fueling road conditions negli gence overloading fires floods riots acts of war acts of God commission of any crime copyright 2014 15 A gradual reduction in operating perfor mance due to normal wear and tear such as but not limited to valve guides valves rings or oil consumption or normal mainte nance items I Equipment components items materials products or goods that are manufactured or supplied by companies other than Power train Integration or which are separately warranted by another manufacturer or supplier of such equipment and or compo nents is the warrantor of these said items m Routine maintenance of the Engine THIS WARRANTY SET FORTH HEREIN IS THE SOLE WARRANTY MADE BY POWERTRAIN IN TEGRATION WITH REGARD TO THESE ENGINES POWERTRAIN INTEGRATION MAKES NO OTH ER WARRANTIES EXPRESS OR IMPLIED OF MERCHANTABILITY OR FITNESS FOR A PARTIC ULAR PURPOSE This Warranty gives you specific legal rights and you may also have other rights which vary from state to state ENGINE EMISSIONS WARRANTY See CleanFUEL USA CFUSA Limited Warranty LIMITATIONS Engines must be operated using only Liquefied Pe troleum Gas LPG It is recommended to use HD5 grade propane HD5 is Heavy Duty Engine grade pro pane with a minimum of 9096 propane and a maxi mum of 5 propylene This grade of propane is 100 plus octane and will provide proper performance and emissions control whic
14. FUEL CFUSA FUEL PI FUEL SYSTEM LEAK FUEL TANK CAPACITIES GENERALINFORMATION PI 8 INTRODUCTION CFUSA INTRODUCTION PI m INSPECTING THE ENGINE AIR CLEANER FILTER s 9 JUMP STARTING iiem teo oti er te nr o ar too tou PER D 21 LIFTING YOUR VEHICLE LIMITED WARRANTY ON 8 0L LPG ENGINES s EPI FUEL TANK CAPACITY Ee MAINTENANCE SCHEDULE CFUSA MAINTENANCE SCHEDULE PI MAINTAINING YOUR VEHICLE CFUSA MAINTENANCE REPLACEMENT COMPONENTS PI MALFUNCTION INDICATOR LAMP ni MODELS COVERED IN THIS MANUALE 19 OIL CHANGE INTERVALS nri tror pre redo 4 Ocopyright 2014 11290 Rev B OIL CONSUMPTION PAINTINGTHEMEHICLE i sientas at PERFORMING SERVICE WORK PPOPANE DIAMOND STICKER E PROPER REFUELING PROCEDURE tt nr ee ha D fient 20 RECOMMENDED FLUIDS AND LUBRICANTS REFUELING STATION INFORMATION RETURINGTO SERVICE neceser rre ter ern coe red ad SAFETY WARNINGS CFUSA 2 4 terne ees 19 STARTING A LPI ENGINE STARTING PROCEDURE CFUSA STARTING THE ENGINE PI STOP ENGINE LAMP STORINGYOUR VEHICLES 21 TANK SHUT OFF VALVE LOCATION BETWEEN FRAME MOUNTED TANK SHUT OFF VALVE LOCATION SIDE MOUNTED TECHNICAL SERVICE CFUSA TECHNICAL SERVICE PI A TOWING YOUR
15. OPERATOR S MANUAL 8 0L LPG V8 ENGINE Powertrain Integration LIQUID PROPANE INJECTION s QA CLEANFUEL TABLE OF CONTENTS 8 0L ENGINE BY POWERTRAIN INTEGRATION jUn M M 4 WARNINGS CAUTIONS AND NOTES SECTION INTRODUCTION USING THIS MANUAL BREAK IN PERIOD NEW ENGINE OIL CHANGE INTERVALS koi erba pS SECTION OPERATING INSTRUCTIONS nr u STARTING THE ENGINE ENGINE WARNING LAMP WAIT TO START LAMP CHECK ENGINE LAMP STEADY CHECK ENGINE LAMP FLASHING MALFUNCTION INDICATOR LAMP STOP ENGINE LAMP NU ENGINE EXHAUST SECTION III SERVICE AND 0 4424 4 4 GENERAL INFORMATION PERFORMING SERVICE WORK ENGINE O ENGINE OIL ADDITIVES ENGINE OIL FLUSHES CHECKING ENGINE OIL CHANGING THE ENGINE OIL OIL CONSUMPTION ENGINE AIR CLEANER FILTER INSPECTING THE ENGINE AIR CLEANER FILTER COOLING SYSTEM ENGINE COOLANT CHECKING COOLANT ENGINE OVERHEATING s EMISSION CONTROL EQUIPMENT ss 11 O tO tO D tO tO tO OO SECTION IV MAINTENANCE 5 11 RECOMMENDED FLUIDS AND LUBRICANTS MAINTENANCE REPLACEMENT COMPONENTS SECTION V WARRANT PP 14 LIMITED WARRANTY ON 8 0L LPG ENGINES LPG ENGINE WA
16. QUID PROPANE INJECTION 8 0 L V8 ENGINE Ga LIQUID PROPANE INJECTION Ocopyright 2014 11290 Rev B INTRODUCTION This vehicle has been designed and built to operate on Liquefied Petroleum Gas LPG commonly re ferred to as propane autogas This manual contains the latest information available at the time of publication CLEANFUEL USA reserves the right to make changes in the products or infor mation contained in this manual without written notification unless the changes specifically affect your vehicle or safety In this case you will be noti fied This manual should remain in the vehicle for refer ence When you sell or trade your vehicle please leave this manual in the vehicle for the future own er MODELS COVERED IN THIS MANUAL This manual contains general information pertaining to vehicles that contain the 8 0L Dedicated LPI Liq uid Propane Injection Engine The information contained herein is meant to sup plement the OEM Operator Manual and is specific to the operation of the LPI Fuel System Failure to fulfill any maintenance service or opera tional requirements in either the OEM Operator Manual or this supplement may void the warranty USING THIS MANUAL This manual contains information which is unique to the propane fuel system and may supersede infor mation in the base vehicle manual If after reviewing the information contained in this manual you have questions please contact Technical Se
17. RANTY DOES NOT COVER Repairs Due to Accidents Comprehensive losses Misuse Storage Damage Negligence or any Modifi cations MAINTENANCE Owner is responsible for the continued operation and continued maintenance of the Engine as speci fied in the applicable Powertrain Integration Opera tion and Maintenance Manual Owner is also re sponsible for providing proof that all recommended maintenance has been performed in the event of a claim Owner must keep verifiable receipts detailing the date mileage hours and type of services per formed All other components must be serviced and maintained in strict accordance with the manufac turers written instructions INCIDENTAL OR CONSEQUENTIAL DAMAGES Powertrain Integration is not responsible for inci dental or consequential costs which the owner may 11290 Rev B incur as a result of a malfunction or failure if covered by this warranty such as vehicle damage earnings personal damage s storage communication costs per diem expenses meals lodging overtime loss of use time inconvenience cargo loss or damage and or other similar costs and expenses LIMITATIONS AND EXCLUSIONS This Warranty only applies to manufacturing defects in material and workmanship on the Engine Refer to Base Engine Warranty for a listing of covered components The Warranty shall not apply to the following a Damage or loss caused in whole or in part by the acts or omissions of any kind by any
18. RRANTY COVERED PARTS SECTION VI CUSTOMER ASSISTANCE rss 18 TECHNICAL SERVICE WARRANTY CLAIMS COMPONENT ORDERS SECTION VII ALPHABETICAL INDEX 31 TABLE OF CONTENTS LIQUID PROPANE INJECTION SYSTEM BY CLEANFUELS USA INTRODUCTION e itti leat 20 MODELS COVERED IN THIS MANUAL se 20 USING THIS MANUAL SAFETY WARNINGS SECTION DRIVING AND OPERATING 20 STARTING A LPI ENGINE EE 20 STARTING PROCEDURE EVAPORATIVE SYSTEM PUMP FILLING YOUR LPI FUEL TANK REFUELING STATION INFORMATION PROPER REFUELING PROCEDURE FUEL SYSTEM LEAK SECTION GENERAL VEHICLE CARE nnne 22 JUMP STARTING TOWING YOUR VEHICLE STORING YOUR VEHICLE RETURING TO SERVICE LIFTING YOUR VEHICLE PAINTING THE VEHICLE SECTION III SERVICE AND MAINTENANTCE eere 24 MAINTAINING YOUR VEHICLE MAINTENANCE SCHEDULE SECTION IV TECHNICAL INFORMATION 00 4 44 002000020 0 0 0 000 24 shte else 24 PROPANE DIAMOND STIC SIDE MOUNTED TANK SHUT OFF LOCATIO s BETWEEN FRAME RAIL MOUNTED TANK SHUT OFF 26 SECTION V WARRANT PP 28 CLEANFUEL USA CFUSA LIMITED VVARRAVTY EMISSION COMPONENTS FOR 8 0L V8 LPG FUELED ENGINE SECTION VI
19. UEL USA distributor Part number VAX 0502 S 5 Inspect the fill valve O ring Note Make sure the O ring is seated in the groove and is not damaged or missing Note A new O ring can be obtained from CLEANFUEL USA or a CLEANFUEL USA distributor Part number VAX 0503 S 11290 Rev B 4 Refueling Valve O Ring Refueling valve and cap WARNING Never connect the fill nozzle to the refueling valve if the O ring is missing or damaged This could cause serious injury or property damage 6 Connect the propane fill nozzle to the fill valve 7 Rotate the fill valve nozzle clockwise until it is firmly attached to the fill valve 8 Close the fill nozzle vent valve if equipped 9 It is not required to use the 80 liquid level valve Only open if required by fill station 10 Turn the propane dispenser ON 11 Open valve on refueling nozzle to begin refuel ing 12 When the OPD stops the flow of fuel into the tank close the valve on the refueling nozzle If required to use the 80 liquid level gauge stop filling when liquid from the level gauge appears in the form of a white cloudy vapor 13 Turn the propane dispenser OFF 14 If equipped open the fill nozzle vent and safely release the pressure from the fill nozzle 15 Carefully disconnect the filling nozzle from the refueling valve by rotating the fill nozzle con nector counter clockwise 16 Return the fueling nozzle to the dispense
20. VEHICLE aa terra teve v r USING THIS MANUAL CFUSA USING THIS MANUAL PI WAIT TO START LAMP WARNINGS CAUTIONS AND NOTES WARRANTY CLAIMS CFUSA WARRANTY CLAIMS PI WARRANTY COVERED PARTS PI 32 Ocopyright 2014 11290 Rev B Powertrain Integ ration Q3 LIQUIDPROPANE INJECTION s GCLEANFUEL Copyright 2014 Part Number 11290 B Powertrain Integration All rights reserved
21. Y CleanFUEL USA CFUSA Limited War ranty Freightliner LPI amp 8 0L Engine Fuel System School Bus 5 Years 100 000 Mile 160 000 km Delivery Truck 2 Years Unlimited Miles or 2 000 hours Warranty Coverage applies to the above Freight liner truck formats This warranty is a supplemental limited warranty to your new Freightliner base vehi cle warranty Certain components unassociated to the fuel system may be covered by different manufacturers This warranty provides coverage to any malfunction of the LPle fuel system resulting from defects in materials or workmanship The origi nal manufacturer s warranty Freightliner or Power train Integration remains valid Federal emissions warranty is 5 years 50 000 miles and California emissions warranty is 7 years 70 000 miles For more specific information about EMISSIONS CON TROL SYSTEMS warranty call CFUSA at 855 305 1500 In California new motor vehicles must be des ignated built and equipped to meet the State s more stringent anti smog standards If your vehicle fails a SMOG inspection all necessary repairs should be obtained through CFUSA MASTER DEALER If an emission related part malfunctions it will be repaired or replaced at no charge during the emis sions warranty period What is covered Propane tank amp all associated components to the tank including the internal fuel pump fuel lines mounting hardware multi valve safety relief valve fil
22. egration 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 The warranty repairs should be completed in a reasonable amount of time Owner is responsible for incidental costs such as communication expenses meals lodging incurred by Owner or employees of Owner as a result of a War rantable Condition Powertrain Integration is not responsible for down time expenses cargo damage fines all applicable taxes business costs and other losses resulting from a Warrantable Condition POWERTRAIN INTEGRATION IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES 11290 Rev B 8 0L LPG ENGINE WARRANTY COVERED PARTS School Bus 5 Years 100 000 miles 160 000 km Whichever occurs first 10 000 per engine Delivery Vehicle 2 Years Unlimited miles or 2 000 hours Whichever occurs first 10 000 per engine Camshaft Connecting Rods Crankshaft Crankshaft Balancer Bolt Crankshaft Reluctor Wheel Cylinder Head Bolts Cylinder Head Gasket Cylinder Heads Engine Block Exhaust Manifold Gasket Exhaust Manifolds Front Timing Cover Front Timing Cover Seal Intake and Exhaust Valves Intake Manifold Gasket Lifter Valley Baffle Oil Pan Gasket Oil Pump Assembly Oil Stem Valve Sea Piston Pins Pistons
23. ehicle towing communication expenses meals lodging overtime loss of use loss of time incon venience cargo loss or damage and other similar costs and expenses including the loss of fuel in the event of an inter nal tank repair Obtaining warranty service Call or visit a Freightliner dealer or authorized LPI ser vice provider Call CFUSA at 855 305 1500 for authorized service war ranty information and technical support Only a CFUSA authorized service center should perform warranty repairs Any service provider that works on the fuel system must have appropriate license where required by applicable federal state or local laws pertaining to the handling of propane laws vary by state Owner s Responsibilities As the vehicle owner you are responsible for the per formance of the required maintenance listed in your own er s manual CleanFUEL USA recommends that you retain all receipts covering maintenance of your vehicle although CleanFUEL USA cannot deny warranty solely for the lack of receipts You are responsible for presenting your truck to a CleanFUEL USA dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time e As the truck owner you should also be aware that CleanFUEL USA may deny you warranty coverage if any of the above conditions are met and or if your vehicle or part has failed due to abuse neglect improper maintenance or unapproved modificat
24. es which sell LPG as an engine fuel it is recommended that you fill your LPG powered vehicle at filling stations capable of filling autogas vehicle tanks Note Propane is a liquid fuel Parking the vehicle on an uneven surface during refueling could result in the vehicle being over or under filled Before refueling you should familiarize yourself with the location of the refueling connectors on your ve hicle Unless you are trained and experienced with illing your LPG fueled vehicle consult a qualified propane station operator The LPI fuel tank equipped with both an 8096 fixed evel gauge and an automatic OPD Overfill Protec tion Device in accordance with NFPA 58 The LPI system is designed to be filled safely and reliably using only the OPD Therefore the usage of the 8096 ixed liquid level valve is not required There is a re quired annual verification of the 8096 valve s accura cy Take your vehicle to a certified LPI service pro vider for annual OPD inspections PROPER REFUELING PROCEDURES 1 Park the vehicle on level ground to ensure that the tank is properly filled 2 Turn the engine off and set the parking break Set wheel chocks if required 3 Ensure there are no open flames or ignition sources 4 Remove the refueling valve cap by turning the cap counter clockwise Be sure to retain the cap for replacement after filling Note Replacement filler valve caps can be obtained from CLEANFUEL USA or a CLEANF
25. fer to the Powertrain Inte gration Service Manual or contact Powertrain Inte gration ENGINE AIR CLEANER FILTER Inspect the air cleaner filter at the scheduled maintenance intervals and replace it when the re striction indicator reaches 15 inches H20 3 7kpa Refer to the OEM Operator Manual for more infor mation If driving in dusty dirty conditions inspect the filter at each engine oil change INSPECTING THE ENGINE AIR CLEANER FILTER Prior to inspection turn the engine OFF Refer to the OEM Operator Manual for proper procedure Never use compressed air to clean the filter COOLING SYSTEM ENGINE COOLANT The cooling system allows the engine to maintain the correct working temperature The cooling system in the vehicle is filled with an Organic Acid Technology with a Nitrite Additive NOAT Extended Life Coolant ELC With proper maintenance this coolant is designed to remain in 11290 Rev B the vehicle for six 6 years or 600 000 mi 960 000km whichever occurs first CAUTION Using engine coolant other than the factory fill can cause premature engine heater core or radiator corrosion In addition the engine coolant could require changing sooner at 50 000 km 30 000 mi or 24 months whichever occurs first Any repairs would not be covered by the vehicle warranty CAUTION Using an improper engine coolant mixture could cause the engine to overheat The repair cost would not be co
26. first 10 000 miles Forthe first 500mi 805km o Keep the vehicle speed at 55 mph 88km h or less o Do not drive at any one constant speed Vary vehicle speed within posted speed lim its Avoid wide open throttle acceleration o Avoid downshifting to brake or slow the ve hicle o Avoid steady idling for extended periods longer than five minutes o NOTE Oil consumption is normal during operation of a propane engine The rate of consumption is highly dependent on vehicle load city and highway driving and duty cycles New engines may experi ence higher oil consumption during the engine break in period After the break in period oil usage up to one quart per 1 500 miles is in the acceptable range Oil level should be checked at every fuel stop OIL CHANGE INTERVALS The engine oil and filter must be changed every 5 000 miles 8 064 km The crankcase capacity is 8 qts 9 qts with the filter Refer to the OEM operator manual for oil change instructions 11290 Rev B SECTION II OPERATING INSTRUCTIONS STARTING THE ENGINE IMPORTANT For service issues and questions call Powertrain Integration Representatives will be able to answer questions and diagnose mechanical issues as well as provide detailed service repair in formation Prior to operating the vehicle perform engine pre trip inspection and daily maintenance checks Refer to the OEM Operator Manual CAUTION If the engine does not start o
27. g or service procedure Fail ure to observe this procedure could result in an un safe condition improper performance of the engine or fuel system and may influence the terms of the warranty SECTION I INTRODUCTION Your new Powertrain Integration 8 0L engine has been designed and built to operate on Liquefied Pe troleum Gas LPG commonly referred to as propane or autogas Propane fuel is readily available and when used as an engine fuel provides a reduction in harmful exhaust emissions Ocopyright 2014 This manual has been prepared 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 please contact Powertrain Integration Refer to Section V Customer Assistance Infor mation for clarification It is recommended that this manual be completely reviewed upon receipt of vehicle This will allow fa miliarization of the operation and special features of the Powertrain Integration 8 0L LPG engine BREAK IN PERIOD NEW ENGINE The engine does not need an elaborate break in However it will perform better if these basic guide lines are followed e Use conventional oil non synthetic for
28. g from gross contamination is NOT covered under warranty LPG is colorless odorless and is stored as a liquid in the fuel tank A distinctive odorant is added to LPG or safety The odor smells similar to sulfur or rotten eggs ENGINE EXHAUST WARNING Engine exhaust contains carbon monoxide CO which cannot be seen or smelled Exposure to CO can cause unconsciousness or loss of life Engine exhaust may enter the vehicle if e The vehicle idles in areas with poor ventila tion parking garages tunnels deep snow that may block underbody airflow or tail pipes e exhaust smells or sounds strange or dif ferent e exhaust system leaks due to corrosion or damage e vehicle exhaust system has been modi fied damaged or improperly repaired e There are holes or openings in the vehicle body from damage or aftermarket modifica tions that are not completely sealed If unusual fumes are detected or if it is suspected that exhaust is coming into the vehicle 11290 Rev B e Drive it only with the windows completely open e Have the vehicle repaired immediately Never leave the engine running vvith the vehicle parked in an enclosed area such as a garage or a building that has no fresh air ventilation SECTION III SERVICE AND MAINTENANCE GENERAL INFORMATION A vehicle with the 8 0L LPG engine is an important investment Proper maintenance helps to keep the engine and vehicle in
29. good working condition im proves fuel economy and reduces vehicle emissions for better air quality It is recommended that ASE trained technicians perform these services This section describes the required maintenance for the engine The owner operator of the vehicle is respon sible for scheduled maintenance CAUTION Damage caused by improper maintenance can lead to costly repairs and may not be covered by the engine warranty Maintenance intervals checks inspections recommended fluids and lubricants are important to keep the engine in good working con dition Maintenance needs vary due to the different ways vehicles are utilized The vehicle might need more frequent checks and services Please read the infor mation under Scheduled Maintenance To keep the vehicle in good condition see your dealer The proper replacement parts fluids and lubricants to use are listed in Recommended Fluids and Lubri cants We recommend the use of genuine parts from your dealer PERFORMING SERVICE WORK WARNING 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 detail on how to service the engine
30. h the fuel system is de signed to deliver Failures other than those resulting from defects in material or factory workmanship are not covered by this Warranty Powertrain Integration is not responsible for failures or damage resulting from what Powertrain Integra tion determines to be abuse or neglect including but not limited to operation without adequate cool ants or lubricants over fueling over speeding lack of maintenance of lubricating cooling or intake sys tems improper storage starting warm up run in or shutdown practices unauthorized modifications of the Engine 11290 Rev B Powertrain Integration is not responsible for failures caused by incorrect oil fuel water dirt or other con taminants in the fuel Powertrain Integration is not responsible for non Engine repairs downtime expenses cargo dam age fines all applicable taxes and business costs and other losses resulting from a Warrantable Condi tion POWERTRAIN INTEGRATION IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES CALIFORNIA EMISSION WARRANTY ON HIGHWAY See CleanFUEL USA CFUSA Limited Warranty OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Powertrain Integration Operator s Manual Ocopyright 2014 16 Powertrain Integration recommends that you retain all receipts covering maintenance on your engine but Powertrain Int
31. ions THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE FUEL SYSTEM AS USED IN ON ROAD VEHICLE APPLICATIONS CFUSA MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE CFUSA SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF CERTAIN DAMAGES OR THE DURATION OF IMPLIED WARRANTIES OR CONDITIONS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU Ocopyright 2014 11290 Rev B EMISSION COMPONENTS FOR 8 0L V8 LPG FUELED ENGINES WARRANTY COVERAGE School Bus and Delivery Vehicle Federal Emissions Warranty 5 Years 50 000 miles 80 000 km Whichever occurs first California Emissions Warranty 7 Years 70 000 miles 113 000 km Whichever occurs first Camshaft Sensor Coolant Temperature Sensor Crankshaft Position Sensor Assembly Engine Control Module Evaporative Charcoal Canister Evaporative Controller Evaporative Emissions Valve Assembly 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 29 Ocopyright 2014 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 o
32. l valve service valve and fuel level gauge Fuel injectors fuel rails fuel supply amp return lines fit tings and mounting hardware Evaporative fuel handling components added or modi fied for the LPle fuel system Wiring harness or wiring components added specifically for the fuel system Proprietary CFUSA electronic evaporative emissions con trol calibration Any vehicle system failure caused by or resulting from a failure of the fuel system What is not covered e Any malfunction that is not related to the LPI fuel sys tem Any component that is not associated with the fuel system Components that have failed due to vehicle modification or alteration Components considered maintenance items identified in the 8 0L Engine Owner s Manual Supplement e g filters Any failure resulting from fuel contamination or the use of LPG not meeting the specifications of HD 5 propane See 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 Arepair due to accidents or comprehensive losses CFUSA is not responsible for incidental or consequential Costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty such as vehicle damage v
33. le 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 is overheated severe engine damage could result The vehicle has indicators to warn of engine over heating Refer to the OEM Operator Manual for lo cation of the vehicle s coolant temperature gauge If the engine becomes overheated there will be a warning buzzer and a message will appear in the instrument cluster The following actions may help the engine return to normal operating temperature e Reduce engine speed e Avoid hard accelerations Avoid steep uphill grades If the condition does not improve The CHECK EN GINE LAMP and STOP ENGINE LAMP will come on the engine will go into reduced power mode and the idle speed will increase to speed up the water pump and cooling fan to cool the engine If the CHECK ENGINE LAMP and the STOP ENGINE LAMP are on pull over as soon as it is safe stop the vehi cle set the parking brake and turn off the engine If the decision is made to open the hood make sure the vehicle is parked on a level surface and that there is no danger from steam leaking fluids and hot surfaces Inspect for e Broken or missing accessory drive belts e Obstructions or debris in front of the vehi cle radiator and grill e Coolant level by looking at the surge tank do not remo
34. n the first attempt make sure that the engine has completely stopped rotating before reapplying the starter switch Fail ure to do so may cause ring gear and starter pinion damage Ring gear and starter pinion damage caused by improper starting procedures is not war rantable CAUTION Never attempt to start any electronically controlled engine using ether or any other starting fluid Seri ous engine damage or personal injury could result NOTE Starting a LPG propane engine is slightly different than a gasoline vehicle Before the vehicle will start the engine must be supplied with liquid fuel Since the previous run period the fuel may have expanded or vaporized in the fuel lines and injectors A priming process is activated each time the ignition key is rotated to the ON position IMPORTANT Do not depress the throttle pedal while starting the engine 1 Make sure that the transmission shift control is in Neutral N and the Parking Brake is set 2 Turntheignition switch to the ON position The Wait to Start Lamp in the instrument cluster will illuminate for a brief time CAUTION 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 Ocopyright 2014 CAUTION Do not crank the engine for more than 30 seconds atatime Wait two minutes after each try to allow the starter to cool Failure
35. nges and any top off through 10 000 miles 16 000 km Partial or fully synthetic oils may be used after the first two oil changes ENGINE OIL ADDITIVES Do not add anything to the oil The recommended oils with the API starburst symbol are all that is needed for good performance and engine protec tion ENGINE OIL FLUSHES NOTE Engine oil system flushes are not recom mended and could cause engine damage not cov ered by the engine warranty CHECKING ENGINE OIL It is important to check the engine oil level regularly and keep it at the proper level In order to get an accurate reading the vehicle must be on level ground Obtaining an accurate oil level reading is essential 1 Turn off the engine and allow several minutes for the oil to drain back into the oil pan Check ing the oil level too soon after engine shutoff will not provide an accurate oil level reading 2 Pullout the dipstick and clean it with a paper towel or cloth then push it back in all the way Remove it again keeping the tip down and check the level 3 Ifthe oil is below the crosshatched area at the tip of the dipstick add 1 quart liter of the rec ommended oil and then recheck the level 4 Add enough oil to put the level in the cross hatched area on dipstick Push the dipstick all the way back in when finished NOTE Oil should be within the cross hatched area of the dipstick Oil levels that are above or below the acceptable ope
36. ngine air cleaner filter Visual inspection of accessory drive belts for fraying excessive cracking or damage Re place as necessary NOTE Refer to the OEM Operator Manual for ser vice procedures 11 Ocopyright 2014 11290 Rev B Recommended Vehicle Maintenance Schedule Maintenance Interval Frequency Miles Kilometers Hours Months Change Oil amp Filter Inspect Evaporative Control System 1 Replace Fuel Fill and Inline Filters Inspect Fuel System 5 Replace Engine Air Cleaner Filter 2 Replace Spark Plugs amp Inspect Spark Plug Wires Replace Spark Plug Wires 100 000 160 000 3 000 Coolant Quality Checks 3 Perform Annual Checks 3 Inspect Engine Drive Belt Tensioner 4 Which ever occurs first 1 Check all fuel and vapor lines and hoses for proper connections and condition 2 Check recommended miles kilometers or every three years 3 Use coolant test strips and refractometers to verify freeze point ph concentration and corrosion inhibitor levels The coolant should also be visually inspected for dirt rust and or other forms of contamination Service the coolant system as needed to correct any out of range measurements or contamination 4 Articulate the tensioner to verify proper function Inspect stops for contact If any stop has contacted the body stops replace the belt and reinspect the tensioner Inspect the belts for wear fraying and cracking across the rib
37. nual for specific maintenance service 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 components can be damaged Service should be only performed by LPI certified dealers CFUSA LPI FUEL SYSTEM RECOMMENDED MAINTENANCE SCHEDULE FREQ 5000 10 000 20 000 30 000 Miles Mile Mile Miles EMEN heck for damage eak check all tank fittings and connections heck all tank mounting hardware OPD 0 ill Protection Device Function Verification inspect lines for damage eak check all line fitting 1 injector Rail and Injecto heck pump cover has no damage Replace filters This maintenance schedule represents CleanFUEL USA recommended maintenance intervals to insure safe amp reliable operation of the CleanFUEL USA LPI Liquid Propane Injection fuel system Vehicles which operate in harsh environments may require operators to perform more comprehensive or frequent inspections If you have any questions regarding the maintenance procedures and or ques tion regarding the system please contact you CleanFUEL USA Service provider SECTION IV TECHNICAL INFORMATION LPI FUEL TANK CAPACITY PROPANE vehicle Tank Formats If not purchased with a body some vehicle applica tions may not have a propane diam
38. o 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 in to reduced power mode If the engine is shut down while the vehicle is in service a single restart attempt may be performed Depending on the na ture of the fault condition a cool 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 Ocopyright 2014 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 powered by clean burning Liquefied Petroleum Gas LPG commonly referred to as pro pane or autogas Propane is recognized worldwide for its contribution to lower emissions cleaner air energy independence and lower operating costs It is recommended to use HD5 grade propane HD5 is Heavy Duty Engine grade propane with a minimum of 90 propane and a maximum of 5 propylene This grade of propane is 100 plus octane and will provide proper performance and emissions control which the fuel system is designed to deliver The fuel should be free of contamination including but not limited to rust dirt sand water salt and brine Damage to components resultin
39. ond sticker at tached to the rear of the vehicle This label is re quired by law in the United States and Canada This label is to be affixed to the right rear of the vehicle body NOT to the bumper and is required to alert emergency personnel that the vehicle runs on pro pane autogas in the event of an accident Side Mounted Tank Between the Frame Rail Mounted Tank PROPANE DIAMOND STICKER 24 Ocopyright 2014 11290 Rev B To attach this sticker 1 Clean the area you wish to place sticker with soapy water solution Be sure to remove excess soap 2 When the area is dry apply the sticker by pushing down on the middle first then working your way out to the edges Note New propane diamond stickers can be ob tained from your dealership SIDE MOUNTED TANK FUEL SHUT OFF To shut off the supply of fuel to the engine both the supply and return valves will need 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 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 Locate the return valve Figure 2 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
40. otect components This reduction in power will be notice able to the operator of the vehicle The vehicle should be taken to an OEM authorized service facili ty for service as soon as possible Failure to maintain the engine operating system could void the warran ty Ocopyright 2014 CHECK 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 Individual cylinders may be deactivated as a means to protect the cata lytic converters which will result in a decrease in engine power To prevent more serious damage to the vehicle Reduce engine speed Avoid hard accelerations Avoid steep uphill grades If the light continues to flash find a safe place to stop and park the vehicle Turn the vehicle off wait at least 10 seconds and restart the engine If the light is still flashing have the vehicle serviced as soon as possible The engine should not be operated for extended periods while a flashing CHECK ENGINE LIGHT is present or damage to the catalytic convert ers will result Catalytic converters damaged by driv ing the vehicle with a flashing check engine light are not covered under warranty The vehicle should be taken to an OEM authorized service facility for ser
41. r 17 Reinstall the refueling valve cap FUEL SYSTEM LEAK WARNING If you smell a persistent propane odor or hear a continual hissing sound there could be a propane leak If the propane is ignited you or others could be injured Do not start the engine or drive the ve hicle Have your vehicle towed to an OEM author ized service facility for service A slight odor of propane may be present for a few moments after refueling your vehicle This 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 Ocopyright 2014 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 to OFF Do not drive the vehicle until the leak is found and repaired The vehicle should be towed to an OEM authorized service facility SECTION II GENERAL VEHICLE CARE JUMP STARTING WARNING If the LPI Propane fuel system has a leak a spark from the jumper cables could ignite the gas causing injury or death Do not attempt to jump start your vehicle if a strong smell of propane is present or you hear a continual hissing sound Have the vehi cle towed to an OEM authorized service facility See Jump Starting
42. r 2 000 hours Whichever occurs first 80 Mechanical Fill Valve Evaporative Purge Hoses Evaporative System Hoses External Fuel Gauge Filler Hoses Fuel Supply and Return Hoses Fuel Supply and Return Lines Stainless Steel Liquid Evacuation Valve Mechanical Fuel Gauge Float Return Valve Safety Relief Valve Supply Valve and Solenoid 11290 Rev B SECTION VI CUSTOMER ASSISTANCE TECHNICAL SERVICE For technical 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 Ocopyright 2014 30 11290 Rev B SECTION VII INDEX ALPHABETICAL INDEX BREAK IN PERIOD NEW ENGINE 4 CALIFORNIA EMISSION WARRANTY ON HIGHWAY CHANGING THE ENGINE OIL CHECKING COOLANT CHECK ENGINE LAMP FLASHING CHECK ENGINE LAMP STEADY CHECKING ENGINE OIL COMPONENT ORDERS CFUSA COMPONENT ORDERS PI s COOLING SYSTEM ENGINE COOLANT 9 ENGINE AIR CLEANER FILTER ENGINE EXHAUST ENGINE EMISSIONS WARRANTY ENG ENGINE OIL ADDITIVES ENGINE OIL FLUSHES ENGINE OVERHEATING ENGINE WARNING LAMP EMISSION COMPONENTS EMISSION COMPONENTS FOR 8 0L V8 LPG FUELED ENGINE EVAPORATIVE SYSTEM PUMP FILLING YOUR LPI FUEL TANK 20
43. rating range the crosshatched area on the dip stick are harmful to the engine If the oil level is above or below the operating range oil should be added or removed to bring it into the operating range Operating the engine when the oil is not in the operating range could cause engine damage Ocopyright 2014 CHANGING 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 or oil change instructions OIL CONSUMPTION All engines require oil to lubricate and protect the oad bearing and internal moving parts from wear including cylinder walls pistons and piston rings When a piston moves down its cylinder a thin film of oil is left on the cylinder wall During the power stroke part of this oil layer is consumed in the com bustion process As a result varying rates of oil con sumption are accepted as normal in all engines Oil consumption is normal during operation of the 8 0L propane engine The rate of consumption is highly dependent on vehicle loading highway city driving and duty cycles New engines may experi ence higher oil consumption during the engine break in period After the engine break in period the acceptable rate of oil consumption for the 8 0L Powertrain Integration propane engine is one quart per 1 500 miles 2 414km For further information re
44. rvice at 1 855 305 1500 It is recommended that you review this manual completely before you operate your vehicle This will allow you to become familiar with the unique opera tion and features of your propane powered vehicle SAFETY WARNINGS This manual contains multiple safety 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 20 Ocopyright 2014 WARNING Propane is extremely flammable Keep sparks and open flames away from propane Do not smoke while refueling your vehicle WARNING Liquid propane can cause serious burns to skin or eyes Prevent contact when handling propane by wearing approved hand and eye protection WARNING Service and repair of the propane fuel system should only be performed by trained service techni cians The propane fuel system requires special tools to make repairs To prevent personal injury or damage to the fuel system do not attempt repairs WARNING Never cut or weld on the propane storage tank Severe bodily injury or fire could result SECTION I DRIVING AND OPERATING STARTING A LPI ENGINE With the parking brake set move the shift lever to N Neutral A safety feature prevents the engine from starting in any other position Starting
45. s Pulleys should be quiet and spin without binding Inspect the pulley bearings for wear or looseness 5 Inspect the Fuel Tank Fuel Lines Fuel Rail and Injectors 12 Ocopyright 2014 11290 Rev B RECOMMENDED FLUIDS AND LUBRICANTS Fluids and lubricants identified below by name part number or specification can be obtained from your dealer USAGE FLUID LUBRICANT Engine Oil Conventional SAE 5W 30 is recommended Must meet the following Daimler Spec 48 254961 Detroit Diesel Spec 93K217 ASTM D6210 Engine Coolant 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 GM AC Delco PART NUMBER NUMBER if applicable Engine Oil Filter 11020 PF1218 Spark Plugs 11309 41 963 Plug Wires 11028 N A Air Compressor Drive Belt 11162 N A PCV Valve 11105 N A Spark plug gap 0 050 13 Ocopyright 2014 11290 Rev B SECTION V WARRANTY LIMITED WARRANTY ON 8 0L LPG ENGINES PRODUCTS WARRANTED This warranty applies to new 8 0L V8 engines sold by Powertrain Integration LLC on the vehicle it was originally installed in The 8 0L engines are fueled by Liquefied Petroleum Gas LPG also known as pro pane or autogas BASE ENGINE WARRANTY Powertrain Integration warrants that its engines
46. to do so may cause starter damage 3 When the Wait to Start lamp goes out do the following 4 Rotate the ignition key to the START position After the engine starts release the key 5 Afterthe engine has started let it run for 20 30 seconds before a load is put on the engine Bring the engine up to operating speed gradual ly as it warms up and develops stable oil pres sure IMPORTANT When the engine is started it takes a short time to build up a lubricating oil film between the shafts and bearings and between the pistons and cylinder walls 6 Donotrace the engine immediately after start ing it Operate the engine and transmission gen tly until the oil warms up and lubricates all mov ing parts 7 Ifthe vehicle starts briefly but then stops turn the key to the OFF position for at least three 3 seconds then repeat the starting process WARNING If the vehicle is left with the engine running it could potentially overheat or the vehicle could move suddenly if the shift lever is not fully engaged in Neutral N and the Parking Brake firmly set Do not leave the en gine running if the vehicle is unattended WARNING It is best to not leave the vehicle parked with the engine running but if required please note that idling a vehicle in an enclosed area with poor venti lation is dangerous Engine exhaust may enter the vehicle Never run the engine in an enclosed area that has no fresh
47. ve the surge tank cap e Fluid Leaks The STOP ENGINE LAMP and buzzer will go out when the engine reaches normal operating tempera ture The CHECK ENGINE LAMP will remain on until an inspection service is performed at an OEM au thorized service facility 11290 Rev B If it is determined that there are no mechanical fail ures or coolant loss and the engine has cooled down and the vehicle is safe to drive the vehicle may be driven to an OEM authorized service facility for in spection as soon as possible EMISSION CONTROL EQUIPMENT Some state provincial and local governments may have programs to inspect the on vehicle emission control equipment For the inspection the emission system test equipment is connected to the vehicle s Data Link Connector DLC The DLC is under the instrument panel to the left of the steering wheel The vehicle may not pass inspection if e malfunction indicator lamp is on with the engine running or e Ifthe 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 e Check engine oil level e Check engine coolant level AT EVERY ENGINE OIL CHANGE Change engine oil and filter Perform visual inspection of oil cooler hoses and fittings Check engine coolant level Inspect engine cooling system Visual inspec tion of hoses pipes fittings and clamps Replace if needed Inspect e
48. vered by the warranty Too much water in the mixture can freeze and crack the en gine radiator heater core and other parts For the LPG engine a 50 50 pre mixture coolant should be used If this mixture is used nothing else needs to be added This mixture will e Give freezing protection down to 34 F 37 C e Give boiling protection up to 265 F 129 C e Protect against rust and corrosion e Will not damage aluminum parts Provide water pump lubrication e Help keep the proper engine temperature WARNING The coolant warning system is set for the proper coolant mixture 50 50 pre mixture coolant Over time water may permeate through hoses resulting in a coolant rich mixture in the cooling system Always use test strips appropriate for the coolant type to check the coolant properties Top off the cooling system accordingly to maintain a 50 50 mixture CAUTION Severe engine damage may result from running the engine when low on coolant or out of coolant En gine damage caused by running the engine low on coolant or out of coolant is not covered by the en gine warranty CHECKING COOLANT Refer to the OEM Operator Manual for checking en gine coolant levels and coolant conditions i e rust cloudy dirt other contaminants 10 Ocopyright 2014 ENGINE OVERHEATING WARNING Steam from an overheated engine can cause burns Stay away from the engine and vehic
49. your propane vehicle is different than a gas oline vehicle Before the vehicle will start the fuel lines and injectors must be refilled with liquid fuel A priming process is used to fill the system with liquid propane each time the ignition key is turned ON STARTING PROCEDURE 1 Turn the key to the ON but engine off position At this time the wait to start light will illuminate on the dash panel 2 After the light turns off 5 to 10 seconds with your foot off the accelerator pedal turn the key to the start position When the engine starts re lease the key High idle might be experienced on startup Idle speed will go down as the engine warms up Do not race the engine upon starting operate gently to allow proper warm up and lu brication of all internal parts Note Long cranking times can cause the starting 11290 Rev B motor to overheat and cause damage Wait 15 sec onds between each cranking cycle to allow starter to cool down 3 If the engine fails to start in two to three seconds during engine cranking sequence turn the key back to the Off position and repeat the starting procedure If the engine still does not start check the fuel level If the gauge registers an adequate fuel level and the engine still won t start the vehicle may require ser vicing EVAPORATIVE SYSTEM PUMP This vehicle utilizes an evaporative emissions system that uses a pump This pump will operate when the vehicles engine has been
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