PSI 8.8L GASOLINE User manual

Power Solutions International, Inc
8.8L GASOLINE For On-Road Applications
Engine Operation and Maintenance Manual
201 Mittel Dr.
Wood Dale, IL 60191
Power Solutions International, Inc. 36100026 – Rev 2
US EPA & CARB HD-SI Certification May 2019

IMPORTANT
The information, specifications, and illustrations contained in this manual are based on data that was current at the time of
publication. Power Solutions International, Inc. reserves the right to make changes and/or improvements at any time without
notification, liability, or without applying those changes or improvements to vehicles previously manufactured and/or sold.
NOTICE
Be advised that this motor veh
icle may be equipped with
computer/recording devices. Their function is to allow an
authorized individual to download data or information relating
to the operation or performance of this vehicle.
The stored data or information may be neither downloaded
nor retrieved except by the vehicle’s registered owner, or, in
the alternative, by another individual or entity authorized by
the registered owner, (e.g., Certified Service Dealer)
who may need this data or information to properly service or
diagnose this vehicle for repair or following an accident.
Any access to this information without the owner’s consent
may be in violation of law and may subject that person or
entity to criminal penalties.

TABLE OF CONTENTS
FOREWORD ..................................................................................................................................................................................2
SAFETY INFORMATION ...............................................................................................................................................................4
WARRANTY.................................................................................................................................................................................10
EPA and CARB Emission System Warranty................................................................................................................................................. 10
Manufacturer's Warranty Coverage............................................................................................................................................................... 10
Owner's Warranty Responsibilities................................................................................................................................................................ 11
Warranty Exclusions...................................................................................................................................................................................... 12
SECTION 1 – ENGINE SYSTEMS ...............................................................................................................................................13
Engine Serial Number ..................................................................................................................................................................................... 14
Engine Emission Label ................................................................................................................................................................................... 15
Engine Spec Label........................................................................................................................................................................................... 15
Engine Accessories ........................................................................................................................................................................................ 15
Engine Specification ....................................................................................................................................................................................... 16
Engine Description ........................................................................................................................................................................................ 16
Engine Features ............................................................................................................................................................................................ 21
Engine Related Optional Features ................................................................................................................................................................ 22
Component Location – Top............................................................................................................................................................................ 25
Component Location – Front ......................................................................................................................................................................... 26
Component Location – Left............................................................................................................................................................................ 27
Component Location – Right ......................................................................................................................................................................... 28

SECTION 2 – REQUIREMENTS FOR FUEL, ENGINE OIL, AND COOLANT .............................................................................30
Fuel ................................................................................................................................................................................................................... 31
Use of Seasonal Fuels .................................................................................................................................................................................. 31
Prohibited Fuels............................................................................................................................................................................................. 31
California Fuel Requirements ........................................................................................................................................................................ 31
Fuels in Foreign Countries ............................................................................................................................................................................ 32
Fuel Additives ................................................................................................................................................................................................ 32
E85 Fuel ........................................................................................................................................................................................................ 32
Engine Oil......................................................................................................................................................................................................... 33
Engine Oil Quality and Service Categories ................................................................................................................................................... 33
Oil Recommendation ..................................................................................................................................................................................... 33
Coolant ............................................................................................................................................................................................................. 33
Coolant Mixtures............................................................................................................................................................................................ 33
Contamination of Coolant .............................................................................................................................................................................. 33
SECTION 3 – INSTRUMENTS, INDICATORS, AND SWITCHES ................................................................................................34
Instrument Panel Gauge Cluster.................................................................................................................................................................... 35
Warning Lamps................................................................................................................................................................................................ 35
Maintenance Lamp ........................................................................................................................................................................................ 35
Amber Warning Lamp (AWL) ........................................................................................................................................................................ 35
Red Stop Lamp (RSL) ................................................................................................................................................................................... 36
Malfunction Indicator Lamp (MIL) .................................................................................................................................................................. 36
Gauges ............................................................................................................................................................................................................. 37
Typical Water Temperature Gauge ............................................................................................................................................................... 37
Oil Temperature Gauge................................................................................................................................................................................. 37

Oil Pressure Gauge ....................................................................................................................................................................................... 37
SECTION 4 – ENGINE OPERATION ...........................................................................................................................................38
Pre-operation Checklist .................................................................................................................................................................................. 39
Starting the Engine.......................................................................................................................................................................................... 40
Starting Engine After Running Out of Fuel................................................................................................................................................... 41
Emergency Starting......................................................................................................................................................................................... 42
Operation.......................................................................................................................................................................................................... 43
Idle Speed ..................................................................................................................................................................................................... 43
Cold Weather Operation................................................................................................................................................................................ 43
Hot Weather Operation.................................................................................................................................................................................. 44
Engine Shutdown .......................................................................................................................................................................................... 44
Engine Warning Protection System (EWPS)................................................................................................................................................. 45
Heavy Duty On Board Diagnostics (OBD HD) Overview .............................................................................................................................. 46
Road Speed Governor (RSG) ....................................................................................................................................................................... 46
Road Operation ............................................................................................................................................................................................. 46
SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES .............................................................................47
Maintenance Schedule.................................................................................................................................................................................... 48
Service Procedure ........................................................................................................................................................................................... 49
Coolant Level................................................................................................................................................................................................. 50
Coolant Freeze Point..................................................................................................................................................................................... 50
External Leakage........................................................................................................................................................................................... 50
Belt, Air Intake Piping And Clamps ............................................................................................................................................................... 51
Oil Level......................................................................................................................................................................................................... 54
Engine Oil And Filter...................................................................................................................................................................................... 55
Electrical System ........................................................................................................................................................................................... 56

SECTION 6 – LONG TERM STORAGE .......................................................................................................................................57
General Information ........................................................................................................................................................................................ 58
SECTION 7 – SERVICE RECORDS.............................................................................................................................................60
Maintenance Service Record ......................................................................................................................................................................... 61
Daily Care and Report ..................................................................................................................................................................................... 65
APPENDIX ...................................................................................................................................................................................68
Engine Specifications ..................................................................................................................................................................................... 69

1| Page
FOREWORD

2 | Page
FOREWORD
Foreword
Power Solutions International, Inc. is committed to continuous
research and development to improve products and introduce
technological advances. Procedures, specifications, and
parts defined in published technical service literature may
be altered.
NOTE: Photo illustrations identify specific parts or
assemblies that support text and procedures; other
areas in a photo illustration may not be exact.
This manual includes necessary information and specifications
for operators to operate and maintain the PSI 8.8L Gasoline
engine. Contact your dealer for more information.
Refer to the applicable technical service literature
Engine Service & Diagnostic Manual
Warranty Policy and Procedures Manual
About the Manual
This manual contains information needed to correctly operate
and maintain your engine as recommended by PSI. Numerous
illustrations, symbols and feature descriptions are used to aid in
understanding the meaning of the text. The illustrations,
symbols or feature descriptions may not be available for all
applications, please contact your dealer for complete
information. Both metric and U.S. customary values are listed
in this manual. The U.S. Customary value is listed first, followed
by the metric value in brackets. For additional service literature
refer to Service Literature noted in this manual. This manual
does not cover vehicle or equipment maintenance procedures.
When referring to the left-hand or right-hand side of the
engine, this will be as viewed from the rear. (Looking at
the flywheel)
Consult the original vehicle or equipment manufacturer for
specific maintenance recommendations.
Technical Service Literature is revised periodically. Use only
up-to-date service information.
To order technical service literature, contact your dealer.
All marks are trademarks of their respective owners.

3| Page
SAFETY INFORMATION

4 | Page
SAFETY INFORMATION
Safety Information
This manual provides general and specific maintenance
procedures essential for reliable engine operation and your safety.
Since many variations in procedures, tools, and service parts exist,
advice for all possible safety conditions and hazards cannot be
stated.
Read safety instructions before doing any service and test
procedures for the engine. See related manuals for more
information.
Obey Safety Instructions, Warnings, Cautions, and Notes in this
manual. Not following Warnings, Cautions, and Notes can lead to
injury, death, or damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe operation of
the engine: Warning, Caution, and Note.
Warning: A warning describes actions necessary to prevent or
eliminate conditions, hazards, and unsafe practices that can cause
personal injury or death.
Caution: A caution describes actions necessary to prevent or
eliminate conditions that can cause damage to the engine or
vehicle.
Note: A note describes actions necessary for correct, efficient
engine operation.
Safety Instructions
Work Area
•Keep work area clean, dry, and organized.
•Keep tools and parts off the floor.
•Make sure the work area is ventilated and well lit.
•Make sure a First Aid Kit is available.
Safety Equipment
•Use correct lifting devices.
•Use safety blocks and stands.
Protective Measures
•Wear protective safety glasses and shoes.
•Wear correct hearing protection.
•Wear cotton work clothing.
•Wear sleeved heat protective gloves.
•Do not wear rings, watches or other jewelry.
•Restrain long hair.

5| Page
SAFETY INFORMATION
Gasoline Safety Specifications
Specification Value Unit
Initial Boiling Point @14.7 psi 399 (204) °F (°C)
Weight per Gallon @ 60°F 6.24 (2.83) lbs/gal (kg/L)
Ignition Temperature in Air 536 (280) °F (°C)
Air Fuel Ratio by Mass 14.7:1

6 | Page
SAFETY INFORMATION
Vehicle
•Shift transmission to park or neutral, set parking brake, and
block wheels before doing diagnostic or service procedures.
•Clear the area before starting the engine.
Engine
•The engine should be operated or serviced only
by qualified individuals.
•Provide necessary ventilation when operating engine in a
closed area.
•Keep combustible material away from engine exhaust
system and exhaust manifolds.
•Install all shields, guards, and access covers before
operating engine.
•Do not run engine with unprotected air inlets or exhaust
openings. If unavoidable for service reasons, put protective
screens over all openings before servicing engine.
•If an engine is not safe to operate, tag the engine and
ignition key.
Fire Prevention
•Make sure charged fire extinguishers are in the work area.
NOTE: Check the classification of each fire extinguisher
to ensure the following fire types can be extinguished.
1. Type A — Wood, paper, textiles, and rubbish
2. Type B — Flammable liquids
3. Type C — Electrical equipment
Batteries
•Always disconnect the main negative battery cable first.
•Always connect the main negative battery cable last.
•Avoid leaning over batteries.
•Protect your eyes.
•Do not expose batteries to flame or sparks.
•Do not smoke in workplace.
Compressed Air
•Use an OSHA approved blow gun. Limit blow gun air
pressure to 30 psi (207 kPa).
•Wear safety glasses or goggles.
•Wear hearing protection.
•Use shielding to protect others in the work area.
•Do not direct compressed air at body or clothing.

7| Page
SAFETY INFORMATION
Tools
•Make sure all tools are in good condition.
•Make sure all standard electrical tools are grounded.
•Check for frayed power cords before using power
tools.
Fluids Under Pressure
•Use extreme caution when working on systems under
pressure. Pay close attention when working with the
fuel system.
•Follow approved procedures only.
Fuel
•Do not smoke in the work area.
•Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
•Reinstall all safety guards, shields, and covers after
servicing the engine.
•Make sure all tools, parts, and service equipment are
removed from the engine and vehicle after all work is done.
Refueling
WARNING: Fuel vapors and fuel fires burn violently and can
cause injury or death.
•To help avoid injuries to you and others, read and follow all
the instructions on the fuel pump island.
•Turn off the engine when refueling.
•Keep sparks, flames, and smoking materials away from fuel.
•Do not leave the fuel pump unattended.
•Do not use a cell phone while refueling.
•Do not re-enter the vehicle while pumping fuel.
•Keep children away from the fuel pump and never let
children pump fuel.
•Fuel can spray out if the fuel cap is opened too quickly. This
spray can happen if the tank is nearly full, and is more likely
in hot weather. Open the fuel cap slowly and wait for any
hiss noise to stop, then unscrew the cap all the way.
WARNING: Overfilling the fuel tank by more than three
clicks of a standard fill nozzle may cause:
oVehicle performance issues, including engine
stalling and damage to the fuel system.
oFuel spills.
oPotential fuel fires.
•Be careful not to spill fuel. Wait a few seconds after you
have finished pumping before removing the nozzle.

8 | Page
SAFETY INFORMATION
Refueling (cont.)
•When replacing the fuel cap, follow OEM
recommendations on tightening procedure.
•The diagnostic system can determine if the fuel cap has
been left off or improperly installed. This would allow fuel
to evaporate into the atmosphere.
WARNING: If a fire starts while you are refueling, do not
remove the nozzle. Shut off the flow of fuel by shutting off the
pump or by notifying the station attendant. Leave the area
immediately.
CAUTION: If a new fuel cap is needed, be sure to get the right
type of cap from your service center. The wrong type of fuel
cap may not fit properly, may cause the malfunction indicator
lamp to light, and could damage the fuel tank and emissions
system.
General Safety Instructions
WARNINGS:
•Keep all sources of ignition away from gasoline vehicles
while the fuel system is being serviced. Even if the tank and
fuel lines are empty, there may still be flammable vapors
near the vehicle.
•Do not disconnect any gasoline hoses unless they have
been completely drained using the proper procedure.
•Always unplug the fuel control box or disconnect the
battery before you work on any part of the fuel system

9| Page
WARRANTY

10 | Page
WARRANTY
Warranty
EPA and CARB Emission System Warranty
WARRANTY PERIOD
Government agencies including the United States Environmental
Protection Agency (EPA) and the California Air Resources Board
(CARB) require Power Solutions International, Inc. to provide
emissions warranty to end users. PSI must warrant the engine is
designed, built and equipped so as to conform at the time of sale
with applicable regulations and be free from defects in materials
and workmanship for a defined period of years or miles,
whichever occurs first (Emissions Warranty). PSI will provide
emissions warranty coverage as required by the EPA and CARB
regulatory agencies. Emissions Warranty does not cover,
remanufactured, dealer rebuilt or dealer exchange engines.
•5 years
•50,000 miles (80,467 km)
•Or if covered by any basic or extended warranty (if greater
than above)
Your 8.8L Gasoline engine conforms to U.S. Environmental
Protection Agency (EPA) regulations for emission systems.
The California Air Resources Board, United States
Environmental Protection Agency and Power Solutions
International, Inc. are pleased to explain the emission control
system warranty on your PSI 8.8L Gasoline engine. In California,
new motor vehicles must be designated, built and equipped to
meet the State's stringent anti-smog standards. Power Solutions
International, Inc. warrants the emission control system on your
engine for the periods of time listed, provided there has been no
abuse, neglect or improper maintenance of your vehicle.
Your emission control system includes parts such as the fuel-
injection system, the ignition system, catalytic converter, and
engine computer. Also, included may be hoses, belts, connectors
and other emission-related assemblies.
Where a warrantable condition exists, Power Solutions
International, Inc. will repair your truck at no cost to you including
diagnosis, parts and labor.
Manufacturer's Warranty Coverage
5 years or 50,000 miles (whichever first occurs):
1) If your truck fails a Smog Check inspection, all necessary
repairs and adjustments will be made by Power Solutions
International, Inc. to ensure that your emission control system is
working properly. This is your Emission Control System
PERFORMANCE WARRANTY.
2) If any emission-related part on your truck is defective, the
part will be repaired or replaced by Power Solutions International,
Inc. This is your short-term emission control system DEFECTS
WARRANTY.

11 | Page
WARRANTY
Federal Emission System Warranty (cont.)
Owner's Warranty Responsibilities
As the truck owner, you are responsible for the performance of
the required maintenance listed in your Operation and
Maintenance manual. Power Solutions International, Inc.
recommends that you retain all receipts covering maintenance on
your truck, but Power Solutions International, Inc. cannot deny
warranty solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.
You are responsible for presenting your truck to a certified dealer
as soon as a problem exists. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30
days.
As the truck owner, you should also be aware that Power
Solutions International, Inc. may deny you warranty coverage if
your truck or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
In the case of emergency when a warranted part or warranty
station is not reasonably available to you, repairs may be
performed at any available service establishment, or by you,
using any replacement part. Power Solutions International, Inc.
will reimburse you for your expenses including diagnostic
charges for such an emergency repair or replacement, which
cannot exceed Power Solutions International, Inc's suggested
retail price for all warranted parts replaced and labor charges
based on Power Solutions International, Inc's recommended time
allowance for the warranty repair and the geographically
appropriate hourly labor rate.
All receipts and failed parts must be kept in order to receive
compensation for warranted repairs reimbursable due to an
emergency.
If you have any questions regarding your warranty rights and
responsibilities, you should contact Power Solutions
International, Inc. at 888-331-5764 or the California Air Resource
Board at 9528 Telstar Avenue, El Monte, CA 91731.

12 | Page
WARRANTY
Federal Emission System Warranty (cont.)
Warranty Exclusions
The following items are not reimbursable under the PSI
warranty terms.
•Any repair on an engine that has exceeded the hour, time
or mileage limitation of the stated warranty.
•PSI may deny any claims that in their sole discretion are the
result of misapplication of the engine or part.
•Units that are under development (i.e. prototype projects,
engineering projects).
•Any repair on an engine where the hours of operation,
mileage or in-service date has been misrepresented.
•Any repair on an engine if the hour meter or odometer has
been altered so that the true hours on the engine cannot be
determined.
•Any repair on an engine where the date of service has been
misrepresented to place an out-of-warranty engine inside the
warranty period.
•Engines damaged by an Act of God or force majeure.
•Routine maintenance repairs.
•Repairs required due to improper storage precautions.
•Adjustments made to improve performance beyond
PSI estimated normal standards.
•Use of other than genuine OEM parts, unless in an
emergency situation.
•Any failure that is a result of the application and not a defect in
the materials or workmanship from PSI as deemed by PSI.
•Repairs to parts that, upon analysis, are found not to
be defective.
•Repairs to engines used for re-powering on-road vehicles.
•All consequential expenses, including, but not limited to, those
resulting from equipment failure such as lodging, food,
downtime or replacement equipment rental.
•Any misapplication or misuse of the product as
deemed by PSI.
•Towing or transportation expense for moving an engine or
engine-powered equipment from the customer location to the
repair location.
•Repairs caused by damage due to poor workmanship.
For additional warranty information please refer to the "Power
Solutions International Warranty Policy and Procedures
Manual".

13 | Page
SECTION 1 – ENGINE SYSTEMS

14 | Page
SECTION 1 – ENGINE SYSTEMS
Engine Serial Number
The engine serial number can be found in two locations.
The serial number label will be located on the
right-hand side valve cover as shown in Figure 2.
The number will also be stamped on the left-hand
side of the engine, near the flywheel as shown in
Figure 3.
Engine Serial Number Examples
8.8L12345
Engine Serial Number Codes
8.8L - Engine Displacement
12345 - Engine Serial Number
Figure 1: Serial Number Label Example
Figure 2: Serial Number Label Location
Figure 3: Stamped Location of Serial Number