Esg 642

OPERATOR HANDBOOK
ESG
642
LIQUEFIED PETROLEUM GAS (LPG)
GASOLINE (EFI) &
NATURAL GAS (NG) ENGINES
FPP 194-308
JANUARY, 2004
WARNING:
WARNING: ENGINE EXHAUST, SOME OF ITS CONSTITUENTS, AND
CERTAIN VEHICLE COMPONENTS CONTAIN OR EMIT CHEMICALS
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM. IN ADDITION, CERTAIN
FLUIDS CONTAINED IN VEHICLES AND CERTAIN PRODUCTS OF
COMPONENT WEAR CONTAIN OR EMIT CHEMICALS KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR
OTHER REPRODUCTIVE HARM.
FORD ESG-642 ENGINES
GASOLINE (EFI)
LIQUEFIED PETROLEUM GAS (LPG)
NATURAL GAS (NG)
Reproduction in any manner, in whole or in part, is prohibited without the

express permission in writing from
Ford Power Products, Publications Department
Ford Power Products policy is one of continuous improvement and while every
effort is made to ensure that this publication is up to date and correct in all respects,
the right to change prices, specifications and equipment at any time without notice
is reserved. Accordingly this publication is not to be regarded as a final description
of any individual engine.
1
CONTENTS
HEALTH & SAFETY ............................................................................................. 4
General Guidelines: ...................................................................................... 4
Important Safety Notice................................................................................. 4
Notes, Cautions, and Warnings .................................................................... 5
FORWARD ........................................................................................................... 6
ENGINE IDENTIFICATION................................................................................... 6
U.S.A. Engine Identification Decal ................................................................ 7
Non-Certified Engine Decal........................................................................... 7
Federal Emissions Warranty Statement........................................................ 8
California Emission Control Warranty Statement .......................................... 8
What Is Covered? ....................................................................................... 10
European Service Identification Plate ......................................................... 11
PARTS AND SERVICE....................................................................................... 12
SERVICE LITERATURE..................................................................................... 12
WARRANTY REGISTRATION ........................................................................... 12
BEFORE OPERATING THE ENGINE ................................................................ 13
OPERATING CONTROLS.................................................................................. 13
Ignition or Isolation Switch .......................................................................... 13
Safety Switch (where fitted) ........................................................................ 14
Power Take-off (where fitted) ...................................................................... 14
Throttle Control (where fitted) ..................................................................... 14
INSTRUMENTS .................................................................................................. 15
Ammeter (Where Fitted).............................................................................. 15
Battery Condition Indicator (Where Fitted) .................................................. 15
Tachometer (Where Fitted) ......................................................................... 15
Hourmeter (Where Fitted) ........................................................................... 15
Oil Pressure Gauge (Where Fitted)............................................................. 15
Temperature Gauge (Where Fitted) ............................................................ 16
Water in Fuel Light (Where Fitted) .............................................................. 16
Malfunction Indicator Light (Where Fitted) .................................................. 16
Charge Indicator Light (Where Fitted) ......................................................... 16
Safety Switch Override Button (Where Fitted) ............................................ 16
Ignition or Isolation Switch .......................................................................... 16
Fuel Gauge (Where Fitted) ......................................................................... 16
STARTING THE ENGINE ................................................................................... 17
Initial Start-up .............................................................................................. 17
To Start From cold ...................................................................................... 17
To Re-start When Warm ............................................................................. 17
Engine Flooded (EFI Only).......................................................................... 17
2
CONTENTS
STOPPING THE ENGINE .................................................................................. 18
Normal Conditions....................................................................................... 18
Abnormal Conditions ................................................................................... 18
RUNNING-IN PROCEDURE .............................................................................. 18
FUEL RECOMMENDATION ............................................................................... 19
Fuel Quality ................................................................................................. 19
Alcohol Gasoline Blends (Gasohol) ............................................................ 20
LUBRICATION AND MAINTENANCE ................................................................ 20
RECOMMENDED MAINTENANCE SCHEDULES ............................................. 21
RECOMMENDED MAINTENANCE OPERATIONS ........................................... 22
Recommended Lubricants .......................................................................... 22
Used Engine Oils ........................................................................................ 23
Change Engine Oil ...................................................................................... 23
Check Engine Oil Level ............................................................................... 24
Renew Engine Oil Filter .............................................................................. 24
Gasoline Fuel System - EFI ........................................................................ 24
Fuel Filter - EFI ........................................................................................... 25
Ignition System - DIS .................................................................................. 26
Renew Spark Plugs..................................................................................... 26
Electronic Actuator ...................................................................................... 27
Check Condition of Ancillary Drive Belts ..................................................... 27
Check Engine Coolant Level....................................................................... 27
Renew Air Cleaner Element ........................................................................ 28
Renew PCV Valve....................................................................................... 28
GENERAL MAINTENANCE INFORMATION ..................................................... 29
Cooling System ........................................................................................... 29
Draining, Flushing and Filling the Cooling System...................................... 31
Engine Lubrication System ......................................................................... 31
Electrical System......................................................................................... 32
Generator .................................................................................................... 33
Storage........................................................................................................ 34
ENGINE SYSTEM CHECK................................................................................. 35
SPECIFICATIONS .............................................................................................. 38
TIGHTENING TORQUES ................................................................................... 39
CONVERSION TABLE ....................................................................................... 40
FORD POWER PRODUCTS SERVICE ............................................................. 41
3
HEALTH & SAFETY
WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS

SHOULD BE CAREFULLY OBSERVED.
Carrying out certain operations and handling some substances can be dangerous
or harmful to the operator if the correct safety precautions are not observed. Some
such precautions are recommended at the appropriate points in this book.
While it is important that these recommended safety precautions are observed,
care near machinery is always necessary, and no list can be exhaustive. ALWAYS
BE ON YOUR GUARD!
General Guidelines:
The following recommendations are for general guidance:
1. Always wear correctly fitting protective clothing which should be laundered
regularly. Loose or baggy clothing can be extremely dangerous when working
on running engines or machinery. Clothing which becomes impregnated with oil
or other substances can constitute a health hazard due to prolonged contact
with the skin even through underclothing.
2. So far as practicable, work on or close to engines or machinery only when they
are stopped. If this is not practicable, remember to keep tools, test equipment
and all parts of the body well away from the moving parts of the engine or
equipment—fans, drive belts and pulleys are particularly dangerous. The
electric cooling fan used on some installations is actuated automatically when
the coolant reaches a specified temperature. For this reason, care should be
taken to ensure that the ignition/isolating switch is OFF when working in the
vicinity of the fan as an increase in coolant temperature may cause the fan
suddenly to operate.
3. Avoid contact with exhaust pipes, exhaust manifolds and silencers when an
engine is, or has recently been running; these can be very hot and can cause
severe burns.
4. Many liquids used in engines or vehicles are harmful if taken internally or
splashed into the eyes. In the event of accidentally swallowing gasoline (petrol),
oil, diesel fuel, antifreeze, battery acid etc., DO NOT ENCOURAGE VOMITING
AND OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Wear protective goggles when handling liquids which are harmful to the eyes;
these include ammonia and battery acid. If any of these substances are splashed
in the eyes, wash out thoroughly with clean water and OBTAIN QUALIFIED
MEDICAL ASSISTANCE IMMEDIATELY.
Important Safety Notice
Appropriate service methods and proper repair procedures are essential for the
safe, reliable operation of all industrial engines as well as the personal safety of the
individual doing the work. This operator handbook provides general directions for
accomplishing service and repair work with tested, effective techniques. Following
them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for
servicing equipment, as well as in the skill of the individual doing the work. This
4
manual cannot possibly anticipate all such variations and provide advice or
cautions as to each. Accordingly, anyone who departs from the instructions
provided in this Manual must first establish that neither personal safety nor
equipment integrity are compromised by the choice of methods, tools or parts.
Notes, Cautions, and Warnings
As you read through the procedures, you will come across NOTES, CAUTIONS,
and WARNINGS. Each one is there for a specific purpose. NOTES gives you
added information that will help you to complete a particular procedure.
CAUTIONS are given to prevent you from making an error that could damage the
equipment. WARNINGS remind you to be especially careful in those areas where
carelessness can cause personal injury. The following list contains some general
WARNINGS that you should follow when you work on the equipment.
GENERAL WARNINGS:
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the
equipment.
• Be sure that the ignition switch is always in the OFF position, unless otherwise
required by the procedure.
• Set the parking brake (if equipped) when working on the equipment. If you have
an automatic transmission, set it in PARK REVERSE (engine off) or NEUTRAL
(engine on) unless instructed otherwise for a specific operation. Place wood
blocks (4”x 4” or larger) to the front and rear surfaces of the tires to provide
further restraint from inadvertent equipment movement.
• Operate the engine only in a well ventilated area to avoid the danger of carbon
monoxide.
• Keep yourself and your clothing away from moving parts when the engine is
running, especially the fan belts.
• To prevent serious burns, avoid contact with hot metal parts such as the
radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on the equipment.
• To reduce the risk of injury, always remove rings, watches, loose hanging
jewelry, and loose clothing before beginning to work on the equipment. Tie long
hair securely behind the head.
• Keep hands and other objects clear of the radiator fan blades. Electric cooling
fans can start to operate at any time by an increase in underhood temperatures,
even though the ignition is in the OFF position. Therefore, care should be taken
to ensure that the electric cooling fan is completely disconnected when working
under the hood.
5
FORWARD
This book contains operating and maintenance instructions for the engine(s) listed
on the title page.
The life of your engine unit and the delivery of the high performance built into it will
depend on the care it receives throughout its life. It is the operator’s responsibility
to ensure that the engine is correctly operated and that the maintenance
operations outlined in this book are carried out regularly after the specified hours
of operation have been reached. We consider it to be in your interests to enlist the
aid of an authorized Ford Power Products Distributor not only when repairs are
required but also for regular maintenance. Distributors are listed at the back of this
handbook.
Regular maintenance will result in minimal operating costs.
Engines manufactured by Ford Motor Company are available through Ford Power
Products Distributors. When in need of parts or service, contact your local
Authorized Distributor. In overseas territories, in the event of difficulties,
communicate directly with the supervising Ford affiliated Company in your area
whose address appears at the end of this book.
Where the terms “Right” or “Left” occur in this publication, they refer to the
respective sides of the engine when viewed from the rear or flywheel end.
Pistons and valves are numbered from the front or timing cover end of the engine
commencing at No. 1.
You may find that your engine assembly includes optional equipment not
specifically covered in the following text. Nevertheless, the maintenance
procedures outlined in this book still apply to your engine
ENGINE IDENTIFICATION
Because Ford Power Products Operations markets such a wide range of industrial
gasoline and diesel engines - manufactured both in the U.S. and overseas - it is
important that you have as complete identification of the engine as possible in
order to provide the correct replacement parts. Review the list of Ford Power
Product distributors for a distributor in your area. You can obtain a standard parts
listing describing the parts. It remains a distributor function to identify the part
number.
The key to identifying the engine is the identification decal mounted on the engine
rocker cover. That decal provides not only the engine serial number, but also the
exact model or type, configuration code and customer name. The combination of
that data permits you to isolate the precise engine, build level and customer so you
can determine the correct replacement parts.
6
U.S.A. Engine Identification Decal
An identification Decal is affixed to the valve cover of the engine. The decal
contains the engine serial number which identifies this unit from all others. Use all
numbers when seeking information or ordering replacement parts for this engine.
ESG-642L
For handy reference, transfer the data recorded on this decal onto your Ford Power
Products Engine Warranty Registration copy (Form #194-103-D).
Unique Engine
Serial Number
Fuel Type
Non-Certified Engine Decal

The identification decal shown below is an example (Non-certified engine build
shown) OF THE DECAL THAT MUST BE AFFIXED to the valve cover of the
engine for a Non-certified engine build or export of an engine outside of the United
States.
Unique Engine
Serial Number
7
Federal Emissions Warranty Statement
Ford Power Products is pleased to explain the emission control system
warranty on your 2004 or later model year compliant certified off-road large
spark-ignition (LSI) engine. Ford Power Products warrants that your new off-road
LSI is designed, built, and equipped to meet the applicable EPA emissions
requirements and is free from defects in factory supplied materials and
workmanship that could prevent it from conforming with these requirements.
Ford Power Products provides the following emissions warranty coverage for your
new off-road LSI engine:
• Three (3) years or 2500 hours, whichever occurs first, for emissions-related
parts (see list below).
• Five (5) years or 3500 hours, whichever occurs first, for high-priced emissions-
related parts (see list below).
In cases where the Original Equipment Manufacturer has sourced components
from suppliers other than Ford Power Products, the Original Equipment
Manufacturer will be responsible for warranty related to these components.These
parts are noted in the “What is Covered” section with the statement “(Supplied and
Warranted by Original Equipment Manufacturer)”.
You will not be charged for repair, replacement, or adjustment of defective
emissions-related parts listed below.
Concerning parts that should be replaced during scheduled maintenance, these
parts remain under warranty until the first scheduled maintenance specified in the
maintenance schedule or the applicable coverage period listed above, whichever
occurs first.
California Emission Control Warranty Statement
Your Warranty Rights and Obligations
The California Air Resources Board and Ford Power Products are pleased to
explain the emission control system warranty on your 2004 or later model year
compliant certified off-road large spark-ignition engine. In California, new off-road
large spark-ignition (LSI) engines must be designed, built and equipped to meet the
State's stringent anti-smog standards. Ford Power Products must warrant the
emission control system on your compliant certified engine for the periods of time
listed below provided there has been no abuse, neglect or improper maintenance
of your engine.
Your emission control system may include parts such as the carburetor, regulator,
or fuel-injection system, ignition system, engine computer unit (ECM), catalytic
converter, and air induction system. Also included may be sensors, hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, Ford Power Products will repair your LSI
compliant certified engine at no cost to you including diagnosis, parts and labor.
In cases where the Original Equipment Manufacturer has sourced components
from suppliers other than Ford Power Products, the Original Equipment
Manufacturer will be responsible for warranty related to these components. These
parts are noted in the “What is Covered” section with the statement “(Supplied and
Warranted by Original Equipment Manufacturer)”.
8
Manufacturer's Warranty Coverage:
The 2004 or later off-road large spark-ignition compliant certified engines are
warranted for three (3) years or 2500 hours, whichever occurs first. High cost
emission related parts are warranted for five (5) years or 3500 hours, whichever
occurs first. If any emission-related part on your engine fails to perform as
designed within the warranty period, the part will be repaired or replaced by Ford
Power Products (see list below).
Owner's Warranty Responsibilities:

As the off-road LSI engine owner, you are responsible for the performance of the
required maintenance listed in your owner's manual. Ford Power Products
recommends that you retain all receipts covering maintenance on your off-road
engine, but Ford Power Products cannot deny warranty solely for the lack of
receipts or for your failure to ensure the performance of all scheduled maintenance.
As the off-road large spark-ignition engine owner, you should however be aware
that Ford Power Products may deny you warranty coverage if your off-road large
spark-ignition engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Your compliant certified engine is designed to operate on gasoline, liquefied
propane gas or natural gas when properly equipped. Use of any other fuel may
result in your engine no longer operating in compliance with California's emissions
requirements.
You are responsible for initiating the warranty process. The ARB suggests that you
present your off-road large spark-ignition engine to a Ford Power Products dealer
as soon as a problem exists. The warranty repairs should be completed by an
authorized FPP distributor or service dealer as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you
should contact a Ford Power Products customer service representative at
1 800 521 0370
9
What Is Covered?
The Federal and California emission warranties cover the following parts.
1. Air / Fuel Feedback Control System and Sensors

2. Air Induction System (Supplied and Warranted by Equipment Manufacturer)
3. Carburetor system (internal parts and/or pressure regulator or fuel mixer or
injection system)
4. Catalytic Converter
5. Electronic Engine Control Sensors and Switches
6. Electronic Ignition System
7. Exhaust Manifold and Gaskets
8. Exhaust Pipe between Exhaust Manifold and Catalyst (Supplied and Warranted
by Equipment Manufacturer)
9. Fuel Injection System
10.Fuel Injector Supply Manifold
11.Electric Fuel Pump
12.Fuel Pressure Regulator
13.Gaseous Fuel System Assembly
14.Idle Air Control Valve Block off Plate and Gasket
15.Ignition Coil and/or Control Module
16.Intake Manifold and Gaskets
17.Malfunction Indicator Lamp
18.PCV System and Oil Filler Cap
19.Engine Performance Module
20.Solenoid Assembly - Carburetor Feedback Control
21.Spark Control Components
22.Spark Plugs and Ignition Wires
23.Synchronizer Assembly
24.Thermostat Assembly
25.Throttle Body Assembly and Gaskets
NOTE: All emissions related bulbs, hoses, clamps, brackets, tubes, gaskets, seals,
belts, connectors, fuel lines, and wiring harnesses used with the above
components are also covered.
Components That Are Considered High Priced Parts

1. Catalytic Converter
2. Catalytic Converter Muffler
3. Engine Performance Module
4. Engine Wiring Harness
5. Fuel System (Gaseous) - Mixer (4.2L engine only)
6. Fuel System (Gaseous) - Regulator, Fuel Pressure (4.2L engine only)
7. Fuel System (Gaseous) - Trimming Device
8. Intake Manifold (2.5L and 4.2L engine only)
10
European Service Identification Plate
This plate is fixed to the engine in a
prominent position. Panels 1 to 6 on
the plate shown to the right, refer to 1
various engine details as listed below:
2 3 4
1. Serial No: This identifies the
engine as supplied by Ford Power 5
Products.
Date: The two letters following the 6
serial No. indicate the year and
month in which the specified build
components were assembled - refer to the chart below:
YEAR JAN FEB MAR APRIL MAY JUNE JULY AUG SEP OCT NOV DEC
1997 U B R A G C K D E L Y S T
1998 V J U M P B R A G C K D E
1999 W L Y S T J U M P B R A G
2000 X C K D E L Y S T J U M P
2001 Y B R A G C K D E L Y S T
2002 Z J U M P B R A G C K D E
2003 A L Y S T J U M P B R A G
2004 B C K D E L Y S T J U M P
2005 C B R A G C K D E L Y S T
2006 D J U M P B R A G C K D E
NOTE: The letters I, O and Q are not used in the year column. The letter
representing the month repeats every five years.
2. This identifies the country of origin of the engine.
3. Engine capacity in liters.
4. Engine model identification.
5. The Build Number indicates the complete specification. The digit to the extreme
right hand side is the build scheme chart issue number.
6. This space is provided for Equipment Manufacturers’ use when extra
equipment is fitted outside of the Ford Motor Company. Reference should be
made to the Equipment Manufacturer for any information or parts required.
11
PARTS AND SERVICE
Replacement parts can be obtained through your local Ford Power Products
Distributors listed in the back portion of this handbook. They also may be found in
the yellow pages under “Engines” or contact Ford Power Products: 1-800 833-
4773 U.S.A. or 44-1708-672-677 Europe.
Ford Power Products Distributors are equipped to perform major and minor
repairs. They are anxious to see that all of your maintenance and service needs
are quickly and courteously completed.
SERVICE LITERATURE
A service manual can be purchased from your distributor. This publication will
provide the necessary servicing and overhaul information for your Ford Power
Products engine.
• SERVICE MANUAL FPP 194-303

• PART LIST FPP 194-310A
• ENGINE SPECIFICATION MANUAL FPP 194-311
• OPERATOR HANDBOOK FPP 194-308
WARRANTY REGISTRATION
The Warranty Registration form must be completed by the consumer or final
purchaser and returned to Ford Power Products to establish an in-service date or
warranty start date. When an in-service date is not established by a Warranty
Registration form, the warranty start date for your new Ford Engine is calculated
from the time a Ford Power Products Distributor purchased the engine.
The Warranty Registration form is supplied with all Ford Power Products engines
and has a postage paid and addressed return envelope. Please complete this form
when you receive your new Ford engine or product powered by a Ford engine.
Retain the purchaser’s copy and mail the remainder of the form using the pre-paid
postage and addressed envelope. For more information or assistance please call
your nearest Ford Power Products Distributor listed in the back of this manual, or
contact Ford Power Products:
• USA: 1-800-833-4773
• Europe: 44-1708-672-677
12
BEFORE OPERATING THE ENGINE
1. Before operating a new engine it should be thoroughly inspected to ensure that
during transit and installation it has not suffered damage likely to affect its
subsequent operation. Controls and instruments should be studied carefully in
order that their functions are thoroughly understood.
2. Check that the radiator (where applicable) is full and top off as necessary --
Refer to “Cooling System” on page 29 for recommended coolant mixtures.
3. In the case of marine/industrial engines, ensure that there is coolant in the
degas/expansion tank (where applicable).
CAUTION: Under no circumstances may the engine be started without liquid

in the cooling system.
4. Check the engine oil level and top up or fill as necessary -- Refer to “Check
Engine Oil Level” on page 24. For the correct type and grade of oil -- Refer to
“Recommended Lubricants” on page 22.
5. Ensure that the battery is fully charged and, if necessary, top up with distilled
water.
NOTE: Ensure that ALL wiring ground connections are properly made to a clean
point on the chassis/frame.
6. The engine must be started in accordance with the starting instructions -- Refer
to “STARTING THE ENGINE” on page 17.
OPERATING CONTROLS
Ignition or Isolation Switch
An ignition or isolation switch is usually fitted which connects the engine starter
motor and other electrical equipment to the battery. The switch can be moved to
any of the four positions shown by rotating the key. These positions are:
Off Run
Auxiliary Circuits Start
1. Auxiliary Circuits - When moved to this position the auxiliary electrical

equipment such as radios and heater fans, can be operated without also
connecting the starting circuit with the battery.
2. Off - When set to this position, the switch disconnects the auxiliary electrical
equipment and the starting circuit from the battery. The key can be removed
from the switch when it is in this position; this will help to prevent unauthorized
operation of the engine.
3. Run - This switch position connects the auxiliary circuits as described
previously, and the alternator is given initial excitation via the battery.
13
4. Start - In this position, the starter solenoid is energized and the starter motor
cranks the engine. The switch, when released, automatically returns to the RUN
position.
Safety Switch (where fitted)
A low oil pressure/high water temperature safety switch may be fitted. This
automatically shuts off the ignition when the oil pressure drops below a pre-set
value, or when the water temperature rises above a pre-set value. A button on the
instrument panel is used to override the safety switch when starting the engine.
The safety switch override button must be depressed to start the engine.
Power Take-off (where fitted)
The power take-off control handle allows engagement and disengagement of the
power take-off clutch. Moving the lever towards the engine engages the clutch and
moving the lever away from the engine disengages the clutch.
When moving the handle to engage the clutch and pick up the load, do so in a
smooth manner. Moving the clutch handle too slowly will cause slippage and wear,
while moving it too fast will cause quick engagement and possible damage to the
power take-off, engine or driven equipment. The normal force required to engage
the clutch is 55 lbf (245 N) for the over-centre type and 25 lbf (110 N) for the spring
loaded type.
Throttle Control (where fitted)
The throttle control adjusts engine speed. Initial engine speed adjustment is
obtained by pressing the throttle control release button while pulling the throttle
knob out to increase the engine speed or pushing it in to decrease the engine
speed.
A final fine speed adjustment is obtained by turning the throttle control
counterclockwise to increase engine speed or clockwise to decrease engine
speed.
14
INSTRUMENTS
Your Ford Powered Equipment will have been fitted with instruments selected by
the manufacturer. The types of instruments most likely to be encountered are
detailed here. A typical instrument panel is shown below.
Ammeter Oil Pressure Gauge
Combined
Temp. Gauge
Tach/Hour Meter
Charge Indicator Light Safety Switch

Override Button
Malfunction Indicator
Fuel Select Switch
Lamp (MIL)
Ignition or isolation Switch
Ammeter (Where Fitted)

This instrument registers the charging current which is being passed to the battery
from the alternator. It also registers a discharge equivalent to the amount of current
being used by the electrical equipment when the alternator is not charging.
Battery Condition Indicator (Where Fitted)
This is sometimes fitted instead of an ammeter and measures the battery voltage
thus indicating the state of charge of the battery.
Tachometer (Where Fitted)
The tachometer indicates the actual engine running speed in crankshaft
revolutions per minute.
Hourmeter (Where Fitted)
This instrument records the number of hours of operation which the engine has
completed at the rated rpm. It is frequently combined with the tachometer and is
used to determine when an engine service operation is required. If no hourmeter is
fitted, a log should be kept.
Oil Pressure Gauge (Where Fitted)
The oil pressure gauge registers the lubricating system pressure in bar (kgf/cm2 or
Ibf/in2) and should be frequently observed to ensure that the system is functioning
correctly.
15
Temperature Gauge (Where Fitted)
The temperature gauge enables a close check to be kept on the coolant
temperatures.
Water in Fuel Light (Where Fitted)
This light indicates when water is present in fuel and proper service should be
complete to eliminate the water.
Malfunction Indicator Light (Where Fitted)
Used on all industrial engines. This light will illuminate whenever there is an engine
malfunction such as low oil pressure, high engine temperature, fuel injection
system fault. The engine can be programmed to shut down in the event of a
malfunction.
Charge Indicator Light (Where Fitted)
If an alternator is fitted to your engine, a charge indicator light will also be fitted. The
light will glow when the isolating switch is in the RUN position with the engine
stationary and will therefore serve as a reminder either to turn the isolating switch
to the OFF position or to start the engine. Once the engine has started, the charge
indicator light should cease glowing.
Safety Switch Override Button (Where Fitted)
This must be depressed when starting the engine, as the safety switch operates
when the oil pressure falls due to the engine stopping -- Refer to “Safety Switch
(where fitted)” on page 14.
Ignition or Isolation Switch
-- Refer to “Ignition or Isolation Switch” on page 13.
Fuel Gauge (Where Fitted)
This instrument indicates the quantity of fuel in the tank.
16
STARTING THE ENGINE
WARNING: ALL INTERNAL COMBUSTION ENGINES GIVE OFF VARIOUS

FUMES AND GASES WHILE RUNNING. DO NOT START OR RUN THE
ENGINE IN A CLOSED OR POORLY VENTILATED BUILDING WHERE THE
EXHAUST GASES CAN ACCUMULATE. AVOID BREATHING THESE GASES
AS THEY MAY CONTAIN POISONOUS CARBON MONOXIDE WHICH CAN
ENDANGER YOUR HEALTH OR LIFE IF INHALED STEADILY FOR EVEN A
FEW MINUTES.
Initial Start-up
On initial start-up follow the daily regular maintenance schedule illustration -- Refer
to “RECOMMENDED MAINTENANCE SCHEDULES” on page 21.
To Start From cold
1. Where possible, disconnect the driven equipment, eg, fully depress the clutch
where a manual transmission is fitted.
If your unit is equipped with the engine warning light system, always turn the
ignition switch to the ON position to make sure that each warning light is
operating before starting engine.
2. Switch on the ignition and operate the starter motor until the engine fires.
NOTE: Where a safety switch is fitted, the override button must be depressed while
the engine is being cranked.
3. Set the throttle to give a fast idle speed until normal operating temperature is
reached (where fitted).
NOTE: For EFI Governor application there is no throttle cable. Turn key to crank to
start engine. When engine starts release key to run position. The ECM will adjust
speed for cold start and altitude automatically.
CAUTION: If the engine stalls or falters in starting, wait 3-4 seconds before
re-engaging starter. This will prevent possible damage to the starter or en-
gine. The starter should not operate for periods longer than 30 seconds at a
time. An interval of at least two minutes should be observed between such
cranking periods to protect the starter from overheating.
To Re-start When Warm

For EFI engines, the ECM automatically controls fuel.
Switch on the ignition and operate the starter motor until the engine starts.
NOTE: Where a safety switch is fitted, the override button must be depressed while
the engine is being cranked.
Engine Flooded (EFI Only)
Contact your nearest distributor located in the back section of this manual.
17
STOPPING THE ENGINE
Normal Conditions
Following normal operating conditions, lower the engine speed to idle, disengage
the clutch, and then turn the ignition switch to the OFF position. If the engine has
been running under high power, let it run at fast idle speed a few minutes to cool
the engine down.
Abnormal Conditions
Under abnormally overheated conditions, the engine may continue to run after the
ignition switch is turned off. If this case is ever encountered, turn on the ignition
switch immediately and allow the engine to idle until it has cooled enough to stop.
If the engine is overheated due to loss of coolant, it is best to stop the engine
immediately, if necessary by applying the load. Add engine oil if necessary, then
after the engine has returned to a normal temperature, add coolant slowly until the
radiator is full.
WARNING: TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT

ENGINE. COVER THE RADIATOR CAP IN A THICK CLOTH AND TURN IT
SLOWLY COUNTERCLOCKWISE TO THE FIRST STOP. AFTER THE
PRESSURE HAS BEEN COMPLETELY RELEASED, PRESS THE CAP
DOWNWARD AND FINISH REMOVING THE CAP.
The above instructions also apply to engines that stop due to operation of the low
oil pressure/high water temperature safety switch. However, if the engine stops
due to low oil pressure, do not restart until the cause has been determined and
corrected -- Refer to “Recommended Lubricants” on page 22.
RUNNING-IN PROCEDURE
A new or reconditioned engine must not be run at high speeds or on full load for
the first 25 hours. The load and speed may be increased to a maximum over this
period. After the first 50 hours running, carry out the maintenance operations listed
-- Refer to “RECOMMENDED MAINTENANCE SCHEDULES” on page 21.
Check the instruments frequently and keep the coolant and oil filled to their
recommended levels.
18
FUEL RECOMMENDATION
This engine is designed to operate on unleaded 87 or 89 octane gasoline. The
engine, with the proper fuel equipment, can also operate on dry fuel such as LPG
Grade HD5 and natural gas (1050 BTU/ft3).
CAUTION: Use of fuels rated lower than the grades specified above may
cause persistent, heavy spark knock, which can lead to engine damage. If
your engine knocks heavily, or if you hear continuous spark knock while
maintaining constant operating speeds, consult your distributor or another
qualified technician.
Fuel Quality
Using a high quality gasoline will help maintain the power, fuel economy and
emissions performance of your engine. A properly formulated gasoline will be
comprised of well refined hydrocarbons and chemical additives and will perform
the following functions:
• Minimize varnish, lacquer, and other induction system deposits.
• Prevent gum formation or other deterioration during storage.
• Protect fuel tank and other fuel system components from corrosion or
degradation.
• Provide the correct seasonally and geographically adjusted volatility. This will
provide easy starting in the winter and avoid vapor lock in the summer.
• Avoid fuel system icing.
In addition, the fuel will be free of water, debris, and other impurities.
We also recommend that the fuel supply be kept fresh; when the equipment is in
storage (especially in hot weather), the fuel tank should be kept at least 3/4 full.
If you anticipate storage of your engine in excess of two months, consult your
distributor or other qualified technician. Also refer to the information on storage in
the “Maintenance Instructions” section of this manual.
19
Alcohol Gasoline Blends (Gasohol)
Gasohol, a mixture of gasoline and ethanol (grain alcohol), is available in some
areas outside Europe. Ford engines should operate satisfactory on gasohol blends
containing no more than 10% ethanol by volume and having an octane (anti knock)
index of 87 or 89, reference engine specifications.
CAUTION: In some cases, methanol (wood alcohol) or other alcohols may be

added to gasoline. Ford engines should operate satisfactory on blends con-
taining up to 5% methanol by volume when cosolvents and other necessary
additives are used. If not properly formulated with appropriate cosolvents
and corrosion inhibitors, such blends may cause performance problems or
damage emissions and fuel system materials. Insufficient data is available to
insure the suitability of all methanol/gasoline blends at this time. To avoid
jeopardizing your engine warranty or incurring unnecessary repairs costs,
DO NOT USE blends containing more than 5% methanol by volume, or
blends that do not contain cosolvents and corrosion inhibitors.
If you are uncertain as to the presence of alcohols in the gasoline you are
purchasing, check the label on the pump or ask the station attendant.
CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if per-

formance problems occur. Do not use such fuels unless they are UNLEAD-
ED.
NOTE: It is highly recommended that a Fuel Stabilizer, Ford Part Number E8AZ-
19C544-A or an equivalent additive be used for any length of storage. It is
imperative in any application where the fuel will not be consumed within thirty days.
Refer to “STORAGE” in this section for further information.
LUBRICATION AND MAINTENANCE

The importance of correct lubrication, periodic inspection and adjustment cannot
be over-emphasized. It will determine, to a very large extent, the service the engine
will give. Detailed instructions regarding this maintenance are given in the following
pages.
Your Authorized Ford Power Products Distributor listed in the back section of this
manual, will be pleased to carry out this regular maintenance for you. The various
maintenance operations are listed -- Refer to “RECOMMENDED MAINTENANCE
SCHEDULES” on page 21.
When carrying out any of the following maintenance operations, any fault or
malfunction should be reported immediately to the supervisor or person
responsible for engine overhaul or repair.
The following Maintenance Schedules give the maximum recommended service
periods. Since operating conditions can vary, it may be advisable to carry out some
operations, for example, changing the engine oil, at an interim period. Your
operating experience is the best guide for determining this time.
20
RECOMMENDED MAINTENANCE SCHEDULES
After 1st 50 hrs. (2500 km or
Every 100 hrs. (5000 km or
Every 200 hrs. (10,000 km
Every 2,400 hrs. (120,000
Details on Page #
km or 80,000 miles)
Every 4 years max.

Hours Running Or Miles Driven
or 12,000 miles)
or 24,000 miles)
or 6000 miles)
1500 miles)
3000 miles)
Daily
Maintenance Operation
Check engine oil level and top up if

necessary X X X X X X 24
Check engine coolant level and top up if
necessary with correct mixture X X X X X X 27
Check visually for oil, fuel or coolant leaks X X X X X X
Lubricate PTO release bearing X X X X X X
Check all instruments, controls and warning
lights. Check hot and cold starting functions X X X X X X
Check coolant, oil, fuel, exhaust and
vacuum hoses/pipes for leaks, damage,
deterioration and correct routing. Check all
visible electrical wiring for security, correct
routing and evidence of chafing or heat
damage X X X X X
Change engine oil and renew engine oil
filter X X 23
Lubricate PTO bearings X X X X
Check condition and adjust tension of drive
belt(s) X X X 27
*Check fuel filter element and renew as
necessary X X X
Renew air cleaner element X X 28
Spark plugs - non-emission certified
- Clean, adjust or replace X X 26
Spark plugs - emission certified
- Replace X 26
*Check all nuts & bolts for tightness X X
*Adjust PTO clutch release & shaft bearings X X
Renew PCV valve X 28
Clean PCV hoses, tubes and fittings X 28
Clean coolant filler cap. Renew cap if seal
has deteriorated X
*It is recommended that this operation is carried out by an authorized Ford

Distributor. Depending upon the quality of the fuel used, it may be necessary to
renew the filter element more frequently.
21
RECOMMENDED MAINTENANCE OPERATIONS
Recommended Lubricants
CAUTION: Do not use supplemental oil additives or other engine treatments.
They are unnecessary and could, under certain conditions, lead to engine
damage which is not covered by Ford warranty.
Lubricating oil cleanliness is vital for the successful operation of your engine. The
oil should be stored under the cleanest possible conditions.When changing or
topping-up engine oil use only clean receptacles. Do not allow the oil to come into
contact with rubber hoses on the engine.
-30° -20° -15° -10° 0° +30° +40°
SAE 5W20
SAE 5W/30
SAE 5W40
SAE 10W30
SAE 10W40
CAUTION: Use Ford/Motorcraft “Formula E”

SAE 5W-30 engine oil or equivalent that meets
Ford Specification WSS-M2C153-H (API Classi-
fication – SJ). If SJ oils are not available, SH
oils are acceptable. Use only engine oil dis-
playing the American Petroleum Institute Certi-
fication Mark on the front of the container, or 5W-30
API specification SH, or SJ.
NOTE: Ford Power Products industrial engines

are designed to perform with engine oils that are
licensed by the American Petroleum Institute
(API), and oils carrying the most current API
classification should be used. API classifications are broken into two categories,
gasoline and diesel engines. API’s classification is designated by a two letter
system. The first letter, the prefix, designates gasoline or diesel. An “S’’ designates
gasoline and a “C’’ designates diesel. The second letter in the system designates
the level of the classification. It should be noted that alternative fuel engines fall into
the “gasoline’’ API category.
Gasoline engines that are converted for LPG or Natural Gas applications must use
oils labeled SH and/or SJ. Do not use oils that are specifically formulated for Diesel
Engines only. CC or CD classification, even when labeled Heavy Duty or for
Natural Gas Engines, are not acceptable. The use of SAE 5W-30 is recommended
for all temperatures:
22
Used Engine Oils
WARNING: PROLONGED AND REPEATED CONTACT MAY CAUSE SERIOUS

SKIN DISORDERS INCLUDING DERMATITIS AND SKIN CANCER.
WARNING: AVOID EXCESSIVE CONTACT—WASH THOROUGHLY AFTER
CONTACT. KEEP OUT OF THE REACH OF CHILDREN.
WARNING: PROTECT THE ENVIRONMENT: IT IS ILLEGAL TO POLLUTE
DRAINS, WATER COURSES OR SOIL. USE AUTHORIZED FACILITIES FOR
DISPOSAL. IF IN DOUBT, CONTACT YOUR LOCAL AUTHORITY FOR
ADVICE.
WARNING: DO NOT HANDLE A HOT OIL FILTER WITH BARE HANDS.

CONTINUOUS CONTACT WITH USED MOTOR OIL HAS CAUSED SKIN
CANCER IN LABORATORY MICE. PROTECT YOUR SKIN BY WASHING WITH
SOAP AND WATER IMMEDIATELY AFTER CONTACT.
Change Engine Oil
1. Warm the engine to normal operating temperature.
2. Make sure that the equipment is standing level and that the engine is stopped.
3. Obtain a sufficiently large draining pan to accommodate the engine oil -- Refer
to “Service Oil fill capacity (including filter):” on page 38.
4. Remove the oil filler cap from the rocker cover, remove the drain plug from the
oil pan and drain the oil into the draining pan.
NOTE: Modern high performance oils have a cleaning action on the engine which
may turn the oil dark, but does not necessarily indicate inadequate oil changes.
5. Replace and tighten the drain plug, then fill the engine via the filler neck in the
rocker cover with the correct quantity of oil -- Refer to “SPECIFICATIONS” on
page 38.
6. Replace the oil filler cap and run the engine for no more than 30 seconds.
7. Check the oil level as described in the following section.
23
Check Engine Oil Level
Dipstick
1. Make sure the equipment is standing
level and that the engine is stopped.
2. Pull out the dipstick and wipe it with a
clean rag.
3. Insert the dipstick fully and again
remove it. At no time should the level of
the oil fall below the lower mark on the
dipstick.
4. If necessary, top up to the dipstick
higher mark with an approved type and
grade of oil.
5. Replace the dipstick, ensuring that it is fully inserted into its tube to maintain a
sealed crankcase condition
Renew Engine Oil Filter
Your engine is equipped with a Motorcraft oil filter. A
filter of this quality should be used throughout the life
of the engine. It is designed to protect your engine by
filtering harmful abrasive and sludgy particles without
clogging up or blocking the flow of the oil to vital
engine parts. This filter is especially designed for use
in engines built by Ford to give successful operation
with the recommended oil filter change intervals.
Contact your nearest Ford Power Product
Distributor/Dealer listed in the back section to obtain
the correct filter. Before commencing, place a drain FPP01169
pan beneath the filter to catch any spilt oil.
1. Using a suitable strap wrench, unscrew the oil filter canister.
2. Thoroughly clean oil filter housing face.
3. Partly pre-fill the new filter with clean engine oil of the correct type and grade.
Apply a thin film of clean engine oil to the oil filter sealing ring.
4. Screw on new oil filter canister until sealing ring abuts the filter head and tighten
a further 1/2 turn. Do NOT use a strap wrench or similar tool to tighten the filter
canister.
5. Run engine and check for any leaks from oil filter.
6. Stop engine, allow oil to settle and top up as necessary.
Gasoline Fuel System - EFI
In the event that your engine is equipped with an EFI (Electronic Fuel Injection)
system follow normal maintenance service. Any necessary service repairs should
be made by your Ford Power Products Distributor. The adjusting procedure
requires the use of tools which are not readily available to consumers. Please
contact Ford Power Products Distributors listed in the back section of this manual.
24
Fuel Filter - EFI
The fuel filter is located between the fuel pump and the fuel rail, and is not mounted
on the engine.
WARNING: WHEN REMOVING THE FUEL FILTER, USE CAUTION SINCE

THERE MAY BE FUEL PRESSURE PRESENT.
The fuel filter should be replaced according to the maintenance schedule -- Refer
to “RECOMMENDED MAINTENANCE SCHEDULES” on page 21, or more often if
needed.
1. Block fuel flow by crimping fuel feed line with appropriate tool between fuel tank
and filter.
2. Place suitable container beneath filter to collect spilled fuel.
3. Remove fuel line clamps and hose at each end of filter.
4. Replace fuel filter using Ford Power Products fuel filter number F8JL-9A011-
AA.
5. Dispose of fuel filter properly.
NOTE: PROTECT THE ENVIRONMENT. It is illegal to pollute drains, water

courses or soil. Use authorized facilities for disposal. If in doubt, contact your local
Authority for advice.
Fuel Rail
Fuel Return
Fuel Pump Fuel Supply
Fuel Filter
FPP01162
25
Ignition System - DIS
The Distributorless Ignition System (DIS) used on this engine does not have a
distributor or vacuum advance mechanism. Ignition timing is set by design and
cannot be readily changed. In the event that the engine is converted to alternative
fuels, the timing can be re-set by trained technicians. Please contact a Ford
Distributor listed at the back of this manual.
Renew Spark Plugs
WARNING: THE DIS IGNITION SYSTEM COMMONLY CARRIES VOLTAGES

IN EXCESS OF 60,000 VOLTS. PLEASE USE CAUTION.
1. Remove the lead from each spark plug by grasping, twisting and then pulling
the molded boot on the end of the lead.
CAUTION: Do not pull directly on the lead as this could cause the wire con-
nection inside the boot to become separated.
2. After loosening each spark plug one or two turns with a proper spark plug
spanner, clean the area around each spark plug port with compressed air then
remove the spark plugs.
WARNING: PROTECTIVE GOGGLES MUST BE WORN TO PROTECT THE

EYES WHEN USING COMPRESSED AIR.
3. Check the gaps of the new spark plugs
with a feeler gauge, and, where
necessary, bend the outer ground
extension to achieve the specified gap.
4. Use a proper spark plug spanner to avoid
damaging the insulators, screw the new
spark plugs into the cylinder head and
tighten them to the specified torque --
Refer to “SPECIFICATIONS” on page 38.
CAUTION: Do not over tighten spark

plugs as the gap may change consider-
ably due to the distortion of the plug outer
shell.
5. Coat the inside of each spark plug boot

with Motorcraft Silicone Brake Caliper
Grease and Dielectric Compound XG-3
or equivalent, using a small screwdriver
blade.
6. Re-connect each high tension lead to the correct spark plug.
NOTE: The plug numbers are printed on the leads to aid correct re-assembly.
NOTE: Be sure each lead is fully pressed onto each plug and that the molded boot
is firmly in place.
26
Electronic Actuator
In the event that your engine is equipped with an electronic actuator, any
necessary adjustment should be made by your Power Products Distributor listed at
the back of this manual. The adjusting procedure requires the use of tools which
are not readily available to consumers
Check Condition of Ancillary Drive Belts
WARNING: ENGINE SHOULD BE STOPPED AND ANY REMOTE STARTER

DISABLED BEFORE CHECKING BELTS.
The serpentine ancillary belt used to drive the generator and water pump, is
tensioned automatically and does not require adjustment.
The belts should be visually inspected for signs of wear or damage. It should be
renewed if necessary. Refer to Service Manual.
NOTE: May be purchased from your local Ford Power Product Distributor listed on
the back of this handbook.
Check Engine Coolant Level
WARNING: TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT

ENGINE. COVER THE RADIATOR CAP WITH A THICK CLOTH AND TURN IT
SLOWLY COUNTER-CLOCKWISE TO THE FIRST STOP. AFTER THE
PRESSURE HAS BEEN COMPLETELY RELEASED, PRESS DOWNWARD
AND FINISH REMOVING CAP. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/
OR PERSONAL INJURY.
CAUTION: Do not add coolant to an engine that has become overheated until
the engine cools. Adding coolant to an extremely hot engine can result in a
cracked block or cylinder head.
1. Allow the engine to cool down to 40°C (110°F).

2. Turn the radiator expansion/degas tank filler cap through 90° in a counter-
clockwise direction. Pause to allow any pressure to drop, then turn cap fully
counterclockwise and remove it.
3. The quantity of coolant in the expansion/degas tank is a direct indication of the
coolant level in the complete system. The acceptable level of coolant in the
expansion/degas tank is shown by the level indicators moulded into the tank
wall. Top up as necessary with a mixture of plain water and antifreeze -- Refer
to “Cooling System” on page 29 for information on mixing antifreeze solutions.
NOTE: It is essential that only the correct type of antifreeze is used -- Refer to
“Cooling System” on page 29.
4. Replace the filter cap and turn down tightly.
27
Renew Air Cleaner Element
Your air cleaner filters air entering the engine induction system and acts as a
silencer and a flame arrester. Air that contains dirt and grit produces an abrasive
fuel mixture, and can cause severe damage to the cylinder walls and piston rings.
Damage to the cylinder walls and piston rings will cause high oil consumption and
short engine life. A restricted or dirty air cleaner will also cause a rich fuel mixture.
Thus, it is extremely important that the air cleaner be serviced at recommended
intervals.
CAUTION: Service the air cleaner more frequently under severe dust condi-
tions to prevent engine damage.
1. Release the air cleaner lid retaining hardware.

2. Lift the air cleaner lid clear of the air cleaner body, then remove the air cleaner
element and discard it.
3. Wipe the inside of the air cleaner body and lid clean, using a lint-free rag.
4. Insert the new element, ensuring that it fits properly and install air cleaner lid.
Renew PCV Valve Connector & Hose
1. Detach the hose, from the top of the PCV Valve
PCV valve located at the top rear of
right valve cover and from the intake
manifold.
2. Withdraw the PCV valve from the
valve cover grommet.
3. Discard the PCV valve and the ‘O’
ring.
4. Thoroughly clean the inside and
outside of the hose.
5. Insert the new PCV valve, complete with a new ‘O’ ring.
6. Re-connect the hose to the PCV valve and to the intake manifold.
28
GENERAL MAINTENANCE INFORMATION
The following section outlines some aspects of general maintenance which will be
of value to the operator.
Cooling System
To obtain maximum engine service life, its operating temperature must be
maintained by an efficient cooling system.
CAUTION: Under no circumstances should the engine be started without liq-

uid in the cooling system. This may cause permanent damage to the engine.
Inspect the exterior of the radiator for obstructions, remove all bugs, dirt or foreign
material with a soft brush or cloth.
Use care to avoid damaging the fins. If available, use low pressure compressed air
or a stream of water in the opposite direction to normal airflow. Check all hoses and
connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they
should be replaced.
CAUTION: Never use a cold coolant mixture to top-up the radiator or degas
tank of a hot engine if the coolant level is very low; this could cause serious
engine damage.
The radiator or degas tank is equipped with a pressure cap. It is dangerous to

remove this when the system is very hot.
WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE

ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. MAY
CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR
ENGINE. TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR
STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE
PRESSURE RELIEF CAP, WAIT UNTIL THE ENGINE HAS COOLED DOWN TO
AT LEAST 40°C (110°F).
1. Wrap a thick cloth around the pressure relief cap and turn it slowly one-half turn
counterclockwise. Stepping back while the pressure is released from the
cooling system.
2. When you are sure all the pressure has been released, (still with a cloth) turn
counterclockwise and remove the pressure relief cap.
In territories where freezing conditions may occur, the coolant should consist of a
mixture of 50% plain water and 50% Motorcraft Super Plus 2000 coolant. This
antifreeze contains additional corrosion inhibitors designed to provide lasting
protection for the engine.
Only this antifreeze, or proprietary antifreeze meeting Ford specification WSS-
M97B44-D or Ford specification ESE-M97B44-A should be used when topping-up
or re-filling the cooling system.
Motorcraft Super Plus 2000 coolant has long life characteristics and if the
concentration is kept to a maximum of 50% it will provide adequate frost protection
and inhibiting for the life of the engine.
29
NOTE: If a major component of the cooling system is renewed such as the
radiator, water pump etc., the system should be flushed and re-filled with a 50%
solution of Motorcraft Super Plus 2000 coolant and clean water.
In territories where the ambient temperature is such that no protection against
freezing is required, it is recommended that a 25% concentration of Motorcraft
Super Plus 2000 coolant is used. This will protect water pumps, core plugs,
thermostat housings and radiators against corrosion for the life of the engine and
raise boiling point when used at this concentration. See previous Note on renewing
cooling system components.
The antifreeze concentration in a cooling system can be determined by using a
suitable hydrometer.
• A reading of 1080 represents a 50% antifreeze concentration.
• A reading of 1040 represents a 25% antifreeze concentration.
• A reading of 1000 represents plain water.
WARNING: ANTIFREEZE CONTAINS MONO ETHYLENE GLYCOL AND

OTHER CONSTITUENTS WHICH ARE TOXIC IF TAKEN INTERNALLY AND
CAN BE ABSORBED IN TOXIC AMOUNTS ON REPEATED OR PROLONGED
SKIN CONTACT. PERSONS USING ANTIFREEZE ARE RECOMMENDED TO
ADHERE TO THE FOLLOWING PRECAUTIONS:
• ANTIFREEZE MUST NEVER BE TAKEN INTERNALLY. IF ANTIFREEZE IS
SWALLOWED ACCIDENTALLY, MEDICAL ADVICE SHOULD BE SOUGHT
IMMEDIATELY.
• PRECAUTIONS SHOULD BE TAKEN TO AVOID SKIN CONTACT WITH
ANTIFREEZE. IN THE EVENT OF ACCIDENTAL SPILLAGE ONTO THE
SKIN, ANTIFREEZE SHOULD BE WASHED OFF AS SOON AS
PRACTICABLE. IF CLOTHING IS SPLASHED WITH ANTIFREEZE, IT
SHOULD BE REMOVED AND WASHED BEFORE BEING WORN AGAIN, TO
AVOID PROLONGED SKIN CONTACT.
• FOR REGULAR AND FREQUENT HANDLING OF ANTIFREEZE,
PROTECTIVE CLOTHING (PLASTIC OR RUBBER GLOVES, BOOTS AND
IMPERVIOUS OVERALLS OR APRONS) MUST BE USED TO MINIMIZE
SKIN CONTACT.
30
Draining, Flushing and Filling the Cooling System
WARNING: NEVER REMOVE THE PRESSURE

RELIEF CAP WHILE THE ENGINE IS Radiator Drain Cock
OPERATING OR WHEN THE COOLING
SYSTEM IS HOT. MAY CAUSE PERSONAL
INJURY OR DAMAGE TO COOLING SYSTEM
OR ENGINE. TO REDUCE THE RISK OF
HAVING SCALDING HOT COOLANT OR
STEAM BLOW OUT OF THE DEGAS BOTTLE
WHEN REMOVING THE PRESSURE RELIEF FPP01111
CAP, WAIT UNTIL THE ENGINE HAS COOLED
DOWN TO AT LEAST 40°C (110°F).
1. Wrap a thick cloth around the pressure relief cap and turn it slowly one-half turn
counterclockwise. Stepping back while the pressure is released from the
cooling system.
2. When you are sure all the pressure has been released, (still with a cloth) turn
counterclockwise and remove the pressure relief cap.
3. Remove the radiator expansion/ degas tank filler cap, then open the radiator
drain cock, where fitted, or detach the bottom radiator hose.
4. Flush the system with water using a hose until clean water emerges and allow
all water to drain out. Close the drain cock (or replace the bottom radiator hose).
Recover all old antifreeze and dispose of properly. Contact your local municipal
government for the proper disposal.
5. Fill the system with the correct coolant mixture via the expansion/degas tank
filler neck. Fill the system slowly, to avoid air locks, up to the ‘maximum’ mark
on the degas tank.
6. Run engine and check hose connections for leaks. Check, and, if necessary,
top up the coolant in the radiator or degas tank.
Engine Lubrication System
The lubrication system should be
maintained regularly -- Refer to
“RECOMMENDED MAINTENANCE Dipstick
SCHEDULES” on page 21, with the
correct grade of lubricant as specified in
the maintenance summary -- Refer to
“Recommended Lubricants” on page 22.
The system is of the force feed type, the
lubricating oil being circulated to the
engine bearings under pressure by an oil
pump driven from the camshaft drive
chain belt.
The dipstick provides some guide to the condition of the oil. An additive type of oil
keeps soot in suspension, and even a small amount of soot causes the oil to
darken rapidly.
However, if the dipstick is found to be heavily coated with sludge, then obviously
the oil should be changed.
31
Electrical System
A NEGATIVE EARTH (NEGATIVE GROUND) SYSTEM IS USED.
EPM - Power Distribution Box
Part of -12A690- Wiring Harness
6 5
Power
Relay 4 3
2 1
Starter Fuel pump

Lockout Relay
Relay
Fuse Amps Circuits protected
1 30 Ground Protection for EPM and Megajector
Ignition Voltage to EPM, Starter Lockout Relay, Fuel Pump

2 5 Relay and Dry Fuel Lock-off Solenoid
3 20 Battery Voltage to EPM and Power Relay
4 15 Fuel pump
Battery Voltage to the Megajector, Ignition Coil and HO2S

5 15 Sensors
6 - Not used
32
ICM - Power Distribution Box
Part of -12A200- Wiring Harness
Relay #2
Starter Relay
1 2
3 4
5 6
Fuse Amps Circuits protected
1 10 Ignition Voltage to ICM, Starter Relay and Ignition Coil
2 - Not Used
3 - Not Used
4 - Not Used
5 - Not Used
6 - Not Used
Generator
This is mounted on a bracket at the front of the engine and is driven from the
crankshaft by a serpentine belt.
The charging rate is adjusted automatically by the built-in regulator to provide
sufficient electric current to keep the battery fully charged under normal operating
conditions.
The generator requires no lubrication or maintenance.
WARNING: IT IS ESSENTIAL THAT THE WIRING CONNECTIONS TO THE

GENERATOR ARE NOT REMOVED WHILE THE ENGINE IS RUNNING, AS
THIS WILL RESULT IN DAMAGE TO THE REGULATOR OR PERSONAL
INJURY.
33
Storage
NOTE: It is highly recommended that a fuel stabilizer, Ford Part Number E8AZ-
19C544-A or an equivalent additive be used for any length of storage. It is
imperative in any application where the fuel will not be consumed within thirty days.
Ford Fuel stabilizer comes in an 8 fl.oz. bottle for consumer use and should be
available through all Power Products Distributors. The correct ratio is 2 oz.
Stabilizer to 5 gallons of gasoline. Without the use of an additive, the unused fuel
in your fuel tank can and will go sour in a very short period of time, causing varnish
and contaminants to form. This causes problems in fuel delivery by clogging fuel
injectors.
Storage - One Month

• Add fuel stabilizer (see previous note).
• While the engine is running, treat upper cylinders by spraying engine fogging
agent (from your local aftermarket supplier) into the air intake for about two
minutes. Open throttle for short burst of speed, shut off engine and allow it to
come to a stop while continuing to spray into air intake.
• Leave spark plugs in holes or seal spark plug holes with suitable threaded metal
plugs and cover all openings into engine with dust-proof caps or shields
(suitable non-hygroscopic material).
• If engine is less transmission, spray flywheel and ring gear with mixture of one
part recommended engine oil, and one part Stoddard Solvent or equivalent.
• Check coolant protection. Store indoors in dry area.
Storage - Indefinite Period

• Add fuel stabilizer (see previous note).
• Drain crankcase completely and refill with recommended engine oil, (SAE 10)
or equivalent.
• Run engine until completely out of fuel. Gasoline only: Restart and run on
unleaded gasoline, mixed with stabilizer, for at least 10 minutes. While engine
is still running and at completion of above run, treat upper cylinders by spraying
fogging agent into the air intake for about two minutes. Open throttle for short
burst of speed, shut off engine and allow it to come to a stop while continuing
to spray into air intake.
• Check coolant protection
• Disconnect and remove battery.
• Clean exterior surface of engine.
• Leave spark plugs in holes or seal spark plug holes with suitable threaded metal
plugs.
• Seal all openings in engine and accessories with non-hygroscopic material.
Mask off all areas to be used for electrical contacts.
• Make sure all surfaces are dry, then spray all taped openings, all engine
accessories including ignition wiring, and all exterior surfaces of engine with
Insulation Compound.
• If engines are equipped with automotive type clutch, block clutch in slightly
disengaged position so that lining and pressure plates are not in contact.
34
ENGINE SYSTEM CHECK
NOTE: Items listed in the possible cause column generally do not set a diagnostic
trouble code (DTC) or illuminate the MIL light.
NOTE: FPP engines are used in many different applications and equipment. When
performing any system diagnosis be aware of any OEM inputs or equipment
monitoring devices that may have an effect on the engine’s performance or any of
the engine’s operating systems.
Engine Performance - No Load
SYMPTOM POSSIBLE CAUSE
Engine Runs Briefly and • Loss of Spark

Shuts Down • Frozen Fuel Regulator (Dry Fuel)
• Low Fuel Pressure
• Air Inlet Restriction
• Wiring Failure
• ICM/EPM Failure
Engine Cranks But No Start • Faulty OEM Drivers Safety Shut-Off Seat Switch
• Coil Power Loss
• ICM/EPM Ground Loss
• ICM/EPM Power Loss
• Severe Vacuum Leak (Dry Fuel)
• Air Inlet Restriction
• Air Inlet Leak (Dry Fuel)
• Fuel Lock-Off Inoperative (Dry Fuel)
• Wiring Failure
• Ancillary Components Binding
Engine Runs Poorly • High Fuel Pressure

• Contaminated Fuel
• Incorrect Fuel Select Table Selected
• Wrong ICM/EPM Installed
• Actuator Air Blockage
• TMAP Sensor Leak
• Fuel Contaminated
• Noise Suppression Capacitor Failure
• Improper PCV Routing
• Valve Timing
• Low Cylinder Compression
Engine Cranks Slowly • Excessive Engine Load (Hydraulic Pump Failing, Binding
Ancillary Drive Components)
• Low Battery Voltage
• Incorrect Battery Specifications
• Incorrect Battery Cable Size
• Starter Relay
• Starter Failure (Excessive Drain)
35
Engine Does Not Crank • Dead Battery

• Ground Loss
• Ancillary Components Binding or Seized
• OEM Shutdown - Oil Level Safety
• Starter Lockout Relay Failure
• Ignition Switch Failure
• Bad Starter
• Crank Control Wire Failure
• Loose Connection or Corrosion
Engine Performance - While Under Load
Engine Stalls/Quits • Faulty OEM Drivers Safety Shut-off Seat Switch

• Low Battery Voltage
• OEM Safety Shutdowns
• Bad TMAP Sensor
• Air Restriction
• Coil Failure
• Fuel Mixer Binding (Dry Fuel)
Runs Rough • Ground Loss

• Misrouted Spark Plug Wires
• Fuel System Failure
• Vacuum Leak
• Wiring Failure
• Spark Plugs Fouled
• Incorrect Valve Timing
Misses • Fuel System Failure

• Misrouted Spark Plug Wires
• Spark Plug Gap Too High
• Cracked Spark Plug Insulator
• Incorrect Valve Timing
• Compression Loss
Hesitation/Stumble • Low Fuel Pressure

• TMAP Sensor Vacuum Signal Loss
Surge • Low Fuel Pressure

• Map Sensor Failure
• Application or Ancillary System Momentarily Binding During
Load or Unload
Backfires • Faulty OEM Drivers Safety Shut-off Seat Switch

• Fouled Spark Plugs
• Spark Plug Wire Broke
• ICM/EPM Momentary Ground Loss
• Excess Lean Condition
• Fuel Lock-Off Leaking (Dry Fuel)
• Intake Manifold Leak
• Bad Intake Valve
36
Lack of Power • Ancillary Components Binding

• Intake Air Restriction
• Crossed Spark Plug Wires
• Fuel System Failure
• Low Cylinder Compression
Spark Knock • Poor Quality or Contaminated Fuel

• Carbon Build-up
• Wrong Spark Plugs (Too High Heat Range)
• Fuel Delivery System
• PCV System
• Fuel Selection Timing
• Cylinder Hot Spots
Engine Concerns
Oil System Concerns • Positive Crankcase Ventilation (PCV) System

- High Oil Consumption • Oil Viscosity
• External Leaks
• Improper Oil Dipstick
• Valve Seals
• Cylinder Wall Taper Excessive
• Worn Piston Rings
Cooling System Concerns • Trapped Air

• Worn Drive Belt
• Worn Water Pump
• Stuck Thermostat
• Plugged Radiator (Internal & External)
• Dry Fuel System Running Rich
Exhaust System Concerns

(visible smoke)
- Black Smoke • Ignition System

• Fuel Delivery System
• Sticking Fuel Injector
• High Fuel Pressure
- Blue Smoke • PCV System

• Worn Piston Rings
• Worn Valve Guides
Fuel System Concerns • Leaky Lines

• Contaminated Fuel
• Excessive Alcohol in Fuel
• Incorrect Octane Rating
Engine Noise • Low Oil Pressure

• Oil Filter Restriction
37
SPECIFICATIONS
GENERAL SPECIFICATIONS
V-6 4 stroke spark ignition 90° Overhead Valve (OHV) chain driven
pushrod camshaft operating the valves via roller cam followers and
hydraulic tappets.
Engine Type:
4.2 / 257
Liter/CID:
96.8325 mm (3.81 in.)

Bore: mm (inch)
95 mm (3.74 in.)
Stroke: mm (inch)
6
Number of cylinders:
9.3:1
Compression Ratio:
FUEL SYSTEM
LPG Liquefied Petroleum Gas

Type: Fumigation
Fuel Specification: EN589 (European) HD-6 (USA)
NG Natural Gas
Type: Fumigation
Fuel Specification: 38.7 MJ/m3 (UK) 39.0 MJ/m3 (USA)
Gasoline (petrol)
Gasoline Electronic Fuel Injection
Type: Unleaded 87 or 89 Octane (Gasoline blends not to exceed 10%
Fuel Specification: Ethanol by volume Octane Index of 87 or 89).
Fuel Pump Pressure

Normal: 63 psi
Max: 100 psi
LUBRICATION SYSTEM
Max. Oil Pressure: Hot@2500 rpm: 275.79 - 413.69 kPa (40-60 psi)
Super Premium SAE 5W30 WSS M2C153-H

Oil Type:
Service Oil fill capacity 5.7 qt. (6.0L) = 5 qt. Pan + 1 qt. filter
(including filter):
Oil filter Ford Service Part Number: 1F2E-6723-BA

Motorcraft: FL-400S
38
COOLING SYSTEM
Thermostat: Type: Wax element

Commences opening: 88.9°C
Fully open:100°C
Coolant 50% Motorcraft Super Plus 2000 plus 50% clear water
Ford Specification: WSS-M97B44-D or ESE-M97B44-A
ELECTRICAL SYSTEM
Polarity: Negative to earth (ground)
Generator Drive Belt Tension is within specification if the tensioner is within the indicator
Tension (8K Poly Belt): markings
Generator Output 95 Amp
IGNITION
Spark Plug Type: Emission Certified - Motorcraft AGSF 42 FCM

Type: Non-Emission Certified - Motorcraft AGSF 42 FCM
Gap: 1.06 - 1.16mm (.042 - .046 in.)
Firing 1-4-2-5-3-6
Order
TIGHTENING TORQUES
ITEM Nm FT. LB. LB. IN.
Oil Pan Drain Plug 22 - 30 16 - 22 195 - 265
Spark Plugs 9-20 7-15
Oil Filter 25-151.6
39
CONVERSION TABLE
TO CONVERT
FROM TO MULTIPLY BY
TO FROM DIVIDE BY
Distance
inches mm 25.4
inches m 0.0254
feet mm 304.8
feet m 0.3048
yards m 0.9144
mile km 1.609
Area
in2 mm2 645.16
ft.2 m2 0.0929
yds2 m2 0.8361
Volume
in3 cm3 16.3871
in3 1 liter 0.016387
pint (us) 1 liter 0.47318
pint (uk) 1 liter 0.56826
quart (us) 1 liter 0.94635
gallon (us) 1 liter 3.7854
gallon (uk) 1 liter 4.5461
ft.3 1 liter 28.3168
ft.3 m3 0.02832
Mass
oz. g 28.3495
lb. kg 0.45359
ton (US) tonne 0.90718
ton (UK) tonne 1.01605
FORCE
lbf N 4.44822
PRESSURE & STRESS
kpa Bar 0.01
lbf/in2 (psi) N/m2 6894.76
lbf/in2 (psi) Bar 0.0689
lbf/in2 (psi) N/mm2 0.00689
lbf/m2 (psi) mmHg 51.715
“H2O mmH2O 25.4
“Hg mmHG 25.4
ton (US)/in2 N/mm2 13.7894
ton (UK)/in2 N/mm2 15.4443
VELOCITY
ft./sec. m/s 0.3048
ft./sec. km/h 1.09728
miles/h m/s 0.44694
miles/h km/h 1.609
ACCELERATION
ft./sec2 m/s2 0.3048
ENERGY
Btu J 1055.06
Kcal J 4186.8
HP.h kW.h 0.7457
PS.h kW.h 0.7355
TORQUE
lb./ft. Nm 1.35582
POWER
HP kW 0.7457
PS kW 0.7355
HP PS 1.01387
SPECIFIC FUEL CONSUMPTION
lb./hp.h g/kW.h 608.277
40
FORD POWER PRODUCTS SERVICE
Ford Service facilities are available in nearly every country of the world.
• Service in Europe is available via a network of Specialist Power Products
distributors, or any other Authorized Ford Dealer.
• Dealers outside of Europe are supervised by Ford Affiliates, worldwide. A
distributors list is provided below for your information.
Distributors
Australia
IF YOU ARE IN THEN CALL ADDRESS TELEPHONE NUMBERS
AUSTRALIA Lees Industries 1224 Lytton Road Tel: 61-7-3390-5522

Australia PTY Ltd. Hemmant, Brisbane Fax: 61-7-3390-7571
Wynnum Central
Queensland 4178 Australia
Europe
FINLAND Masino OY Karkikuja 3, FIN-01740 Tel: 358-9-476-800

Vantaa Finland Fax: 358-9476-80300
FRANCE Fornaut S.A. 45, Rue Charles Nodier, Tel: 33-148-450-394
93310 Le-Pre-St.-Gervais Fax: 33-148-457-504
France
GERMANY I.M.A -H.-D Westring 41 Tel: 49-5202-987-510
Groeschler GmbH D-33818 Leopoldshoehe Fax: 49-5202-987-515
H.D. Groschler Germany
Sauer & Sohn Gross Zimmerner Strasse 51 Tel: 49-6071-206-330
Sauer Motive D-64807 Dieburg Germany Fax: 49-6071-206-219
Systems
GREAT BRITAIN Dalton Power Unit 6, Autumn Park Industrial Tel: 44-1476-576-666
Products Ltd. Estate Fax: 44-1476-577-127
(Main Office) Dysart Road, Grantham
Lincolnshire
NG31 7DD England
Dalton Power Suite 3, Concord House Tel: 44-191-416-1922
Products Ltd. Concord, Fax: 44-191-415-3682
Washington
Tyne & Wear NE37 1AS
England
Dalton Power Ellesmere Street Manchester Tel: 44-161-833-2932
Products Ltd. M15 4LP England Fax: 44-161-834-8465
Hendy Power School Lane Tel: 44-2380-579-800
Chandlers Ford Industrial Fax: 44-2380-271-471
Estate,
Eastleigh, Hampshire SO53
4DG England
Power Torque Herald Way, Binley, Coventry Tel: 44-2476-635-757
Engineering Warwickshire CV3 2RQ Fax: 44-2476-635-878
England
ITALY Compagnia Via Magellano 1, I-20090 Tel: 39-02-450 581
Technica Motori Cesano Boscone, (Milano) Fax: 39-02-450 582 60/62
S.p.A. Italy
Appendix - 1
Europe (Continued)
SWITZERLAND Minelli AG Mattenstr. 3, CH-8330 Tel: 41-1-950-1720

Pfäeffikon (ZH) Switzerland Fax: 41-1-950-1132
New Zealand
NEW ZEALAND Lees Industries 345 Gt. South Road Tel: 64-9-299-6019
Group Takanini Papakura, Auckland Fax: 64-9-298-9986
Delta Centre New Zealand
North America - Canada

BRITISH Industrial Engines 1020 Cliveden Ave. Tel: 1-604-525-8529

COLUMBIA Ltd. Delta, Annacis Island, British 1-877-438-6560
Columbia, Fax: 1-604-525-0974
Canada, V3M 5R5
ONTARIO, M-K Power 5641 McAdam Road Tel: 1-905-890-5323
QUEBEC, Products Corp. Mississauga, Ontario, CAN 1-800-263-5011
MONITOBA Canada, L4Z-1N9 Fax: 1-905-890-6660
ALBERTA, Industrial Engines, 14335 12th Avenue Tel: 1-780-484-6213
SASKATCHEWAN Ltd. Edmonton, Alberta Canada, CAN 1-866-484-6213
T5L 2R8 Fax: 1-780-732-0400
NOVA SCOTIA, Lunenburg 53 Falkland Street, PO 1240 Tel: 1-902-634-8827
NEW Industrial Foundry Lunenburg, Nova Scotia Fax: 1-902-634-8886
BRUNSWICK, & Engineering Canada, BOJ 2C0
NEW
FOUNDLAND,
PRINCE EDWARD
ISLAND
North America - United States

ALABAMA M&I Engine 30762 State Highway 181 Tel: 1-251-626-8080

Company, Inc. Daphne, AL 36526 1-800-633-1834
Fax: 1-251-626-2744
ALASKA E.C. Power 6051 S. 194th Street Tel: 1-253-872-7011
Systems Kent, WA 98032 1-800-247-5899
Fax: 1-253-872-6947
ARIZONA E.C. Power 8360 E. Via de Ventura Blvd., Tel: 1-480-905-5585
Systems Suite L-200 Fax: 1-503-224-3907
Scottsdale, AZ 85258
ARKANSAS Kansas City Power 80 South James Tel: 1-913-321-7040
Products, Inc. Kansas City, KS 66118 1-800-486-5277
-(Northern) Fax: 1-913-321-7341
-(Extreme Lightbourn 13649 Beta Road Tel: 1-972-233-5151
Southern Equipment Co. Dallas, TX 75244 Fax: 1-972-661-0738
Territory)
Appendix - 2
North America - United States (Continued)
CALIFORNIA Powertech 2933 E. Hamilton Avenue Tel: 1-559-264-1776

Engines Inc. Fresno, CA 93721 1-800-891-1776
(Main Office) Fax: 1-559-264-2933
Powertech 2003 Leghorn Street Tel: 1-650-968-2434
Engines Inc. Mountainview, CA 94043 Fax: 1-650-969-1267
Powertech 1410 South Acacia Avenue, Tel: 1-714-635-1774
Engines Inc. Suite B 1-800-784-1776
Fullerton, CA 92831 Fax: 1-714-635-1771
COLORADO Industrial Power 3233 Oakland Street Tel: 1-303-360-7110
Systems, Inc. Aurora, CO 80010 1-800-678-3673
Engine Division Fax: 1-303-360-7519
CONNECTICUT Engine 400 University Court Tel: 1-856-228-7298
Distributors, Inc. Blackwood, NJ 08012 1-800-220-2700
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
DELAWARE Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
DISTRICT OF Engine 400 University Court Tel: 1-856-228-7298
COLUMBIA Distributors, Inc. Blackwood, NJ 08012 1-800-220-2700
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
FLORIDA Highway 1016 West Church Street Tel: 1-407-843-6310
Equipment & Orlando, FL 32805 1-800-827-6495
Supply Co. Fax: 1-407-849-0740
(Main Office)
Highway 4850 Collins Rd. Unit 103, Tel: 1-904-215-6356
Equipment & Jacksonville, FL 32073 1-800-827-3019
Supply Co. Fax: 1-904-215-7109
Highway 6015 U.S. Highway 301 Tel: 1-813-621-9634
Equipment & North 1-800-827-9092
Supply Co. Tampa, FL 33610 Fax: 1-813-621-6873
M&I Engine 30762 Highway 181 Tel: 1-251-626-8080
Company, Inc. Daphne, AL 36526 1-800-633-1834
- (Panhandle) Fax: 1-251-626-2744
GEORGIA Engine 303 Interstate Drive Tel: 1-336-434-6616
- (Western) Distributors, Inc. Archdale, NC 27263 1-800-220-7080
- (Central) Fax: 1-336-434-6612
- (Southeastern Highway 4850 Collins Road, Unit 103 Tel: 1-904-215-6356

Corner) Equipment & Jacksonville, FL 32073 1-800-827-3019
Supply Co. Fax: 1-904-215-7109
HAWAII Powertech 2933 E. Hamilton Avenue Tel: 1-559-264-1776
(Main Office) Fax: 1-559-264-2933
IDAHO E.C. Power 4499 Market Street Tel: 1-208-342-6541
Systems Boise, ID 83705 1-800-354-6767
Fax: 1-208-345-4308
Appendix - 3
ILLINOIS Engine Power, Inc. 1830 Executive Drive Tel: 1-262-567-8575

- (Central) Oconomowoc, WI 1-800-242-2289
- (North Central) 53066 Fax: 1-262-567-2556
- (Northeastern)
- (Southern) Kansas City Power 80 South James Tel: 1-913-321-7040

Fax: 1-913-321-7341
- (Northwestern) Anderson 5532 Center Street Tel: 1-402-558-8700

Industrial Engines Omaha, NE 68106 1-800-747-1438
Fax: 1-402-558-8249
INDIANA Engine Power, Inc. 1830 Executive Drive Tel: 1-262-567-8575
Oconomowoc, WI 53066 1-800-242-2289
Fax: 1-262-567-2556
IOWA Anderson 5532 Center Street Tel: 1-402-558-8700
Fax: 1-402-558-8249
KANSAS Kansas City Power 80 South James Tel: 1-913-321-7040

Fax: 1-913-321-7341
KENTUCKY Engine Power, Inc. 1830 Executive Drive Tel: 1-262-567-8575
- (Western) Oconomowoc, WI 53066 1-800-242-2289
Fax: 1-262-567-2556
- (Eastern) Pitt Auto Electric 1241 Freedom Road Tel: 1-724-778-8200

Co. Cranberry Twp., PA 16066 US: 1-800-367-3463
Industrial Engine Fax: 1-724-778-8206
Division
LOUISIANA Lightbourn 13649 Beta Rd., Tel: 1-972-233-5151
Equipment Co. Dallas, TX 75244 Fax: 1-972-661-0738
Lightbourn 8272 El Rio, Suite 110, Tel: 1-713-741-2003

Equipment Co. Houston, TX 77054 Fax: 1-713-741-1909
MAINE Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
MARYLAND Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
MASSACHUSETTS Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
MICHIGAN Engine Center, Inc. 2351 Hilton Road Tel: 1-248-399-0002
- (Lower Peninsula) Ferndale, MI 48220 1-800-726-8870
Fax: 1-248-399-3142
- (Upper Peninsula) Engine Power, Inc. 1830 Executive Drive Tel: 1-262-567-8575
Oconomowoc, WI 53066 1-800-242-2289
Fax: 1-262-567-2556
MINNESOTA Northern Power 2859 Lexington Avenue S. Tel: 1-651-452-8900
Products, Inc. Eagan, MN 55121 1-800-284-6247
Fax: 1-651-452-9182(Sales)
1-651-452-9047(Parts)
Appendix - 4
MISSISSIPPI Kansas City Power 80 South James Tel: 1-913-321-7040

- (Northern) Products, Inc. Kansas City, KS 66118 1-800-486-5277
Fax: 1-913-321-7341
- (Southern) Lightbourn 8272 El Rio, Suite 110, Tel: 1-713-741-2003

MISSOURI Kansas City Power 80 South James Tel: 1-913-321-7040

Fax: 1-913-321-7341
MONTANA Industrial Power 3233 Oakland Street Tel: 1-303-360-7110
- (Eastern) Systems, Inc. Aurora, CO 80010 1-800-678-3673
- (Central) Engine Division Fax: 1-303-360-7519
- (Western) E.C. Power 4499 Market Street Tel: 1-208-342-6541

Systems Boise, ID 83705 1-800-354-6767
Fax: 1-208-345-4308
NEBRASKA Anderson 5532 Center Street Tel: 1-402-558-8700
Fax: 1-402-558-8249
NEVADA Powertech 2933 E. Hamilton Avenue Tel: 1-559-264-1776
Fax: 1-559-264-2933
NEW HAMPSHIRE Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
NEW JERSEY Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
NEW MEXICO E.C. Power 8360 E. Via de Ventura Blvd., Tel: 1-480-905-5585
- (Southern) Systems Suite L-200 Fax: 1-503-224-3907
Scottsdale, AZ 85258
- (Northern) Industrial Power 3233 Oakland Street Tel: 1-303-360-7110

NEW YORK Engine 400 University Court Tel: 1-856-228-7298
- (New York City) Distributors, Inc. Blackwood, NJ 08012 1-800-220-2700
- (Nassau Co.) Fax: 1-856-228-5657(Parts)
- (Suffolk Co.) 1-856-228-5531(Sales)
- (Upstate) Pitt Auto Electric 1241 Freedom Road Tel: 1-724-778-8200

- (Hudson Valley) Co. Cranberry Twp., PA 16066 US: 1-800-367-3463
Division
NORTH Engine 303 Interstate Drive Tel: 1-336-434-6616
CAROLINA Distributors, Inc. Archdale, NC 27263 1-800-220-7080
Fax: 1-336-434-6612
NORTH DAKOTA Northern Power 2859 Lexington Avenue S. Tel: 1-651-452-8900

Fax: 1-651-452-9182(Sales)
1-651-452-9047(Parts)
Appendix - 5
OHIO Graham Ford, Inc. 707 W. Broad Street Tel: 1-614-464-6006

- (Central) Columbus, OH 43216 1-800-837-7070
Fax: 1-614-464-6013
North Coast Ford 11885 Bellaire Road Tel: 1-216-251-5800
- (Northern) Industrial, Inc. Cleveland, OH 44135 1-800-423-1316
Fax: 1-216-251-8675
Pitt Auto Electric 1241 Freedom Road Tel: 1-724-778-8200
- (Southern) Co. Cranberry Twp., PA 16066 US: 1-800-367-3463
Division
OKLAHOMA Kansas City Power 7714 Melrose Lane Tel: 1-405-491-9491

- (Except Panhandle) Products Oklahoma City, OK 73127 1-800-654-3673
Fax: 1-405-491-9495
- (Panhandle) Lightbourn 13649 Beta Road, Dallas, Tel: 1-972-233-5151

Equipment Co. TX 75244 Fax: 1-972-661-0738
OREGON E.C. Power 1805 N.W. 21st Avenue Tel: 1-503-224-3623
Systems Portland, OR 97210 1-800-452-1511
Fax: 1-503-224-3907
PENNSYLVANIA Engine 400 University Court Tel: 1-856-228-7298
- (Eastern) Distributors, Inc. Blackwood, NJ 08012 1-800-220-2700
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
- (Western) Pitt Auto Electric 1241 Freedom Road Tel: 1-724-778-8200

Division
RHODE ISLAND Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
SOUTH Engine 303 Interstate Drive Tel: 1-336-434-6616
CAROLINA Distributors, Inc. Archdale, NC 27263 1-800-220-7080
Fax: 1-336-434-6612
SOUTH DAKOTA Northern Power 2859 Lexington Avenue S. Tel: 1-651-452-8900

Fax: 1-651-452-9182(Sales)
1-651-452-9047(Parts)
TENNESSEE M&I Engine 30762 Highway 181 Tel: 1-251-626-8080
- (Central) Company, Inc. Daphne, AL 36526 1-800-633-1834
- (Eastern) Fax: 1-251-626-2744
- (Western) Kansas City Power 80 South James Tel: 1-913-321-7040

Fax: 1-913-321-7341
TEXAS Lightbourn 13649 Beta Rd., Tel: 1-972-233-5151

Equipment Co. Dallas, TX 75244 Fax: 1-972-661-0738
Lightbourn 8272 El Rio, Suite 110, Tel: 1-713-741-2003
Appendix - 6
UTAH Industrial Power 2492 W. Custer Road Tel: 1-801-908-8099

- (Northern) Systems, Inc. Salt Lake City, UT 84104 1-800-678-3673
- (Southern) E.C. Power 3683 West 2270 South, Tel: 1-801-886-1424

Systems Suite A, Salt Lake City, 1-800-462-3370
UT 84120 Fax: 1-801-886-1464
VERMONT Engine 400 University Court Tel: 1-856-228-7298
Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
VIRGINIA Engine 400 University Court Tel: 1-856-228-7298
- (Central) Distributors, Inc. Blackwood, NJ 08012 1-800-220-2700
- (Eastern) Fax: 1-856-228-5657(Parts)
1-856-228-5531(Sales)
- (Southwestern) Pitt Auto Electric 1241 Freedom Road Tel: 1-724-778-8200
Division
WASHINGTON E.C. Power 6051 S. 194th Street Tel: 1-253-872-7011
Systems Kent, WA 98032 US 1-800-247-5899
Fax: 1-253-872-6947
WEST VIRGINIA Pitt Auto Electric 1241 Freedom Road Tel: 1-724-778-8200
Division
WISCONSIN Engine Power, Inc. 1830 Executive Drive Tel: 1-262-567-8575
- (Eastern) Oconomowoc, WI 53066 1-800-242-2289
- (Central) Fax: 1-262-567-2556
Northern Power 2859 Lexington Avenue S. Tel: 1-651-452-8900
- (Northwestern) Fax: 1-651-452-9182(Sales)
1-651-452-9047(Parts)
WYOMING Industrial Power 3233 Oakland Street Tel: 1-303-360-7110
Appendix - 7
Headquarters
Ford Power Products
15700 Lundy Parkway Dr., Suite 200
Dearborn, MI 48126 USA
313-845-1400
800-833-4773
(Fax) 313-619-2600
European Engineering and Sales Operations

Ford Power Products
20/586 Arisdale Avenue
South Ockendon
Essex, RM15 5TJ England
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Esg 642

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OPERATOR HANDBOOK

Reproduction in any manner, in whole or in part, is prohibited without the

Ford Power Products, Publications Department

WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS

Non-Certified Engine Decal

Owner's Warranty Responsibilities:

1. Air / Fuel Feedback Control System and Sensors

Components That Are Considered High Priced Parts

• SERVICE MANUAL FPP 194-303

CAUTION: Under no circumstances may the engine be started without liquid

Auxiliary Circuits Start

1. Auxiliary Circuits - When moved to this position the auxiliary electrical

Ammeter Oil Pressure Gauge

Charge Indicator Light Safety Switch

Ignition or isolation Switch

Ammeter (Where Fitted)

WARNING: ALL INTERNAL COMBUSTION ENGINES GIVE OFF VARIOUS

To Re-start When Warm

WARNING: TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT

CAUTION: In some cases, methanol (wood alcohol) or other alcohols may be

CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if per-

LUBRICATION AND MAINTENANCE

After 1st 50 hrs. (2500 km or

Every 100 hrs. (5000 km or

Every 200 hrs. (10,000 km

Every 400 hrs. (20,000 km

Every 800 hrs. (40,000 km

Every 2,400 hrs. (120,000

Every 4 years max.

Check engine oil level and top up if

*It is recommended that this operation is carried out by an authorized Ford

-30° -20° -15° -10° 0° +30° +40°

CAUTION: Use Ford/Motorcraft “Formula E”

NOTE: Ford Power Products industrial engines

WARNING: PROLONGED AND REPEATED CONTACT MAY CAUSE SERIOUS

WARNING: DO NOT HANDLE A HOT OIL FILTER WITH BARE HANDS.

WARNING: WHEN REMOVING THE FUEL FILTER, USE CAUTION SINCE

NOTE: PROTECT THE ENVIRONMENT. It is illegal to pollute drains, water

Fuel Pump Fuel Supply

WARNING: THE DIS IGNITION SYSTEM COMMONLY CARRIES VOLTAGES

WARNING: PROTECTIVE GOGGLES MUST BE WORN TO PROTECT THE

CAUTION: Do not over tighten spark

5. Coat the inside of each spark plug boot

WARNING: ENGINE SHOULD BE STOPPED AND ANY REMOTE STARTER

WARNING: TO REDUCE THE RISK OF INJURY WHEN CHECKING A HOT

1. Allow the engine to cool down to 40°C (110°F).

1. Release the air cleaner lid retaining hardware.

CAUTION: Under no circumstances should the engine be started without liq-

The radiator or degas tank is equipped with a pressure cap. It is dangerous to

WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE

WARNING: ANTIFREEZE CONTAINS MONO ETHYLENE GLYCOL AND

WARNING: NEVER REMOVE THE PRESSURE

EPM - Power Distribution Box

Part of -12A690- Wiring Harness

Starter Fuel pump

Fuse Amps Circuits protected

1 30 Ground Protection for EPM and Megajector

Ignition Voltage to EPM, Starter Lockout Relay, Fuel Pump

3 20 Battery Voltage to EPM and Power Relay