Related Manuals for Zenith NA428
Summary of Contents for Zenith NA428
- Page 1 NA428- NA857 Stationary Emergency Industrial engines Operator Manual and Maintenance Log 202890 Rev-5 Dec 2, 2019...
- Page 2 202890 Rev-5 Dec 2, 2019...
- Page 3 Disclaimer All information and specifications in this manual are based on the latest data available at the time of the publication. Zenith Power Products reserves the right to make changes or improvements at any time without notice.
- Page 4 TABLE OF CONTENTS Page U.S. EPA Legal Requirements Safety Symbols & Precautions Fuels Starting, running, and stopping the engine Engine maintenance Schedule Air filter Battery PCV system Engine coolant, radiator, and cooling system Drive Belt Engine oil & filter Checking for gas leaks Natural Gas &...
- Page 5 U.S. EPA Legal Requirements The ZPP NA428 & NA857 Natural Gas and LPG Vapor engines have been certified by the U.S. Environmental Protection Agency (EPA) as Stationary Emergency Engines. It is illegal to operate these engines in a prime or emergency mobile application or a prime stationary application.
- Page 6 Spare Page Rev-5 Dec 2, 2019...
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Page 7: Safety Symbols
SAFETY SYMBOLS This section identifies the ISO 8999 symbols that may be used in this manual. Electrical Battery hazards Engine Engine coolant coolant fill level temperature Engine oil fill Engine oil level pressure Hot surface Warning warning Read the No Smoking or handbook Flame Rev-5 Dec 2, 2019... - Page 8 SAFETY PRECAUTIONS – STARTING WARNING Starting an engine incorrectly may cause injury to the operator and/or cause damage to the engine. Engine operators must be instructed in the correct procedures before attempting to start any engine. Before Starting Inspect the engine, intake, exhaust, cooling system, and drivetrain to verify that the engine is fully assembled and not in the process of being serviced.
- Page 9 SAFETY PRECAUTIONS – ELECTRICAL The battery produces flammable and explosive hydrogen gas. The battery electrolyte contains poisonous and corrosive sulfuric acid. The precautions listed below must be followed to ensure operator safety. Do not smoke or allow any flame near the battery. With the engine stopped and the ignition switch in the OFF position, disconnect the negative battery cable from the battery before working on the engine.
- Page 10 FUELS Natural gas and LPG are combustible gases, and can be explosive if leaked and contained in a confined area. Keep cigarettes and all other flame sources away from these areas. If you can hear a fuel leak, shut off the fuel supply at the source immediately and fix the leak or have it serviced.
- Page 11 STARTING, RUNNING, & STOPPING THE ENGINE Observe the safety precautions listed in "SAFETY PRECAUTIONS - STARTING" before starting the engine. Starting the engine Turn the key switch to the ON position and verify that the MIL is illuminated. If not determine why the lamp is not working. Turn the key switch to the START position and hold until the engine has started.
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Page 12: Engine Maintenance
ENGINE MAINTENANCE You should properly maintain your engine for the following reasons. You are legally required to maintain your engine and keep maintenance records to ensure emissions compliance. See "U.S. EPA Legal Requirements" at the front of this manual. Your engine warranty will be void if the engine is not properly maintained. - Page 13 ZPP NA428 & NA857 STATIONARY EMERGENCY ENGINE AND This table lists the periodic maintenance required to ensure quality performance MAINTENANCE Periodic maintenance should be performed after specified Years intervals have elapsed in years or hours, whichever comes first Hours Air filter...
- Page 14 EMISSIONS CONTROL SYSTEM MAINTENANCE SCHEDULE and good reliability of the engine and emission control system in your application. INTERVAL 1000 1250 1500 1750 FOR LPG FUEL SYSTEM Rev-5 Dec 2, 2019...
- Page 15 STORAGE If the Stationary Emergency engine will not be placed in service right away, or if the unit is removed from service and will be stored for an unanticipated length of time, please follow the steps below to avoid damage to your engine. 1.
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Page 16: Air Filter
AIR FILTER NA428 Air Filter: 200476 NA857 Air Filter: 200469 Primary 200289 Secondary (If Equipped) Inspection 1. Remove air filter element from enclosure. 2. Tap filter to knock off loose dirt. 3. Visually check filter. 4. If filter is clean, reinstall old filter. - Page 17 BATTERY The battery produces flammable and explosive hydrogen gas. The battery electrolyte contains poisonous and corrosive sulfuric acid. Review the safety precautions in "SAFETY PRECAUTIONS - ELECTRICAL" before working on the battery. Battery Specifications Nominal Voltage: 12 V Cranking Amps: Cold Cranking Amps: Ampere Hours Battery voltage during alternator charging:...
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Page 18: Pcv System
PCV SYSTEM The Positive Crankcase Ventilation (PCV) system recirculates the crankcase blow-by gases into the intake manifold to be combusted in the engine. When the blow-by vapor pressure is high enough to overcome the spring pressure in the PCV valve, the valve opens to allow blow-by vapor into the intake manifold for combustion along with the fuel/air mixture. - Page 19 ENGINE COOLANT, RADIATOR, AND COOLING SYSTEM To avoid being scalded or burned, never remove the radiator cap unless the engine is off and coolant has fully cooled. The coolant in the radiator is pressurized when hot and may boil over when the radiator cap is loosened.
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Page 20: Drive Belt
DRIVE BELT 428 Belt P/N: 201368 857 Belt P/N: 200196 Inspection Check the belt for visible cracks, missing chunks, and fraying. Small cracks on the inside of the belt are OK. Replace the belt if cracks are visible on the outside of the belt, chunks are missing from the inside of the belt, or the belt is frayed. - Page 21 DRIVE BELT – CONTINUED NOTE: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. After installing a belt, check that it fits properly in the ribbed grooves.
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Page 22: Engine Oil And Filter Replacement
ENGINE OIL AND FILTER REPLACEMENT NA428 NA857 Filter: 200449 201105 Oil Grade: See “SELECTION OF ENGINE OIL” API Certification: SJ or better Oil Capacity (with filter): 5.0 qt/4.7L 5.0 qt/4.7 L DRAIN THE ENGINE OIL 1. Remove the oil filler cap. - Page 23 SELECTION OF ENGINE OIL API SERVICE GRADE CERTIFIED Use engine oil that is API Service Grade Certified. Standard engine oil identification notations have been adapted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans.
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Page 24: Checking For Gas Leaks
CHECKING FOR GAS LEAKS Natural gas and LPG are combustible gases, and can be explosive if leaked and contained in a confined area. Keep cigarettes and all other flame sources away from these areas. Inspection 1. If you can hear a fuel leak, shut off the fuel supply at the source immediately and fix the leak or have it serviced. - Page 25 NATURAL GAS & LPG FUEL LOCK-OFF VALVES ZPP recommends the following lock-offs for the 428 and 857 engines. NA428: 201469 NA857: 201471 The fuel lock-off valve is located between the final stage regulator and NG fuel supply line or LPG cylinder. The Engine Control Module (ECM) opens the fuel lock-off when the ECM detects engine speed from the CRANK sensor during cranking.
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Page 26: Oxygen Sensor
ZPP Part Number: 201279 Sensor Locations: The NA428 oxygen sensor is located at the outlet of the exhaust manifold. The NA857 oxygen sensor is located in the exhaust pipe. Snug the exhaust manifold and exhaust pipe bolts when replacing the... - Page 27 SPARK PLUGS, WIRES, DISTRIBUTOR CAP AND ROTOR Ignition System Part Specifications NA428 NA857 Distributor 202354 Distributor 202355 rotor Spark plugs 200990 200174 Spark plug 0.035 in. 0.028 in. 0.89 mm 0.711 mm Spark plug wires 201025 201106 Distributor cap inspection (NA857 only) 1.
- Page 28 DIAGNOSTICS How to manage and retrieve fault codes A MIL (malfunction indicator lamp) is provided to notify the engine operator of potential problems with the emissions control system. With the key ON and engine OFF the MIL will illuminate to indicate it is functioning properly. If the key switch is ON and the engine is OFF and the MIL is not illuminated there is a problem with the MIL circuit.
- Page 29 Diagnostic Trouble Code (DTC) List Fault Description Flash Code Auto engine crank function exceeded specified number of engine crank attempts without succesful engine start Manual engine crank function exceeded specified number of engine cranks without succesful engine start Engine Coolant Temperature Sensor voltage is Low. Normally set if the coolant sensor wire has shorted to chassis ground or the sensor has failed.
- Page 30 DTC List – Continued Fault Description Flash Code Manifold Absolute Pressure Sensor Voltage is Low, normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the circuit has opened to the SECM Manifold Absolute Pressure Sensor Voltage is Low, normally set if the TMAP pressure signal wire has been disconnected or shorted to ground or the circuit has opened to the SECM Manifold Absolute Pressure Sensor Voltage is High, normally set if the...
- Page 31 DTC List – Continued Fault Description Flash Code EST1 output shorted high or low, EST1 signal shorted to ground or power or defective spark module EST2 output shorted high or low, EST2 signal shorted to ground or power or defective spark module EST3 output shorted high or low, EST3 signal shorted to ground or power or defective spark module EST4 output shorted high or low, EST4 signal shorted to ground or power...
- Page 32 DTC List – Continued Fault Description Flash Code Pre-Throttle sensor is out of range low, possible short to ground Pre-Throttle sensor is out of range high, possible short to power +12V or +24V System voltage too low +12V or +24V System voltage too high +5V Sensor reference voltage XDRP too low +5V Sensor reference voltage XDRP too high Engine speed has exceeded the third level (3 of 3) of overspeed protection...
- Page 33 DTC List – Continued Fault Description Flash Code EGR dP Sensor Voltage is Low, normally set if the pressure signal wire has been disconnected or shorted to ground or the input circuit to the SECM is open EGT is to High which caused the Torque Limiting fault action to be enabled Emergency shutdown of the engine either manually by the operator or automatically by specified external conditions...
- Page 34 DTC List – Continued Fault Description Flash Code Pre-catalyst O2 sensor inactive on Gas 1, may be due to open O2 sensor signal or heater leads, defective O2 sensor Post-catalyst fuel control on Gas 1 has sensed the O2 sensor is changing too frequently and too much.
- Page 35 DTC List – Continued Fault Description Flash Code Fuel pressure sensor signal indicates higher pressure than expected Fuel pressure sensor signal indicates lower pressure than expected Fuel pressure sensor voltage out of range high, normally set if the pessure signal wire has become shorted to power or the SECM input circuit has failed Fuel pressure sensor voltage out of range low, normally set if the pessure signal wire has become shorted to ground, disconnected, or the SECM...
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Page 36: Specifications
NA428: 200449 NA857 201105 Oxygen Sensor: 201279 Spark Plugs: NA428: 200990 NA857: 200174 Spark Plug Gap: NA428: 0.028 in. (0.711) mm NA857: 0.028 in. (0.711) mm Spark Plug wires: NA428: 201125 NA857: 200174 Recommended NA428: 201469 Natural Gas NA857: 201471 &... - Page 37 Engine Identification Engine part number _____________________________________ Engine serial number ____________________________________ Engine application _______________________________________ Purchased from ________________________________________ In-service date __________________________________________ Engine hours at delivery __________________________________ Rev-5 Dec 2, 2019...
- Page 38 Engine Warranty Warranty Provisions Zenith Power Products, LLC warrants that this engine was designed, built, and equipped so that it fully complies with the applicable emissions standards of U.S. EPA 40 CFR 60 and 90 at the time of sale to you, the end customer, and that the engine is free of defects in materials and workmanship that may keep it from meeting the emissions standards.
- Page 39 Engine Warranty Components Covered under the 2 year Warranty Air Valve Carburetor CAM sensor CRANK sensor Distributor cap & rotor (NA857 only) Engine Coolant Temperature (ECT) sensor Engine Control Module (ECM) Electronic throttle Engine wiring harness Exhaust manifold Final stage natural gas fuel pressure regulator Fuel supply pressure trim valve Ignition coil pack Intake manifold...
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Page 40: Maintenance Log
MAINTENANCE LOG Service Interval: 250 Hours or 1 Year Inspect Drive belt Inspect battery Inspect engine coolant Clean radiator outside Replace engine oil and filter Inspect fuel lines, hoses, and fittings for gas leakage Date: Engine Hours: Mechanic: Rev-5 Dec 2, 2019... - Page 41 MAINTENANCE LOG Service Interval: 500 Hours or 2 Years Inspect air filter Inspect Drive belt Inspect battery Inspect engine coolant Clean radiator outside Replace engine oil and filter Inspect fuel lines, hoses, and fittings for gas leakage Date: Engine Hours: Mechanic: Rev-5 Dec 2, 2019...
- Page 42 MAINTENANCE LOG Service Interval: 750 Hours or 3 Years Inspect Drive belt Inspect battery Inspect engine coolant Clean radiator outside Replace engine oil and filter Inspect fuel lines, hoses, and fittings for gas leakage Date: Engine Hours: Mechanic: Rev-5 Dec 2, 2019...
- Page 43 MAINTENANCE LOG Service Interval: 1000 Hours or 4 Years Replace air filter Inspect Drive belt Inspect battery Replace engine coolant Clean radiator outside Replace engine oil and filter Inspect spark plugs Inspect spark plug wires Inspect distributor cap and rotor (NA857 only) Inspect PCV system Inspect fuel lines, hoses, and fittings for gas leakage Inspect fuel lock-off valve(s)
- Page 44 MAINTENANCE LOG Service Interval: 1250 Hours or 5 Years Inspect Drive belt Inspect battery Inspect engine coolant Clean radiator outside Replace engine oil and filter Inspect fuel lines, hoses, and fittings for gas leakage Date: Engine Hours: Mechanic: Rev-5 Dec 2, 2019...
- Page 45 MAINTENANCE LOG Service Interval: 1500 Hours or 6 Years Inspect air filter Inspect Drive belt Inspect battery Replace engine coolant Clean radiator outside Replace engine oil and filter Inspect fuel lines, hoses, and fittings for gas leakage Date: Engine Hours: Mechanic: Rev-5 Dec 2, 2019...
- Page 46 MAINTENANCE LOG Service Interval: 1750 Hours or 7 Years Inspect Drive belt Inspect battery Inspect engine coolant Clean radiator outside Replace engine oil and filter Inspect fuel lines, hoses, and fittings for gas leakage Date: Engine Hours: Mechanic: Rev-5 Dec 2, 2019...
- Page 47 Notes Rev-5 Dec 2, 2019...