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Zenith NA665 Operator's Manual

Heavy duty engine
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Heavy Duty
Engine
Operator Manual
and Maintenance Log
ZPP NA665, NA690, TA690, & TA6120
Stationary & Constant-Speed Mobile Industrial Engines
202892
Rev-13 Nov 24, 2020

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  • Page 1 Heavy Duty Engine Operator Manual and Maintenance Log ZPP NA665, NA690, TA690, & TA6120 Stationary & Constant-Speed Mobile Industrial Engines 202892 Rev-13 Nov 24, 2020...
  • Page 2 202892 Rev-13 Nov 24, 2020...
  • Page 3 Service Parts To ensure that your engine continues to run reliably and efficiently for as long as possible, use only genuine Zenith Power Products (ZPP) parts. For genuine ZPP service parts for your engine, or for technical assistance in servicing your engine, call:...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Page U.S. EPA Legal Requirements Safety Symbols & Precautions Fuels Starting, running, and stopping the engine Engine maintenance Schedule • ECM Identification • Air filter • Battery • CCV system • Engine coolant, radiator, and cooling • system Accessory drive belts •...

  • Page 5: U.s. Epa Legal Requirements

    U.S. EPA Legal Requirements The ZPP NA665, NA690, TA690, and TA6120 Natural Gas and LPG engines have been certified by the U.S. Environmental Protection Agency (EPA) as stationary and mobile constant-speed engines. It is illegal to operate these engines in a variable-speed (foot pedal speed control) application.

  • Page 6: Safety Symbols & Precautions

    SAFETY SYMBOLS This section identifies the ISO 8999 symbols that may be used in this manual. Electrical Battery hazards Engine Engine coolant coolant temperatur fill level Engine Engine oil oil fill pressure level surface Warning warning Read the handboo Smoking or Flame Rev-13 Nov 23, 2020...
  • Page 7 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, •...
  • Page 8 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. •...

  • Page 9: Fuels

    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 10: Starting, Running, And Stopping The Engine

    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.
  • Page 11 Running the engine Idle the engine during the first 3 minutes of • operation. Do not fully load until coolant level ª reaches 167 deg. F (75 deg. C). Verify that the "CHECK ENGINE" light is off • while the engine is running. If it is on, refer to the DIAGNOSTICS section.

  • 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 •...
  • Page 13 48 AND 70 PIN ECM’s During the 2017-2018 model years, ZPP’s NA665, NA690, and TA690 will transition from a 48-pin ECM to a 70-pin ECM. It is important to know which ECM you have on your engine, as the ECM determines the control system voltage, the type of pre-cat oxygen sensor, and knock sensing.
  • Page 14 Rev-13 Nov 23, 2020...

  • Page 15: Air Filter

    AIR FILTER Engine Element Part Number NA665/NA690 Primary 200469 Secondary 200289 TA690 Primary 202186 Secondary 201050 TA6120 Primary 202519 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 16: Battery

    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: 24 V Cranking Amps: 1200 Cold Cranking Amps: 1000...

  • Page 17: Ccv System

    CCV SYSTEM: NA665, NA690, & TA690 Engines Cartridge Part Number: 200584 TA6120 Engine Cartridge Part Number: 202541 The crankcase ventilation system processes the crankcase blow-by gases and oils in the filtration system. Gases are delivered to the intake air to be combusted in the engine.

  • Page 18: Engine Coolant, Radiator, And Cooling System

    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. When using antifreeze coolant, mix the antifreeze coolant with water, observing instructions attached to antifreeze container.

  • Page 19: Accessory Drive Belts

    ACCESSORY DRIVE BELTS Engine Belt P/N # per Engine NA665 202334 NA/TA690 200577 TA6120 202544 - Alt/WP 202545 - Fan Inspection Check the belt for visible cracks, missing chunks, and fraying. Small cracks on the inside of the belt are OK.

  • Page 20: Electrical Connections

    ELECTRICAL CONNECTIONS 1. Visually inspect the electrical connections in the wiring harness for loose connections. 2. If you see a loose connection, or suspect a loose connection for other reasons, take the connection apart. 3. Visually inspect the pins in the male connector and the sockets in the female connector.
  • Page 21 ENGINE OIL AND FILTERS REPLACEMENT Oil Grade: See “SELECTION OF ENGINE OIL” API Certification: SJ or better NA665 Engine Filter: 201989 Oil Capacity - Without filter 18 US 17.0 Liters Quarts - With filter 19 US 17.9 Liters Quarts NA690 & TA690 Engines...
  • Page 22 DRAIN THE ENGINE OIL 1. Remove the oil filler cap. 2. Remove the oil drain plug and drain the oil into a container. REPLACE THE OIL FILTER 1. Remove the oil filter. 2. Check and clean the oil filter installation surface. 3.

  • Page 23: 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 or smell a fuel leak, shut off the fuel supply at the source immediately and fix the leak or have it serviced.

  • Page 24: Natural Gas & Lpg Fuel Lock-Off Valves

    NATURAL GAS & LPG FUEL LOCK-OFF VALVES Due to the many variances of Fuel Lock-Off valves, if replacement is necessary, please contact ZPP Parts Sales to assure proper application and fitment. The fuel lock-off valve is located between the final stage regulator and NG fuel supply line or LPG supply.
  • Page 25 PRE- AND POST-CATALYST OXYGEN SENSORS During the 2017-2018 model years, ZPP will be transitioning from a 48-pin ECM to a 70-pin ECM. The switching type (HEGO) used by the 48 pin and the wide-range (UEGO) sensors used by the 70 pin use different connectors.

  • Page 26: Spark Plugs & Wires

    SPARK PLUGS & WIRES Ignition System Part Specifications NA690 & NA665 TA6120 TA690 Spark Plugs 200613 200613 201004 Socket Size 14 mm 14 mm 5/8 in Spark plug gap .025 in 0.013 in 0.020 in .0635 mm 0.330 mm 0.508 mm...

  • Page 27: Diagnostics

    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.
  • Page 28 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 29 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 30 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 31 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 32 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 33 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 34 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...

  • Page 35: Specifications

    SPECIFICATIONS for NA665 Engine Component NA665 Air Filter Elements: Primary: 200469 Secondary: 200289 Accessory Drive 202344 belts: 24 V, 150 Amp Hours Battery: 950 Cranking Amps, 750 Cold Cranking Amps CCV Cartridge: 200584 See “ENGINE OIL AND FILTER Oil: REPLACEMENT”...
  • Page 36 SPECIFICATIONS for NA690 & TA690 Engines Component NA690 TA690 Air Filter Primary: 200469 Primary: 202186 Elements: Secondary: 200289 Secondary: 201050 Accessory Drive 200577 belts: 24 V, 170 Amp Hours Battery: 24 V, 2,200 Cranking Amps, 1,900 Cold Cranking Amps CCV Cartridge: 200584 See “ENGINE OIL AND FILTER Oil:...
  • Page 37 SPECIFICATIONS for TA6120 Engine Component TA6120 Air Filter Elements: 202519 202544 - Alt/WP Accessory Drive belts: (2) 202545 - Fan 24 V, 180 Amp Hours Battery: 1,200 Cranking Amps 950 Cold Cranking Amps CCV Filter: 202541 See “ENGINE OIL AND FILTER Oil: REPLACEMENT”...

  • Page 38: Common Components

    Selecting the wrong components can cause damage to the engine and/or fuel control system. If you are uncertain of the ECU Type, please call Zenith Power Products at (276)525-4760 with your engine serial number for assistance.

  • Page 39: Engine Warranty

    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 1048 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 40 Components Covered under the 2500 hour/3-year Warranty CAM sensor • CCV system • EGR cooler (TA6120 only) • EGR flow control valve (TA6120 only) • EGR pressure regulator (TA6120 only) • EGR 3-way solenoid valve (TA6120 only) • Electronic throttle (except TA6120) •...
  • Page 41 Engine Warranty Details ZPP’s warranty on emissions-related parts is specified as follows: 1) Any part that is not scheduled for replacement as required maintenance in the Operators Manual shall be warranted for the entire Emissions Control System (Emissions) Warranty Period. If any emissions-related part fails during the Emissions Warranty Period, it will be replaced by ZPP per subsection 4) below.

  • Page 42: Engine Identification

    Engine Identification Engine part number _____________________________________ Engine serial number ____________________________________ Engine application _______________________________________ Purchased from ________________________________________ In-service date __________________________________________ Engine hours at delivery __________________________________ Rev-13 Nov 23, 2020...

  • Page 43: Maintenance Log

    MAINTENANCE LOG Service Interval: 250 Hours or 4 Months □ Replace engine oil and filters □ Clean debris from radiator core □ Inspect fuel filter □ Inspect fuel lines, hoses, and fittings for gas leakage □ Inspect exhaust system for cracks or leaks & tighten □...
  • Page 44 MAINTENANCE LOG Service Interval: 750 Hours or 13 Months □ Replace engine oil and filters □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and □ Inspect charge cooler pipes and connections □...
  • Page 45 MAINTENANCE LOG Service Interval: 1500 Hours or 25 Months □ Replace engine oil and filters □ Inspect crankcase ventilation filter □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and deterioration □...
  • Page 46 MAINTENANCE LOG Service Interval: 2250 Hours or 38 Months □ Replace engine oil and filters □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and □ Inspect charge cooler pipes and connections □...
  • Page 47 MAINTENANCE LOG Service Interval: 3000 Hours or 50 Months □ Replace engine oil and filters □ Inspect crankcase ventilation filter □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and deterioration □...
  • Page 48 MAINTENANCE LOG Service Interval: 3750 Hours or 63 Months □ Replace engine oil and filters □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and □ Inspect charge cooler pipes and connections □...
  • Page 49 MAINTENANCE LOG Service Interval: 4500 Hours or 76 Months □ Replace engine oil and filters □ Inspect crankcase ventilation filter □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and deterioration □...
  • Page 50 MAINTENANCE LOG Service Interval: 5250 Hours or 88 Months □ Replace engine oil and filters □ Inspect air filter element □ Inspect accessory drive belts □ Clean debris from radiator core □ Inspect coolant hoses for cracks, swelling, and □ Inspect charge cooler pipes and connections □...
  • Page 51 ZPP recommends a maximum of 1, 90° elbow per installation. The following are guidelines for vapor fuel supply line installation: Supply NA665 NA690 TA690 TA6120 Line 1” •...

  • Page 52: Engine Installation Guide

    LPG Liquid Withdrawal Fuel System Installation All LPG Liquid Withdrawal systems must utilize a hydrostatic relief valve or a device providing pressure- relieving protection that complies with section 2-4.7 of NFPA 58. Relief valve should be installed in each section of piping (including hose), in which liquid LP-Gas can be isolated between shutoff valves, to relieve the pressure that could develop from the trapped liquid, to a safe atmosphere.
  • Page 53 Air inlet temperature should not exceed ambient temperature. Measurements between ambient and manifold temperature sensor should not exceed 30° F. High air inlet temperatures can cause engine detonation and improper fueling which can lead to poor performance and severe engine damage. Electrical components and controls should be properly shielded from water.
  • Page 54 Engine Misfire/Backfire Troubleshooting Improper air to fuel ratio • Failing oxygen sensor Improper or insufficient fuel pressure Poor fuel quality Incorrect spark plug or gap • Cracked insulator on spark plug • Damaged or leaking ignition cable • High resistance in Ignition cable •...
  • Page 55 Appendix This supplement is to assist in the operation of ZPP engines equipment equipped with Dynagen TE350 and TG410 controllers. The following pages will assist you in navigating through the basic controller functions. Rev-13 Nov 23, 2020...
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This manual is also suitable for:

Na690Ta690Ta6120

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