Zenith NA428, Operator'S Manual

Page 1: ...202890 Rev 5 Dec 2 2019 NA428 NA857 Stationary Emergency Industrial engines Operator Manual and Maintenance Log...

Page 2: ...202890 Rev 5 Dec 2 2019...

Page 3: ...any qualified engine service provider that you choose However your engine warranty does not cover damage or failure caused by improper maintenance or repairs Operators Manual Maintenance Log Storage U...

Page 4: ...ng system x Drive Belt x Engine oil filter x Checking for gas leaks x Natural Gas LPG fuel lock off valves x Oxygen sensor x Spark plugs wires Distributor cap and rotor 8 Diagnostics x How to retrieve...

Page 5: ...w to keep detailed maintenance records 2 If you operate your engine as a Stationary Emergency Engine but do not operate and maintain your engine as specified in this Operators Manual your engine will...

Page 6: ...3 Rev 5 Dec 2 2019 Spare Page...

Page 7: ...entifies the ISO 8999 symbols that may be used in this manual Battery Electrical hazards Engine coolant fill level Engine coolant temperature Engine oil fill level Engine oil pressure Hot surface warn...

Page 8: ...n without obstruction x Check that all safety guards are in their correct position and secure x Check that the coolant level in the radiator overflow bottle is between Add and Full x Check that the oi...

Page 9: ...trolyte in your eyes or on your skin or clothes If electrolyte gets in your eyes flush with clean water immediately and get medical help If electrolyte gets on your skin wash immediately with soap and...

Page 10: ...y natural gas as being composed of at least 70 methane by volume or having a heating value of 950 1100 BTUs per cubic foot In addition pipeline quality natural gas must be provided by a supplier throu...

Page 11: ...the engine during the first 3 minutes of operation x Verify that the CHECK ENGINE light is off while the engine is running If it is on refer to the DIAGNOSTICS section x Verify that there are no fuel...

Page 12: ...and fuel economy Scheduled Maintenance A schedule of the required engine maintenance tasks is listed on the following page The scheduled maintenance should be performed when the engine reaches the sp...

Page 13: ...vy duty operating condition more frequent maintenance may be necessary B At time of LPG cylinder replacement inspect tank connections for leakage with soapy water Abbreviations I Inspection R Replace...

Page 14: ...NTENANCE SCHEDULE and good reliabilityof the engine and emission control system in your application INTERVAL 3 4 5 6 7 750 1000 1250 1500 1750 R I I I I I I I I I I I I I I I I C C C C C R R R R R R R...

Page 15: ...battery does not need to be removed unless extended storage will be more than 30 days or if temperatures will fall below freezing The battery MUST be fully charged to prevent freezing Disconnect negat...

Page 16: ...7 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 reinsta...

Page 17: ...inspection 1 Check electrolyte level 2 If low top off with distilled water Do not overfill Battery corrosion inspection 1 Check battery posts and clamps for corrosion 2 If corroded remove negative ca...

Page 18: ...re 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 Inspection Cleaning 1...

Page 19: ...e Clean outside of radiator with dry compressed air Inspect cooling system hoses and connections Check hoses and fittings for loose connections or for any sign of oil deterioration or soft spots in th...

Page 20: ...t Tension Measure the belt tension midway between the alternator and water pump pulley as specified by the arrow in the left figure above Use a tensioning tool such as the one shown in the right figur...

Page 21: ...that it fits properly in the ribbed grooves Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley After installing a new belt run the engine for a...

Page 22: ...Remove the oil filter 2 Check and clean the oil filter installation surface 3 Check that the part number of the new oil filter is correct 4 Apply clean engine oil to the gasket of the new oil filter...

Page 23: ...rial applications regardless of the fuel selection i e gasoline LPG or natural gas SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil SAE 15W 40 specifies multiple vis...

Page 24: ...k or have it serviced 2 If there are no audible leaks start the engine 3 Check the entire fuel supply line from the source to the engine with a soapy water mixture A stream of bubbles indicates leak s...

Page 25: ...y switch is turned off or the ECM shuts down the engine for low oil pressure or engine overheat The lock off can sometimes gum up due to fuel deposits in the lock off The procedure below will verify i...

Page 26: ...ld The NA857 oxygen sensor is located in the exhaust pipe Snug the exhaust manifold and exhaust pipe bolts when replacing the oxygen sensor but do not overtighten Check for exhaust leaks by feeling fo...

Page 27: ...for cracks 3 Check posts for excessive wear 4 Replace cap if cracked or posts are badly worn Distributor rotor inspection NA857 only 1 Remove rotor and check tip for wear 2 If tip is worn 1 16 or mor...

Page 28: ...ve Data group Faults can be viewed and cleared with the CAN Gauge simply follow the steps when prompted Faults can also be viewed through the use of a PC tool with the appropriate software and communi...

Page 29: ...to noise on the signal or an intermittent connection on the crankshaft sensor 194 199 Communication response longer than expected 199 221 TPS1 sensor voltage out of range low normally set if TPS1 sign...

Page 30: ...or pressure higher than expected for a specified period of time 354 371 Manifold Air Temperature Sensor Voltage is Low normally set if the MAT temperature sensor wire has shorted to chassis ground or...

Page 31: ...tronic Throttle Control Driver has failed Normally set if either of the ETC driver signals have opened or become disconnected electronic throttle or SECM is defective 471 481 Electronic Throttle Contr...

Page 32: ...s upper limit for a specified amount of time and the desired boost pressure set point has not been reached 612 613 Intergal term on the boost control PID is at it s lower limit for a specified amount...

Page 33: ...14 Pre Catalyst O2 Sensor Heater Fault Heater has opened or shorted to ground or power or defective heater element 714 715 EGR Control Solenoid Fault control wire is open or shorted to power or ground...

Page 34: ...alyst failure sensor failure or wiring relay failure causing the sensor to not be properly heated If any Pre O2 753 761 Pre catalyst O2 sensor indicates extended lean operation on Gas 2 761 762 Post c...

Page 35: ...nt temperature 854 855 Sensor Heater duty cycle upper limit reached and sensor hasn t reached set point temperature 855 856 Sensor Temperature Set Point not reached after a specified period of time 85...

Page 36: ...ttery 12 V 750 Cranking Amps 600 Cold Cranking Amps 56 Ampere Hours Oil See ENGINE OIL AND FILTER REPLACEMENT Oil Filter NA428 200449 NA857 201105 Oxygen Sensor 201279 Spark Plugs NA428 200990 NA857 2...

Page 37: ...___ Engine serial number ____________________________________ Engine application _______________________________________ Purchased from ________________________________________ In service date _______...

Page 38: ...nty period is 2 years The warranty period begins when your engine is sold to the ultimate purchaser the original owner of the engine Owner Obligations This warranty is valid only if you operate and ma...

Page 39: ...rotor NA857 only x Engine Coolant Temperature ECT sensor x Engine Control Module ECM x Electronic throttle x Engine wiring harness x Exhaust manifold x Final stage natural gas fuel pressure regulator...

Page 40: ...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 le...

Page 41: ...e 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...

Page 42: ...OG 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 le...

Page 43: ...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 syste...

Page 44: ...OG 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 l...

Page 45: ...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...

Page 46: ...OG 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 l...

Page 47: ...44 Rev 5 Dec 2 2019 Notes...

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