Zenith NA665 Operator'S Manual Download Page 1

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202892

Rev-13 Nov 24, 2020

Heavy Duty

Engine

Operator Manual

and Maintenance Log

ZPP NA665, NA690, TA690, & TA6120

Stationary & Constant-Speed Mobile Industrial Engines

Summary of Contents for NA665

Page 1: ...202892 Rev 13 Nov 24 2020 Heavy Duty Engine Operator Manual and Maintenance Log ZPP NA665 NA690 TA690 TA6120 Stationary Constant Speed Mobile Industrial Engines...

Page 2: ...202892 Rev 13 Nov 24 2020...

Page 3: ...by you or 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...

Page 4: ...ons Engine oil filters Checking for gas leaks Natural Gas LPG fuel lock off valves Pre Post cat oxygen sensors Spark plugs wires 9 Diagnostics How to retrieve fault codes Fault Code List 24 Specificat...

Page 5: ...r engine as specified in this Operators Manual your engine will be considered a non certified engine In this case you must Keep a maintenance plan and records of conducted maintenance To the extent pr...

Page 6: ...entifies the ISO 8999 symbols that may be used in this manual Battery Electrical hazards Engine coolant fill level Engine coolant temperatur e Engine oil fill level Engine oil pressure Hot surface war...

Page 7: ...nsure the engine is free to turn without obstruction Check that all safety guards are in their correct position and secure Check that the coolant level in the radiator Check that the oil level on the...

Page 8: ...ectrolyte 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 a...

Page 9: ...ine quality natural gas must be provided by a supplier through a pipeline If your natural gas supply does not meet these specifications your engine is considered to be being operated as a non certifie...

Page 10: ...new engines disable the fuel lock off and crank the engine for 15 seconds to allow engine oil to circulate the engine before starting Enable the fuel lock off Turn the key switch to the START position...

Page 11: ...the engine serviced Listen to the engine If you hear an abnormal noise while the engine is running turn it off and correct the problem or have the engine serviced No adjustments are necessary to the f...

Page 12: ...nd 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 spec...

Page 13: ...pe of pre cat oxygen sensor and knock sensing The ECM s voltages and pre cat oxygen sensors are not interchangeable or upgradeable Using the wrong ECM voltage or pre cat oxygen sensor may damage your...

Page 14: ...11 Rev 13 Nov 23 2020...

Page 15: ...469 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...

Page 16: ...n 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 cable first...

Page 17: ...mbusted in the engine Oils which have been separated from the blow by gases are returned to the oil pan Service the CCV system at the intervals prescribed in the Maintenance schedule page 11 or more f...

Page 18: ...ratio Clean radiator outside 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 deteri...

Page 19: ...belt tension is to apply a force of 50N 5kg 11lb and measure the deflection between the alternator and Crankshaft pulley If the belt tension is not as specified adjust it DEFLECTION 10 20 mm 0 390 0...

Page 20: ...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 4 If any pins or...

Page 21: ...Oil Capacity Without filter 18 US Quarts 17 0 Liters With filter 19 US Quarts 17 9 Liters NA690 TA690 Engines Filter 201372 Oil Capacity Without filter 20 5 US Quarts 19 4 Liters With filter 22 0 US...

Page 22: ...of used oil at your local oil recycling center SELECTION OF ENGINE OIL API SERVICE GRADE CERTIFIED Use engine oil that is API Service Grade Certified Standard engine oil identification notations have...

Page 23: ...e leak or have it serviced 2 If there are no leaks detected 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...

Page 24: ...fitment The fuel lock off valve is located between the final stage regulator and NG fuel supply line or LPG supply The Engine Control Module ECM opens the fuel lock off when the ECM detects engine spe...

Page 25: ...are not interchangeable ZPP Part Numbers See Common Components in Figure 2 pg 19 for proper part number for your application Sensor Locations On Naturally Aspirated NA engines the pre cat O2 sensor i...

Page 26: ...Spark plug wire set 200614 202543 201071 Ignition Coils See Common Components Spark plug inspection 1 Remove one plug 2 Inspect plugs for fouling and erosion 3 Clean or replace plugs if needed Ignitio...

Page 27: ...ive 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 commun...

Page 28: ...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 sig...

Page 29: ...sor 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 30: ...ctronic 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 Cont...

Page 31: ...t 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 amoun...

Page 32: ...714 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 groun...

Page 33: ...talyst 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...

Page 34: ...int 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 8...

Page 35: ...4 Oil See ENGINE OIL AND FILTER REPLACEMENT Oil Filter 201989 Pre Cat Oxygen Sensor See Common Components Post Cat Oxygen Sensor See Common Components Spark Plugs 200613 Spark Plug Gap 0 025 inches 0...

Page 36: ...e 200584 Oil See ENGINE OIL AND FILTER REPLACEMENT Oil Filter 201372 Engine Coolant Filter 200582 Pre Cat Oxygen Sensor See Common Components Post Cat Oxygen Sensor See Common Components Spark Plugs 2...

Page 37: ...e ENGINE OIL AND FILTER REPLACEMENT Oil Filter 202542 2 per engine Pre Cat Oxygen Sensor See Common Components Post Cat Oxygen Sensor See Common Components Spark Plugs 200613 Spark Plug Gap 0 013 inch...

Page 38: ...201279 Post Catalyst 02 Sensor 201280 201280 Figure 2 Note Please note the type of ECU your engine is equipped with before ordering parts Selecting the wrong components can cause damage to the engine...

Page 39: ...catalyst and throttle are warranted for 3500 hours or 5 years whichever comes first The engine s operating hours are determined based on the Engine Control Module s ECM s hour meter The warranty perio...

Page 40: ...Exhaust manifold Rear Final stage LPG fuel pressure regulator Final stage natural gas fuel pressure regulator Fuel valve Ignition coils Ignition wires Intake manifold Knock sensors TA690 and TA6120 on...

Page 41: ...s covered until the end of the Emissions Warranty Period 3 Any warranted part that is scheduled for replacement in the Operators Manual is covered until the first replacement point for that part If th...

Page 42: ...____ Engine serial number ____________________________________ Engine application _______________________________________ Purchased from ________________________________________ In service date ______...

Page 43: ...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 Insp...

Page 44: ...coolant hoses for cracks swelling and Inspect charge cooler pipes and connections Inspect engine coolant filter Inspect engine coolant Clean fuel filter Inspect fuel lines hoses and fittings for gas l...

Page 45: ...or cracks swelling and deterioration Inspect charge cooler pipes and connections Replace engine coolant filter Inspect engine coolant Clean fuel filter Inspect fuel lines hoses and fittings for gas le...

Page 46: ...coolant hoses for cracks swelling and Inspect charge cooler pipes and connections Inspect engine coolant filter Inspect engine coolant Replace fuel filter Inspect fuel lines hoses and fittings for gas...

Page 47: ...for cracks swelling and deterioration Inspect charge cooler pipes and connections Replace engine coolant filter Replace engine coolant Clean fuel filter Inspect fuel lines hoses and fittings for gas...

Page 48: ...oolant hoses for cracks swelling and Inspect charge cooler pipes and connections Inspect engine coolant filter Inspect engine coolant Clean fuel filter Inspect fuel lines hoses and fittings for gas le...

Page 49: ...for cracks swelling and deterioration Inspect charge cooler pipes and connections Replace engine coolant filter Inspect engine coolant Replace fuel filter Inspect fuel lines hoses and fittings for gas...

Page 50: ...oolant hoses for cracks swelling and Inspect charge cooler pipes and connections Inspect engine coolant filter Inspect engine coolant Clean fuel filter Inspect fuel lines hoses and fittings for gas le...

Page 51: ...toff valve Dual fuel systems must have shutoff valves on both supply lines Fuel supply line fittings must be assembled with O2 sensor safe thread sealant ZPP recommends the use of Loctite 592 Thread S...

Page 52: ...l devices Electrical and electronic components should be spaced at least 12 if practical from exhaust components and other external heat sources Proper shielding and airflow should be provided to prot...

Page 53: ...to bystanders Isolation mounting can be utilized provided that proper earth grounds are used to insure the reduction of electrical emissions as well as static electricity Exhaust System Installation...

Page 54: ...oor or improper engine ground Improper ignition timing or phasing Sync loss between cam and crank sensor o Air gap between tooth and sensor o Failing camshaft or crankshaft position sensor o Debris on...

Page 55: ...0 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...

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