Zenith 428 644_Engine OPM 644 Engine

User Manual: Zenith-428-644_Engine-OPM

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428 & 644 Stationary
Industrial Engines
Owner's Manual and
Maintenance Log
2015

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:

1-276-525-4760
Hours:
Monday-Friday 8:00 – 5:00 Eastern Time

Maintenance Providers
Maintenance and repair services may be performed 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.

Owners Manual & Maintenance Log Storage & Use
Store this Owners Manual and Maintenance Log in a safe,
visible place by your engine. The maintenance log must be
updated whenever your engine is serviced.

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.
For additional information see:
www.ZenithPowerProducts.com

428 & 644 Stationary Engines
Owners Manual

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
 CCV system
 Engine coolant, radiator, and cooling system
 Drive Belt
 Engine oil & filter
 Checking for gas leaks
 Natural Gas & LPG fuel lock-off valves
 Pre- & Post-cat oxygen sensors
 Spark plugs & wires

2
3
6
7
8

Diagnostics
 How to retrieve fault codes
 Fault Code List

Specifications
Engine Identification
Engine Warranty
 Warranty provisions
 Base warranty period
 Emissions-related warranty period
 Owner's obligations
 Component lists

28
29
30

Maintenance Log

428 & 644 Stationary Engines
Owners Manual

U.S. EPA Legal Requirements
The ZPP 428 & 644 Natural Gas and LPG Vapor 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.
To ensure emissions compliance, the U.S. EPA requires you to do one of
the following two options:
1. Operate and maintain your engine as specified in this Owners
Manual. In addition, you are required by law to keep detailed
maintenance records.
2. If you do not operate and maintain your engine as specified in
this Owners Manual, your engine will be considered a noncertified engine.
In this case, you must:
 Keep a maintenance plan and records of conducted
maintenance.
 To the extent practicable, maintain and operate the engine in
a manner consistent with good air pollution control practice
for minimizing emissions.
 Conduct an initial performance test within 1 year of engine
startup to demonstrate compliance. Contact your regional
EPA office for instructions on how to conduct an initial
performance test.
Per section 113 of the U.S. Clean Air Act, failure to abide by these legal
requirements can result in fines up to $25,000 per day.
A maintenance plan and log are provided at the back of this manual for
you to record your engine maintenance. Update the log each time you
service your engine.

428 & 644 Stationary Engines
Owners Manual

SAFETY SYMBOLS
This section identifies 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
warning

Warning

Read the
handbook

No Smoking or
Flame

428 & 644 Stationary Engines
Owners Manual

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.



Ensure 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 overflow bottle is between
"Add" and "Full".



Check that the oil level on the dipstick is between "Add" and "Full".



Check that the fuel supply is connected, shut-off valves are open,
and there are no leaks.



If a LPG fuel system is being used, verify that there is fuel in the
cylinder/tank.



If a natural gas fuel system is being used, verify that the correct fuel
supply pressure is being supplied to the engine.



Check that the battery is connected and charged.



When possible, disengage any driven equipment while starting.

428 & 644 Stationary Engines
Owners Manual

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.



Be careful not to short circuit battery positive to ground with tools
when working on the engine.



Avoid getting battery electrolyte 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 water and get medical
help if you feel pain or burning. Remove and wash any clothing
that is exposed to electrolyte.



Never remove any electrical cables while the battery is
connected in the circuit.



Be careful to not short-circuit or cross battery positive and
negative.



Never ‘flash’ any connection to check the current flow.



The battery and alternator must be disconnected before
commencing any electric welding when a pole strap is directly or
indirectly connected to the engine.



When charging the battery, only do a slow charge (5 A or less),
and ensure there is good ventilation.
5

428 & 644 Stationary Engines
Owners Manual

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. Check the entire fuel
supply line from the cylinder/tank to the engine for leaks with a soapy
water bubble mixture anytime a cylinder/tank is changed or the fuel
supply line is worked on. Fuel leaks should also be checked as part of
the regular engine maintenance.
Depending on your engine and fuel system configuration, your engine is
designed to run on natural gas and/or vapor LPG. The fuel requirements for
each are discussed below. See the "SPECIFICATIONS" section for the required
fuel supply pressures for each fuel.
Natural Gas
Your engine is certified to run on "pipeline-quality natural gas". EPA defines
pipeline-quality natural gas as being composed of at least 70% methane by
volume or having a heating value of 950-1100 BTUs per cubic foot. If your
natural gas supply does not meet these specifications, your engine is considered
to be being operated as a non-certified engine. See "U.S. EPA Legal
Requirements" at the front of this manual.
LPG
In order to maintain emissions compliance and the engine warranty, use
commercial-grade HD-10 or better LPG.
Liquid LPG is drawn off of the bottom side of a LPG tank or cylinder and is a
liquid until it has passed through the regulator/vaporizer, at which point it is
vaporized to a gas. If you connect vapor LPG to a liquid LPG fuel system, you
may starve the engine for fuel, causing it to produce low power and excessive
emissions.
Vapor LPG is drawn off of the top side of a LPG tank or cylinder and is a gas
from the tank/cylinder through to the engine intake. If you connect liquid LPG to
a vapor LPG fuel system the fuel will not vaporize properly, causing the engine to
run rich, produce low power and excessive emissions.

428 & 644 Stationary Engines
Owners Manual

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.
 Release the key promptly after the engine starts to avoid
grinding the starter.
 Do not crank the engine for more than 15 seconds at a time.
 Allow at least 30 seconds between cranking attempts.
 If the engine does not start after 3 starting attempts, review the
"Before Starting" checklist.
Running the engine
 Do not race or fully load the engine during the first 3 minutes of
operation.
 Verify that the "CHECK ENGINE" light is off while the engine is
running. If it is on, refer to the DIAGNOSTICS section.
 Verify that there are no fuel, coolant, or oil leaks while the engine
is running. If there are leaks, stop the engine and fix them or
have 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 fuel or ignition systems.
Stopping the engine
 If the engine has been running under load and is hot, run the
engine at no load for 3 minutes to allow the engine to cool before
stopping the engine.
 Stop the engine by turning the key switch to the OFF position.
The engine may run-on for 1-5 seconds while the fuel is depleted
from the carburetor and the air/fuel mixture is depleted from the
intake manifold.

428 & 644 Stationary Engines
Owners Manual

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.



Keeping your engine properly maintained will ensure the best
engine life, power, 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 specified operating hours or the specified months
have elapsed, whichever comes first.
Daily Maintenance
In addition to the scheduled maintenance, daily checks are required to
keep your engine running properly. These checks are listed in the
"SAFETY PRECAUTIONS - STARTING" and "STARTING, RUNNING, &
STOPPING THE ENGINE" sections.
Maintenance Log
Keep a record of your engine's scheduled maintenance in the
Maintenance Log at the back of this manual.

428 & 644 Stationary Engines
Owners Manual

Spare Page

428 & 644 Stationary Engines
Owners Manual

ZPP 428 & 644 ENGINE AND FUEL
The following table lists the periodic maintenance required to ensure that your engine, fuel system and catalyst work properly

MAINTENANCE
Periodic maintenance should be performed after specified
intervals have elapsed in months or hours, whichever comes first.

Months
Hours

4
250

8
500

13
750

17
1000

21
1250

25
1500

I
I

I
I
I

I
I

R
I
I

I
I

I
I
I

ENGINE
Air filter
Battery
Drive Belt

(A)

Engine coolant
Radiator outside

(A)

I
C

R
C

I
C

Engine oil
Oil Filter

(A)
(A)

R
R

Spark Plugs
Spark Plug Wires (428 only)

I
I

Pre-Catalyst and Post-Catalyst HEGO Sensors
CCV system

FUEL SYSTEM
Check fuel hoses and fittings for gas leakage
Fuel Lock-off valve(s)
Notes:

Abbreviations:

(B)

I
I

A) Under heavy duty operating condition, more frequent maintenance might be necessary.
B) At time of LPG cylinder replacement, inspect tank connections for leakage with soapy water.
I = Inspection
I = Inspection
R= Replace
A= Adjust
C= Clean
D= Drain
T= Retighten

428 & 644 Stationary Engines
Owners Manual

SYSTEM MAINTENANCE SCHEDULE
and stay in good condition.

INTERVAL
29
1750

34
2000

38
2250

42
2500

46
2750

50
3000

55
3250

59
3500

63
3750

67
4000

71
4250

76
4500

80
4750

84
5000

MAINTENANCE
I
I

R
I
I

I
I

I
I
R

I
I

R
I
I

I
I

I
I
I

I
I

R
I
I

I
I

I
I
I

I
I

R
I
R

I
C

R
C

I
C

R
C

I
C

R
C

I
C

R
C

R
R

I
I

R
R

R
I

MAINTENANCE
I

I
I

428 & 644 Stationary Engines
Owners Manual

AIR FILTER
428 Air Filter: Enginaire 3-FW-E1 or equivalent
644 Air Filter: Enginaire 3.75 FW-E1 or equivalent
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.
If filter is dirty, replace with a new filter.

428 & 644 Stationary Engines
Owners Manual

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:
Cranking Amps:
Cold Cranking Amps:
Battery voltage during alternator charging:
Fully charged battery with key off @ 20 C (68 F):
Half charged battery with key off @ 20 C (68 F):
Discharged battery with key off @ 20 C (68 F):

12 V
750
600
14.0 -15.0 V
12.5 -13.0 V
12.0 - 12.5 V
less than 12.0 V

Battery electrolyte 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 cable first, then positive.
3. Clean both posts and both clamps with a small wire brush.
4. Reconnect cables, positive cable first.
If the engine is cranking slowly or not at all:
1. Remove the battery negative lead from the battery.
2. Remove the positive lead from the battery.
3. Clean the battery posts and cables with a small wire brush.
4. Replace leads, positive lead first.
If the engine is still cranking slowly or not at all:
1. Remove the battery negative leads.
2. Recharge the battery in a well-ventilated area.
3. Reinstall the battery.
If the engine is still cranking slowly or not at all:
Replace the battery.

428 & 644 Stationary Engines
Owners Manual

CCV SYSTEM
Fresh
Air Inlet

CCV
Orifice

The crankcase ventilation system recirculates the crankcase blow-by
gases into the intake manifold to be combusted in the engine. A small
constant stream of air is drawn from air inlet, circulated under the valve
cover, then sucked through the CCV orifice into the intake manifold for
combustion along with the fuel/air mixture.
Inspection & Cleaning:
1. Remove and inspect the fresh air inlet hose and fitting.
Clean or replace if needed.
2. Remove and inspect the CCV hose.
Clean or replace as necessary.
3. Remove and inspect the CCV orifice.
Clean orifice as necessary.

428 & 644 Stationary Engines
Owners Manual

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. Use only
antifreeze approved for aluminum components in a 50/50 mixture 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
deterioration or soft spots in the hoses. Retighten connections or replace
hoses if needed.
Check coolant level. If low, top off coolant with a premixed 50/50 mixture
of antifreeze and water.
Engine Coolant Replacement
1. Open overflow bottle cap.
2. Drain old coolant.
3. Flush system with fresh, clean water.
4. Slowly refill system with premixed 50/50 antifreeze/water
mixture.
5. Idle engine with radiator cap off to allow air to escape.
6. Top off coolant in overflow bottle if needed.
7. Stop engine.
8. Replace radiator cap and close overflow bottle cap.

428 & 644 Stationary Engines
Owners Manual

DRIVE BELT
428 & 644 Belt P/N:

C672-701

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.
Belt 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 figure above (OTC 6673LG or
equivalent).
Deflection:
A second method of measuring belt tension is to apply a force of 98N
(10kg, 22lb), and measure the deflection between the alternator and
water pump pulley. If the belt tension is not as specified, adjust it.
DEFLECTION
New belt
8.5 ~ 9.5mm (0.3346 ~ 0.3740in.)
Used belt
9.5 ~ 11.0mm (0.3740 ~ 0.4331in.)
16

428 & 644 Stationary Engines
Owners Manual

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. 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 about 5 minutes and recheck the belt
tension.
Belt Replacement
1. Release all tension from the old belt.
2. Remove the old belt.
3. Install the new belt.
4. Apply tension to the belt as specified in "Belt Tension".
5. Recheck tension after 25-50 hours of operation.

428 & 644 Stationary Engines
Owners Manual

ENGINE OIL AND FILTER REPLACEMENT

428
Filter:
Oil Grade:
API Certification:
Oil Capacity (with filter):

644

WIX 51626
See “SELECTION OF ENGINE OIL”
SJ or better
5.0 qts/4.7 L
6.5 qt/6.1 L

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. 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 and screw on
until finger tight.
5. Tighten it an additional ¾ turn.
REFILL WITH ENGINE OIL
1. Clean and install the oil drain plug with a new gasket.
2. Fill with fresh engine oil. Do not overfill.
3. Install the oil filler cap.
4. Start engine and check for oil leaks.
5. Recheck the engine oil level.
Dispose of used oil at your local oil recycling center.

428 & 644 Stationary Engines
Owners Manual

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.
API recommendation: SJ or above
NOTE: This applies to all automotive/industrial 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 viscosity engine oil. When choosing engine oil,
consider the range of temperatures the vehicle will be operated in before
the next oil change. Select engine oil that is best suited to your area’s
particular ambient temperature range and variation.

CAUTION: Do not use an oil filter with SAE 3/4-16 threads. An oil filter
with incorrect threads can result in oil leaks and engine failure. The
correct oil filter has 20x1.5 metric threads.

428 & 644 Stationary Engines
Owners Manual

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.
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
sources.
4. Tighten fittings and clamps as needed to eliminate slow leaks.
5. If any fuel line components (hoses, pipe, fittings, etc.) need to be
replaced, first bleed the fuel out of the line by shutting off the gas
supply at the source with the engine running at idle. Wait for the
engine to stop before disassembling the fuel line.

428 & 644 Stationary Engines
Owners Manual

NATURAL GAS & LPG FUEL LOCK-OFF VALVES
ZPP recommends the following lock-offs for the 428 and 644 engines.
428 and 644: Asco 8215G030DC12
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. The ECM turns off the fuel lock-off
when the key 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 if the lock-off is opening and closing
correctly.
Inspection
1. Turn off the engine.
2. Disconnect the fuel lock-off positive and negative wires from the
wiring harness.
3. Apply 12 VDC across the lock-off.
4. You should hear the valve open immediately when 12 V is
applied and hear the valve close immediately when 12 V is
removed. This indicates that the valve is moving freely.
If you cannot hear the valve open and close, replace the valve.

428 & 644 Stationary Engines
Owners Manual

PRE AND POST-CAT OXYGEN SENSORS
ZPP Part Numbers:
Pre-Cat Sensor:
Post-Cat Sensor:

39210-22610
ZPP-C298-5

Sensor Locations:
The 428 pre-cat oxygen sensor is located at the outlet of the exhaust
manifold.
The 644 pre-cat oxygen sensor is located immediately downstream of
the exhaust manifold Y-pipe junction.
The 428 & 644 oxygen sensors are located in the outlet of the catalyst.

428 & 644 Stationary Engines
Owners Manual

SPARK PLUGS & WIRES
Ignition System Part Specifications
Spark plugs
Champion 7034 Double Platinum
Spark plug gap

0.030 - 0.040 inches
0.762 – 1.016 mm

Spark plug wires
(428 only)

ZPP-C190-428

Spark plug inspection
1. Remove one plug from each bank.
2. Inspect plugs for fouling and erosion.
3. Clean or replace plugs if needed.
Ignition wires inspection
1. Visually check ignition wires.
 Look for spark arcing while the engine is running.
 Check for cracks in the wire insulation.
2. If arcing and/or cracked insulation is evident, replace the entire
set of ignition wires.

428 & 644 Stationary Engines
Owners Manual

DIAGNOSTICS
How to manage and retrieve fault codes
The Engine Control Module (ECM) uses fault codes to identify and report
control system faults. The ECM has three ways of reporting fault codes
to the service technician. Each method uses a unique fault code format.
#
1

Device
Malfunction Indicator Lamp (MIL)

Code Format
Flash codes

J1939 CAN (Controller Area Network) Link

PC Service Tool

SPN & FMI
codes
DTC codes

Each fault has a unique set of codes and an associated diagnostic
procedure. Each fault and its associated codes are listed in the “Fault
Code List” following this section.
If the MIL is on while the engine is running, the operator is advised to
have the engine serviced as soon as possible. Continuing to operate the
engine with a fault condition may lead to engine and/or catalyst damage.
The ECM will automatically clear a fault code from its memory if the
engine completes 20 consecutive start-run-stop cycles without the fault
recurring.
Malfunction Indicator Lamp (MIL)
The MIL, or Check Engine lamp, is a light on the engine control panel.
The MIL is usually yellow, amber, or orange.
As a bulb check, the ECM turns on the MIL when the ignition key is on
and the engine is not running. If the MIL is off during this condition,
check for a burned-out bulb or wiring problem.
If the engine is running and the MIL is off, there are no current or recent
faults to report.

428 & 644 Stationary Engines
Owners Manual

DIAGNOSTICS - CONTINUED
If the MIL is on while the engine is running, the ECM has a fault to report.
The MIL will stay on for 3 start-stop cycles after a fault is detected. The
MIL will turn off on the 4th cycle if the fault has not recurred during the
previous 3 cycles.
To retrieve flash codes from the ECM:
1. Install the ZPP-C282-457 shorting cap on the COMM connector
or ground the Orange/Black pin of the COM connector.
2. Turn the ignition key on without starting the engine.
3. The ECM will flash the leader code (111), then the fault code(s),
then trailer code. Each code is repeated 3 times.
J1939 CAN Link
The ECM also reports faults over the J1939 CAN link. If the engine is
equipped with a CAN monitor or the technician has access to a handheld
CAN reader, the technician can retrieve the fault codes from the CAN
link.
The J1939 CAN standard uniquely defines each fault using a Suspect
Parameter Number (SPN) and a Failure Mode Indicator (FMI).
PC Service Tool
The “SparroWatch” PC service tool reports a unique Diagnostic Trouble
Code (DTC) and a text fault message for each fault.
The PC service tool also displays the values read from each sensor both
in terms of the signal voltage/frequency and the engineering units (kPa,
degrees C, etc.) which is very helpful for diagnosing signal faults.
The PC service tool also allows the service technician to clear the fault
codes.

428 & 644 Stationary Engines
Owners Manual

Fault Code List
DTC
/Pcode

Fault

P0107
P0108
P0112
P0113
P0117
P0118
P0122
P0123
P0131
P0132
P0133
P0134
P0135
P0137
P0138
P0141
P0171
P0172
P0215
P0217
P0219
P0340
P0523
P0524
P0562
P0563
P0603
P0615
P0638
P0642
P0650
P0655
P0681
P01122
P01123
P01219
P01222
P01223
P01562
P01602
P01605
P01609
P01619
P01681
P01682
P01683

Leader/Trailer Code
MAP Signal open or shorted to ground
MAP signal shorted high
IAT Sensor Low/Shorted Input
IAT Sensor High/Open Input
ECT Sensor Low/Shorted Input
ECT Sensor High/Open Input
Throttle Position Signal 1 low voltage
Throttle Position Signal 1 high voltage
O2 Bank 1 Sensor 1 Low Input
O2 Bank 1 Sensor 1 High Input
O2 Bank 1 Sensor 1 Slow Response
O2 Bank 1 Sensor 1 No Activity
Front O2 sensor heater control fault
Rear oxygen sensor low voltage
Rear oxygen sensor high voltage
Rear oxygen sensor heater control fault
Pre-cat A/F is lean
Pre-cat A/F is rich
LP or NG fuel purge time exceeded following key-off
Engine Overheat Condition
Engine Overspeed Condition
Camshaft Position Sensor A (no signal)
Oil pressure signal open or shorted high
Engine Oil Pressure Too Low
Battery Voltage Low
Battery Voltage High
Keep Alive Memory Error
Starter relay fault
Electronic throttle control performance
5V Reference #1 (pin 9) voltage low
Malfunction Indicator Lamp Control open
Engine Protection Lamp fault
Customer Auxiliary Shutdown #1
Throttle Actuator TPS A Low Input
Throttle Actuator TPS A High Input
Customer specified engine overspeed limit exceeded
Throttle Actuator TPS B Low Input
Throttle Actuator TPS B High Input
Extreme overvoltage - ECM damage possible
EEPROM version incorrect
EEPROM calibration information lost
Calibration mismatch with firmware
Unauthorized calibration upload or update
Customer Auxiliary Shutdown #1
Customer Auxiliary Shutdown #2
Customer Auxiliary Shutdown #3

CAN
SPN

CAN
FMI

106
106
105
105
110
110
3464
3464
3225
3225
3225
3225

4
3
4
3
4
3
4
3
4
3
10
14

3235
3235

4
3

520200
520200

0
1

110
190
190
100
100
158
158
627
677
51

0
0
3
3
2
4
3
2
31
7

624
623

11
31

000051
000051
190
000051
000051
158
520194
520196
630
520197
970
TBD
TBD

4
3
15
4
3
0
1
1
13
1
31
TBD
TBD

MIL Flash
Code
111
127
128
112
113
117
118
122
123
131
132
133
134
135
137
138
141
171
172
215
217
219
342
523
524
562
563
613
615
638
642
651
655
681
122
123
229
222
223
564
622
625
629
619
681
682
683

428 & 644 Stationary Engines
Owners Manual

Fault Code List – Continued
DTC
/Pcode
P02300
P02301
P02302
P02303
P02304
P02305
P02306
P02307
P02308

CAN
SPN
1268
1268
1268
1269
1269
1269
1270
1270
1270

Fault
Ignition coil A low current
Ignition coil A high current
Ignition coil A secondary open
Ignition coil B low current
Ignition coil B high current
Ignition coil B secondary open
Ignition coil C low current
Ignition coil C high current
Ignition coil C secondary open

CAN
FMI
5
6
31
5
6
31
5
6
31

MIL Flash
Code
411
412
413
421
422
423
431
432
433

428 & 644 Stationary Engines
Owners Manual

SPECIFICATIONS
Component
Air Filter:

Part Number or Specification
428: Enginaire 3-FW-E1
644 Enginaire 3.75 FW-E1

Drive belt:

428 & 644: C672-701

Battery:

12 V, 750 Cranking Amps,
600 Cold Cranking Amps

Oil:
Oil Filter:

See “ENGINE OIL AND FILTER
REPLACEMENT”
WIX 51626

Pre-Cat Oxygen Sensor:

ZPP P/N 39210-22610

Post-Cat Oxygen Sensor:

ZPP-C298-5

Spark Plugs:

Champion 7034 Double Platinum

Spark Plug Gap:

0.030 - 0.040 inches
0.762 – 1.016 mm

Spark Plug wires:

428: ZPP-C190-428
644: N/A

Recommended Natural Gas
& Vapor LPG Lock-Off Valves:

428 and 644: Asco
8215G030DC12

428 & 644 Stationary Engines
Owners Manual

Engine Identification
Engine part number _____________________________________

Engine serial number ____________________________________

Engine application _______________________________________

Purchased from ________________________________________

In-service date __________________________________________

Engine hours at delivery __________________________________

428 & 644 Stationary Engines
Owners Manual

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.
Base Warranty Period
The engine's base warranty period is 2500 hours or 1 year, whichever
comes first.
Emissions-Related Warranty Period
Your engine's emissions-related warranty period is 2500 operating hours
or 3 years, whichever comes first.
The engine's operating hours are determined based on the Engine
Control Module’s (ECM’s) hour meter. The warranty period begins, at
time of sale, to the end customer.
Owner Obligations
This warranty is valid only if you operate and maintain your engine as
specified in this Owners Manual. In particular, you must maintain your
engine as specified in the Maintenance Schedule and record your
maintenance in the Maintenance Log.

428 & 644 Stationary Engines
Owners Manual

Engine Warranty
Components Covered under the 2500 hour/3 year Emissions
Warranty

















Carburetor
Catalyst
CRANK sensor
Engine Control Module (ECM)
Engine Coolant Temperature (ECT) sensor
Electronic throttle
Engine wiring harness
Exhaust manifold
Final stage natural gas fuel pressure regulator
Fuel supply pressure trim valve
Ignition coil pack
CAM sensor
Intake manifold
Manifold Absolute Pressure (MAP)/Intake Air Temp (IAT) sensor
Pre-catalyst oxygen sensor
Post-catalyst oxygen sensor

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

250 Hours or 4 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□

500 Hours or 8 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

750 Hours or 13 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□
□
□
□
□

1000 Hours or 17 Months

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 (428 only)
Inspect CCV system
Inspect fuel lines, hoses, and fittings for gas leakage
Inspect fuel lock-off valve(s)

Date:
Engine Hours:
Mechanic:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

1250 Hours or 21 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□

1500 Hours or 25 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

1750 Hours or 29 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□
□
□
□
□

2000 Hours or 34 Months

Date:
Engine Hours:
Mechanic:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

2250 Hours or 38 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□

2500 Hours or 42 Months

Inspect air filter
Replace 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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

2750 Hours or 46 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□
□
□
□
□

3000 Hours or 50 Months

Date:
Engine Hours:
Mechanic:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

3250 Hours or 55 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□

3500 Hours or 59 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

3750 Hours or 63 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□
□
□
□
□

4000 Hours or 67 Months

Date:
Engine Hours:
Mechanic:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

4250 Hours or 71 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□

4500 Hours or 76 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□

4750 Hours or 80 Months

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:

428 & 644 Stationary Engines
Owners Manual

MAINTENANCE LOG
Service Interval:

□
□
□
□
□
□
□
□
□
□
□
□

5000 Hours or 84 Months

Replace air filter
Replace Drive belt
Inspect battery
Replace engine coolant
Clean radiator outside
Replace engine oil and filter
Replace spark plugs
Replace spark plug wires (428 only)
Replace pre and post-cast oxygen sensors
Inspect CCV system
Inspect fuel lines, hoses, and fittings for gas leakage
Inspect fuel lock-off valve(s)

Date:
Engine Hours:
Mechanic:

428 & 644 Stationary Engines
Owners Manual

Notes

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.5
Linearized                      : No
Page Count                      : 54
Language                        : en-US
Tagged PDF                      : Yes
Author                          : Dave Morris
Creator                         : Microsoft® Word 2010
Create Date                     : 2015:09:30 15:41:09-04:00
Modify Date                     : 2015:09:30 15:41:09-04:00
Producer                        : Microsoft® Word 2010

EXIF Metadata provided by EXIF.tools

Zenith 428 644_Engine OPM 644 Engine

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