Archive CG13 Installation and operation manual

Foreword
This booklet has been prepared to provide the necessary information
for the operation, inspection and maintenance of the ZPP Engine.
We urge you to follow the recommendations contained in this booklet
so that the ZPP Engine will remain free of trouble throughout its work-
ing life. Please familiarize yourself with the booklet and refer to it
when necessary.
If you encounter any problems with your Nissan Engine contact the
authorized ZPP dealer in your area.
All information, specifications and illustrations in this
manual are on a basis of the latest data obtainable at the
time of the publication. ZPP reserves the right to make
changes or improvements at any time without notice.
Contents
Names of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Other Handling and Operations . . . . . . . . . . . . . 5
Daily Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Trouble Diagnosis and Corrections . . . . . . . . . . 23
Recommended Lubricant . . . . . . . . . . . . . . . . . . 36
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Serial Number . . . . . . . . . . . . . . . . . . . . 41
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1

Names of Parts
ENGINES
2
1 Spark plug
2 Distributor
3 Oil level gauge
4 Oil filter
5 Oil drain plug
6 Water outlet
7 Water pump
8 Fuel filter
9 Fuel pump
10 Oil pan
11 Oil filter cap
12 Front engine slinger
13 V Belt (for governor)
14 V Belt (for fan & alternator)
15 Air cleaner
16 Governor
17 Cooling fan
18 Water inlet
19 Alternator
20 EFI
21 Rocker cover
22 Intake manifold
23 Exhaust manifold
24 Flywheel housing
25 Starter motor
26 Rear engine slinger
27 Crank pulley

Operation
HANDLING OF NEW ENGINE
The life and performance of an engine are
greatly influenced by how it is handled and
serviced during the initial period.
Operate the engine by observing the follow-
ing precautions during the initial 100 hours of
operation.
Cautions in operation
1. After starting, warm the engine thorough-
ly by means of warming-up operation until
the cooling water temperature rises above
50°C (122°F)
2. Never attempt to race the engine under
non-loaded conditions
3. Always maintain the operation speed of
the engine below 70% of the maximum
engine rpm.
4. Avoid overloading.
ENGINE HANDLING PRECAUTIONS
When handling the engine, be sure to
observe the following precautions.
When Starting the engine
1. Check the engine oil and coolant level
and refill if necessary.
2. After the engine starts, make sure that the
oil and charge warning lamps are off.
3. Warm up the engine until it runs smoothly,
emitting normal exhaust gases.
4. During this warming up operation or
when the cooling water the cooling water
temperature is still low, never attempt to
race the engine.
During engine operation
1. During operation, always make sure that
the cooling water temperature and lubri-
cating oil pressure are both normal.
Normal cooling water temperature is 75
to 85°C )167 to 185°F)
Oil pressure is normal if the “OIL” warn-
ing lamp remains OFF during engine
operation.
2. Always be aware of the condition of the
engine, paying attention to any abnormal
vibration, noise or other unusual circum-
stances. If any abnormality is found,
immediately stop the operation, examine
the cause, and make the necessary correc-
tion.
When Stopping the engine
Upon completion of operation, idle the
engine for some time to lower its temperature
before stopping this procedure will help to
extend the engine life.
Note that stopping the engine immediately
after heavily loaded operation will deterio-
rate the engine because it is still in a very hot
state.
Others
Perform periodical inspection and replace-
ment of the following items:
Engine, oil, oil filter, air cleaner element, fuel
filter element.
3

STARTING AND OPERATING
Starting
1. Turn the ignition key to the extreme right.
Release the key as soon as the engine
starts.
Do not turn the starting motor for
more than 10 seconds at any time. It
is not good for starter motor to run
for long time.
2. Never race the engine during this warm-
ing-up period.
Stopping
To stop the engine, idle the engine, turn the
ignition key to the “OFF” position, then the
engine will stop.
Except in an emergency, be sure to
turn the ignition key off only after the
engine speed has returned to idle.
CCAUTIONS DURING OPERATION
During engine operation, the warning light
should remain OFF. If it comes ON immedi-
ately stop operation, and take the actions that
are described below.
If any other abnormalities such as unusual
noise vibration or shocks are observed again,
stop the operation, and make the necessary
inspection and repair.
At completion of the day’s opera-
tions
1. Make sure that there is no oil leak, water
leak, or any other defects.
2. Clean the exterior of the engine so that
any oil leak, water leak, fuel leak or other
defect may be easily detected.
3. If antifreeze is not used in the cooling sys-
tem in cold weather, be sure to discharge
the cooling water to prevent damage to
the engine and/or radiator due to freez-
ing water.
4. Repair any faulty parts detected during
operation.
4

AGAINST COLD AND HOT
WEATHER
In cold weather
• Oil
Use engine oil suitable for ambient tempera-
ture (Refer to RECOMMENDED LUBRICANTS)
• Coolant
When coolant might freeze under low ambi-
ent temperature, drain out the coolant com-
pletely.
In such a cold weather, it is recommended to
mix anti-freeze solution into cooling system
because it makes you free from draining
coolant.
Coolant capacity (Engine proper):
2.7 l(2-7/8 US qt. 2-3/8 lmp qt)
Coolant mixture ratio
Battery
Battery should not be left in discharged state.
When battery performance becomes ques-
tionable, check the specific gravity of the elec-
trolyte, terminals of battery and alternator for
looseness.
The normal specific gravity is 1,260 as
5
Other Handling and Operations

corrected at 20°C (68°F). If changes about
0.0007 for every 1°C (1.8°F). If the specific
gravity for electrolyte does not reach the
desirable value, charge the battery soon.
In hot weather
Oil
Engine oil should be changed to summer type
oil (Refer to RECOMMENDED LUBRICANTS)
Coolant
Because the engine is more likely to overheat
in hot weather, the engine should be placed
in the shade. Overheating sometimes comes
from defective hoses, connections, loosened
radiator cap, or defective fan belt. So check
carefully the cooling system to maintain the
best cooling effect.
It is recommended to add antifreeze solution
into the cooling system because it increases
the coolant boiling point.
Battery
Since the battery electrolyte evaporates much
in hot weather, it is necessary to top up dis-
tilled water frequently.
WHEN USING THE ENGINE ONLY
DURING A PARTICULAR PERIOD
OF THE YEAR
When the engine is to be used only in a par-
ticular period of the year, such as summer or
winter, the service life of the engine will be
determined by how it is maintained during
the out-of-use period. Follow the procedures
below when preparing the engine.
During in-use period
Follow the normal handling procedures dur-
ing this period. However, it will be necessary
to shorten the oil replacement internal and
other service intervals, because the engine
will often be operated for a longer than nor-
mal period of time during a single day and
the load applied will often be greater than
usual.
During out-of-use period
During the out-of-use period, perform the fol-
lowing maintenance procedures for the
engine. If it is impossible to perform these
operations, refer to “Long Term Storage”.
1. Perform loaded operation once a month.
Run the engine and perform checks set forth
in item 1 above.
Apply a load in excess of 50% of the rated
load to the engine, and operate it for more
than 10 minutes. Make sure that no abnormal
noise or vibration is produced.
2. Perform the following inspection and
adjustment before placing the engine in
use period.
Drain sediment from the fuel system (fuel
filter and fuel tank).
Change engine oil and oil filter element.
Check and adjust valve clearance.
Check and adjust fan belt tension.
Check battery electrolyte level and
specific gravity.
Change air cleaner element.
Check cooling water
Check exhaust leakage
6

PROCEDURES FOR PLACING THE
ENGINE IN LONG-TERM
STORAGE
Before storing the engine for a long period of
time (more than 3 months), perform the fol-
lowing procedures to prevent formation of
rust. If the storage period is short, follow the
maintenance procedures for the engine as
described in the previous paragraph.
Lubricating system
Drain the engine oil, pour the specified
amount of rust preventive oil into the oil pan,
and then run the engine under no load at
approximately 1,500 rpm for about 10 min-
utes. Stop the engine, and seal all the open-
ings of the lubricating system with sealing
tape.
For a greater rust preventing effect, perform
this operation in combination with the rust
preventing procedure for the fuel system and
cooling system.
Fuel system
Drain fuel from the fuel system, and pour the
mixed fuel (the ratio of fuel to rust preventing
oil should be 1 : 1) into the fuel tank. Operate
the engine under no load at 1,500 rpm for
about 10 minutes. Stop the engine, drain the
mixed fuel, and then seal all of the openings
in the fuel system (such as the breather of the
fuel tank) with sealing tape.
Cooling system
Flush the cooling system, and pour antifreeze
or an anti-rust agent into the cooling water.
Run the engine under no load at 1,500 rpm
for about 10 minutes. Stop the engine, and
seal all of the openings in the cooling system
(such as overflow pipe, etc.) with sealing
tape. If antifreeze is used, keep the cooling
water in the system. If an anti-rust agent is
used, thoroughly drain the cooling water
before sealing.
When using antifreeze, pay attention to the
freezing point of coolant and choose a mix-
ing ratio of at least 30%, a mixing ratio of
less than 30% provides only a limited rust pre-
venting effect. Note that the anti-rust agent
will freeze when the temperature falls below
0°C (32°F). In such event, either thoroughly
drain the cooling water or use antifreeze.
Combustion chamber
After completing the rust preventive proce-
dure, allow the engine temperature to drop to
room temperature. Then disconnect the air
cleaner from the EFI, and spray or pour rust
preventing oil into the combustion chamber.
Next, disconnect the high tension cable from
the spark plugs, turn the ignition switch to the
“START” position, and crank the engine five
to ten times, and than install the
high tension cables and air cleaner.
Engine exterior
Using a petroleum solvent, remove dirt and
oil from the uncoated metal surfaces of the
engine (intake manifold, exhaust manifold,
rocker cover, fan and governor belt grooves
of pulleys, etc.). Spray or apply anti-rust
agent to the cleaned surfaced. Do not apply
any type mineral or vegetable oil to the fan
and governor belt grooves of pulleys.
Others
1. Remove the fan belt and keep it loosened.
2. Seal the air intake hole of the air cleaner
and air outlet hole of the exhaust tube with
adhesive tape.
3. Wrap the open type generator with a
porous bag, and fasten the bag with a
rubber band or similar item.
4. If the engine is equipped with a clutch.
Spray an evaporative anti-rust agent into
the clutch housing, and seal the opening
with adhesive tape.
5. When storing the engine as a complete
assembly outdoors, cover it fully with a
porous water-proof sheet.
Do not use a vinyl sheet, because it lacks
porosity and retains water inside.
7

Preparations for operation after
long-term storage
1. Remove all adhesive sealing tapes from
the openings of the engine.
2. Drain the rust preventing oil and anti-rust
agent by using the following procedure,
and replace it with the specified amount
of engine oil, fuel and cooling water.
Lubricating system:
Drain oil through the drain plug of oil pan
and oil filter.
Fuel system:
First operate the engine with the mixed
fuel that is used in the rust preventing
operation, and then drain the fuel.
Cooling system:
If antifreeze is used, drain cooling water
from the drain valves on each of the radi-
ator and cylinder block, and flush the
cooling system.
If an anti-rust agent is used, flush the cool-
ing system.
Exterior of engine:
Clean the exterior surfaces of the engine
with a petroleum solvent (Trichlene).
3. Replace the elements of the oil filter, the
air cleaner and the fuel filter with new
ones.
4. Adjust the fan and governor belt for
proper tension.
5. Check and adjust valve clearance. Apply
engine oil to the rocker arm and other
valve mechanism.
6. Check the battery electrolyte level and
specific gravity. Refill and/or recharge if
it is necessary.
7. Before the engine starts, disconnect the
high tension cables from the spark plugs.
8. Set the ignition switch at the “START”
position, and crank the engine for about
10 seconds. Repeat this cranking opera-
tion two or three times in order to dis-
perse engine oil to every portion of the
engine, and then install the high tension
cable.
9. Start the engine, and let it idle for about
5 minutes.
10. Gradually increase the engine speed to
the rated rpm, and run the engine for
about 10 minutes under no load. Make
sure that the charge warning lamp and
oil warning lamp are off and cooling
water temperature are normal, and that
the engine does not produced any abnor-
mal vibration or noise.
8

In order to prevent trouble in daily operation,
it is necessary that the operator be constantly
aware of the condition of the engine. To
achieve this awareness, the operator must
personally inspect the engine before starting
the day’s activities.
If you note any defects, notify your authorized
ZPP dealer.
CHECK ENGINE OIL LEVEL
To check the oil level, pull out the level gauge,
wipe it clean and reinsert it; remove it again
to read the oil level. The level should be
between the “L” and “H” marks.
CHECK COOLING WATER LEVEL
Remove the radiator cap, and check the cool-
ing water level. Also check the cap and deter-
mine if it functions correctly. The cooling
water level is correct if it is near to the filler
neck of radiator. Insufficient water level may
be caused by leakage from the engine or
radiator. Check carefully for any sign of leak-
age; if no leaks are discovered, add water to
the filler neck portion.
If cooling water is dirty, flush the cooling
system.
When replacing the radiator cap, be sure to
fit it securely. If replaced loosely or improper-
ly, the cooling water will quickly evaporate,
causing the engine to overheat.
9
Daily Care

CHECKING THE ENGINE FOR
LEAKAGE
1. Insure that the engine, radiator and hoses
are not leaking.
2. Check each portion of the engine, and
make sure that there is no sign of an oil
leak.
3. Check the fuel system to make sure that
there is no sign of fuel leaking from the
fuel pipe and hose.
CHECKING THE ENGINE OPERA-
TION DURING BOTH IDLING AND
ACCELERATION
Make sure that the engine runs normally at
idling speed, and that engine rpm increases
smoothly as it is accelerated.
OTHERS
Correct all of the faults and problems that
were observed during the previous day’s
operation.
If any faults are discovered during the daily
inspection, contact an authorized ZPP dealer
for additional inspection, adjustment or
repair. Always maintain the engine in its top
condition.
10

11
ENGINE AND EFI MAINTENANCE SCHEDULE - ZPP MODEL: CG13, A15, H20 II AND H25
The following table lists the periodic maintenance required to ensure quality performance and good mechanical conditions of the Engine, Fuel
systems and Catalytic converter in your application unit.
MAINTENANCE OPERATION
Periodic maintenance should be performed after specified Months 1 2 345678910
intervals have elapsed in months or hours, whichever comes first Hours 250 500 750 1000 1250 1500 1750 2000 2250 2500
ENGINE MAINTENANCE (LPG Fuel System Includes Items below)
1. Intake & exhaust valve clearances (operating temp) I I I
2. Drive Belt Tension I I IIIIIIII
3. Cylinder head bolts & manifold nuts T T
4. Radiator outside (A) C C C
5. Engine oil (A) R R RRRRRRRR
6. Oil Filter (A) R RRRR
7. Engine coolant (L.L.C.) R
8. Fuel Filter gasoline R
9. Air cleaner element (A) I I/R I I/R I I/R I I/R I I/R
10. Ignition timing (Gasoline & LPG) I I IIIIIIII
11. Spark Plugs I I/R I I/R I I/R I I/R I I/R
12. Distributor inside (IC ignition system) C C
13. P.C.V. valve (Gasoline) (A) I I I
14. P.C.V. hoses (Gasoline) I I I
15. Fuel supply & return lines for leaks I I I

12
ENGINE MAINTENANCE (LPG Fuel System)
1. Fuel line supply and connectors portion for gas leakage (B) I I IIIIIIII
2. Fuel line supply and connectors for damage (B) I I IIIIIIII
3. Filter LPG I/R I/R R
4. Primary Vaporize/Regulator Plug (oil contamination) I/D I/D
5. LPG lock off II
Notes: 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
Abbrevations: I = Inspection
R = Replace
A = Adjust
C = Clean
D = Drain
T = Retighten

MAINTENANCE OPERATION
Retightening cylinder head nuts,
manifold bolts and nuts and
carburetor securing nuts
Cylinder head bolts
When the engine is cold, retightening should
be made in the sequence shown.
: Cylinder head bolt
H20 & H25
78 to 93 N•m
(8.0 to 9.5 kg-m,
58 to 69 ft-lb)
Manifold and exhaust tube nut and
carburetor attaching nut
: Carburetor nuts
8 to12 N•m
(0.8 to 1.2 kg-m,
5.8 to 8.7 ft-lb)
Manifold nuts
14 to 18 N•m
(1.4 to 1.8 kg-m,
10 to 13 ft-lb)
13
T
T
H25

Adjusting intake and exhaust
valve clearance
Adjustment should be made while
engine is warm but not running.
1. Start engine and warm it up, sufficiently.
Then turn off engine.
2. Remove valve rocker cover.
3. Rotate crankshaft.
(1) Set No. 1 cylinder in top dead center on
its compression stroke, and adjust valve
clearance.
H20:
, , , and .
(2) Set No. 4 cylinder in op dead cen-
ter on its compression stroke and
adjust valve clearance.
H20:
, , , and .
Valve clearance (Hot):
Intake & exhaust:
0.35 mm (0.015 in)
14

Checking and adjusting drive
belts
1. Visually inspect for cracks, fraying, wear
or oiliness.
The belts should not touch the bottom
of the pulley groove.
2. Check belt tension by pushing midway
between pulleys.
Drive belt deflection:
8 to 12 mm (0.31 to 0.47 in)
Pushing force:
98 N (10 kg. 22 lb)
15

Changing engine oil and oil filter
1. Start engine and warm up engine suffi-
ciently, then stop engine.
2. Remove oil filter cap and oil pan drain
plug, and allow oil to drain.
WARNING:
Be careful not to burn yourself, as the
engine oil may be hot.
• A milky oil indicates the presence
of cooling water, isolate the cause
and take corrective measure.
• An oil with extremely low viscosi-
ty indicates dilution with fuel.
3. Clean and install oil pan drain plug with
washer.
: Oil pan drain plug
20 to 28 N•m
(2.0 to 3.0 kg-m, 14 to 22 ft-lb)
4. Using Tool, remove oil filter.
5. Wipe oil filter mounting surface with a
clean rag.
6. Smear a little engine oil on rubber gasket
of new oil filter.
7. Install new oil filter. Handtighten ONLY.
DO NOT use a wrench to tighten the filter.
16
T

8. Refill engine with new recommended
engine oil, referring to Recommended
Lubricants.
Check oil level with dipstick.
Oil capacity:
Unit: liter (US qt. lmp qt)
H20
With oil 4.2
filter (4-1/2, 3-3/4))
Without 3.7
oil filter (3.7/8, 3-1/4)
9. Start engine. Check area around drain
plug and oil filter for any sign of oil leak-
age.
If any leakage is evident, these parts have
not been properly installed.
10. Warm up engine sufficiently. Then stop
engine and wait a few minutes. Check
oil level. If necessary, add engine oil.
When checking oil level, set engine
at level.
Changing engine coolant
WARNING:
To avoid the danger of being scald-
ed, never attempt to change the
coolant when the engine is hot.
When using antifreeze coolant, mix the
antifreeze coolant with water, observing
instructions attached to antifreeze container.
Cleaning radiator outside
Clean outside of radiator with dry com-
pressed air.
Checking cooling system, hoses
and connections.
Check hoses and fittings for loose connec-
tions or deterioration. Retighten or replace if
necessary.
17

Checking engine compression
pressure
1. Warm up engine sufficiently, then stop
engine.
2. Remove all spark plugs.
3. Properly attach a compression tester to
spark plug hole in cylinder being tested.
4. Set carburetor throttle valve at fully-open
position.
5. Crank engine and read gauge indiction.
 Engine compression measurement should
be made as quickly as possible.
Compression pressure:
Standard
1,275 kPa (12.75 bar,
13.0 kg/cm2,
185 psi)/300 rpm
Minimum
1,079 kPa (10.79 bar,
110.0 kg/cm2,
158 psi)/300 rpm
6. Cylinder compression in cylinders should
not be less than 80% of the highest read-
ing.
If cylinder compression in one or more cylin-
ders is low, pour a small quantity of engine oil
into cylinders through the spark plug holes
and retest compression.
If adding oil helps the compression pres-
sure, chances are that piston rings are worn
or damaged
If pressure stays low, valve may be sticking
or sealing improperly
If cylinder compression in any two adjacent
cylinders is low, and if adding oil does not
help the compression, there is leakage past
the gasketed surface.
Oil and water in combustion chambers can
result from this problem.
Checking fuel lines (Hoses,
piping, connections, etc.)
Check fuel lines for proper attachment, leaks,
cracks, damage, loose connections, chaffing
and deterioration. If necessary, replace any
damaged or defective parts.
18

Cleaning and replacing air clean-
er element (Dry paper type)
1. Remove air cleaner cover and filter ele-
ment.
2. Blow dust off inner side of element with
dry compressed air.
3. Wipe inside of air cleaner housing and
cover with damp cloth.
Be careful not to drop into carburetor.
4. Install element and air cleaner cover.
Checking crankcase ventilation
hose
1. Check hoses and hose connections for
leaks.
2. Check each hose for cracks or distortion.
3. Disconnect all hoses and blow them out
with dry compressed air.
If any hose cannot be made free of obstruc-
tions, replace with a new one.
Checking and replacing spark
plugs
1. Disconnect the high tension cables from
the spark plugs.
Do not pull on the cable.
2. Remove spark plugs with spark plug
wrench.
3. Clean plugs in sand blast cleaner
4. Inspect insulator for cracks or chips, gas-
ket or damage or deterioration and elec-
trode for wear or burning. If they are
excessively worn, replace with new ones.
5. Check spark plug gap.
Spark plug type:
Reference Parts Manual
19

IC IGNITION SYSTEM
IC IGNITION SYSTEM TROUBLE-SHOOTING
20
Engine turns erratically.
Check ignition timing.
Adjust.
Check for burned or fouled spark plug.
Clean or replace.
N.G.
N.G.
O.K.
O.K.
O.K.
O.K.
N.G.
Check fuel
system.
Check air gap betwen reluctor and
stator.
Check IC ignition system.
IC Ignition System is checked using a
volt-ohm-milliam-meter (V.O.M.)
Follow the steps in the sequence
indicated. If a fault is found, correct
the problem before continuing. If all
tests indicate “O.K.” replace the IC
Ignition Unit. DO NOT REPLACE THE
UNIT UNTIL ALL TESTS HAVE BEEN
COMPLETED AND INDICATE “O.K.” .
Attach adapter #1 to high tension
cable and position tip of adapter
approx. 6 mm (0.24 in) away from
cylinder block. With adapter held
in that position, crank engine to see
if spark jumps across gaps between
tip and cylinder block at regular
intervals.
Engine cranks but does not
start.
Before cranking, disconnect fuel cut
solenoid harness.
Before operation, make sure there is
no inflammable material.
Adapter
Specified air gap…Refer to S.D.S.
Go to test table.
SEL5788
SEL6405