ALPHA SERIES ENGINES WORKSHOP MANUAL
65
5.1 PRELIMINARY INSTRUCTION
WARNING
Routine maintenance must be performed by
qualified
persons who are conversant with the
hazards of fuels, electricity and machinery.
Read the Safety Precautions in "1.General
Information" and observe all instructions and
precautions in this publication.
These recommendations and instructions cover
several engine models therefore they are of a
general nature.
The engines are assembled to predetermined
builds and individual engines may include optional
equipment not specifically covered in this book
in which case any Lister Petter Power Systems
Distributor or Dealer can be consulted.
•
The engine should receive regular attention
during the
first
50 hours of its life from new and
after a major overhaul.
•
Long periods of light or ‘no load’ running early in
the engine’s life may lead to cylinder bore glazing
and high oil consumption.
•
The instructions given in "5.3 Maintenance
Schedules" are based on average operating
conditions and cover the minimum requirements to
keep
an engine running at
peak
performance with
trouble free operation.
•
Under very dusty conditions, air cleaners,
lubricating oil and fuel
filters
will require more
frequent attention
•
Decarbonising may be required more often if
the engine has been running on light loads for long
periods.
•
Before carrying out any maintenance
work
on
an engine it is advisable to remove the battery.
The battery and alternator must be disconnected
before commencing any electric welding when a pole
strap is directly or indirectly connected to the engine.
•
It is essential to ensure that nuts and bolts are
tightened to the torques specified in this manual.
•
When reassembling an engine lubricate all
moving parts with engine oil.
•
Renew nuts and bolts that have been
taken
from
high stress locations. In particular nuts and/or bolts
from the connecting rods should be renewed.
•
The fuel injector can only be che
ck
ed and set off
the engine using suitable specialist test equipment.
•
A Hurth or Newage gearbox may be
fitted
to the
engine and the gearbox manufacturers publication
should be consulted for information on operating
and routine maintenance procedures.
WARNING
ON NO ACCOUNT ALLOW ANY UNPROTECTED
SKIN TO COME INTO CONTACT WITH THE
INJECTOR SPRAY AS THE FUEL MAY ENTER
THE BLOOD STREAM WITH FATAL RESULTS.
WARNING
SOME ENGINES MAY BE FITTED WITH SEALS
OR ‘O’ RINGS MANUFACTURED FROM ‘VITON’
OR A SIMILAR MATERIAL. WHEN EXPOSED
TO ABNORMALLY HIGH TEMPERATURES, IN
EXCESS OF 400°C (752°F), AN EXTREMELY
CORROSIVE ACID IS PRODUCED WHICH
CANNOT BE REMOVED FROM THE SKIN. IF
SIGNS OF DECOMPOSITION ARE EVIDENT,
OR IF IN DOUBT, ALWAYS WEAR DISPOSABLE
HEAVY DUTY GLOVES.
5.1.1 Waste Disposal Precautions
•
Extreme care must be
taken
to ensure that waste
fuel, oil,
filter
elements, acid, coolant concentrate,
paint, solvents or other toxic wastes are disposed
of in accordance with local regulations to prevent
contamination.
5.1.2 Initial Attention
Change the
first
fill
lubricating oil and
filter
at 100
hours.
All subsequent oil changes must be as
specified
in
"5.2 Oil and Filter Change Periods".
It is recommended that the following receive
attention after the engine has run 50 hours and
again after 250 hours.
Check
and tighten nuts, bolts and unions paying
•
particular attention to the fuel system.
Check the drive belt tension.
•
Check
the lubricating oil level and top up if
•
necessary.
Check
the radiator coolant level and top up if
•
necessary.
A 40% coolant concentration must be maintained
at all times.
Observe the exhaust at the normal full load.
•
The exhaust must be free from soot.
A
black
exhaust means that the engine is
•
overloaded or that the injection equipment is
out of order.
Do not allow the engine to run with a dirty
•
exhaust without investigating the cause as this
may result in an expensive breakdown.
5. ROUTINE MAINTENANCE