Lister Petter 0600123LPW3A01 Workshop Manual Download

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LPW, LPWS & TURBO

ENGINES

WORKSHOP MANUAL

ALPHA SERIES

P027-08240

Summary of Contents for 0600123LPW3A01

Page 1: ...LPW LPWS TURBO ENGINES WORKSHOP MANUAL ALPHA SERIES P027 08240 ...

Page 2: ...tinued development and we reserve the right to amend any technical information with or without prior notice Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the Manufacturer the Distributor nor the Dealer shall in any circumstances be held liable for any inaccuracy or the consequences thereof The information given is subject to the Com...

Page 3: ...formation 5 2 Engine Servicing and Adjustments 12 3 Engine Fluids 59 4 Operating Instructions 62 5 Routine Maintenance 65 6 Troubleshooting 74 7 Engine Build Details 77 8 Technical Data 80 9 Dismantle and Rebuild 82 10 Conversion Factors 84 ...

Page 4: ...inaccuracy or the consequences thereof The information given is subject to the Company s current Conditions of Tender and Sale is for the assistance of users and is based upon results obtained from tests carried out at the place of manufacture This Company does not guarantee that the same results will be obtained elsewhere under different conditions Parts that have not been approved by the Lister ...

Page 5: ...atteries do not smoke or work near to heaters or other ﬁre hazards b Store ﬂammable liquids away from ﬁre hazards c Do not expose pressurised containers to heat and do not incinerate or puncture them d Handle fuel with care and always stop the engine before refuelling Do not overﬁll the fuel tank e Thoroughly clean any lubricating or fuel oil from the skin as soon as possible f Rectify all fuel co...

Page 6: ...f sufficient output to cope with the total electrical load required by the machine to which it is fitted d Ensure engine wiring cables are Bound together in a loom and adequately supported Routed to avoid any hot surfaces particularly the exhaust system Not in contact with any sharp corners or rough surfaces so as to avoid any possibility of chaffing taking place Alternator Precautions a Never rem...

Page 7: ...se the risk of condensation contaminating the fuel Ifcansareused avoidtippingoutthelastfewdrops h Funnels are very difﬁcult to keep clean in dusty conditions Wash them before and after use and wrap them up when not required or ﬁll the tank direct from a small mouthed screw capped fuel can i The fuel injection equipment is manufactured to very accurate limits and the smallest particle of dirt will ...

Page 8: ...Lift Pump Lifting Eye Turbocharger Fuel Filter Radiator Fan Oil Cooler Oil Filter Water Pump Thermostat housing 1 3 Engine Features LPW2 Inlet Manifold Exhaust Manifold Fuel Filter Oil Filter Oil Filler Engine Stop Control Radiator Fan Flywheel Housing ...

Page 9: ...arts or accessories When new parts are required for such a build it is suggested that reference be made to Lister Petter Power Systems to determine the exact engine speciﬁcation and which parts are non standard Where the engine serial number contains a G for example GLPW3 this denotes the engine was built into a generating set by Lister Petter Power Systems A full list of builds is given in 7 Engi...

Page 10: ...m using two 6 volt batteries connected in series 1 5 4 Connecting a Slave Battery A slave or booster battery can be connected in parallel with the existing battery to aid starting in cold weather conditions WARNING Heavy duty jumper leads must always be used and no attempt must be made to use any others WARNING Do not allow the jumper lead free ends to directly or indirectly touch the engine at an...

Page 11: ... 26 to 32 15 to 26 Below 32 26 LPW LPWS A D B D F C D I C D I G C D I G H LPWT4 B D F I 1 15 7 1 Table Code A 15W 40 Lubricating oil in the sump B 10W 30 Lubricating oil in the sump C 5W 20 Lubricating oil in the sump D 12 volt starting E Air inlet manifold heater energised while cranking F High discharge low resistance artic type or alkaline batteries G Heating of the engine and batteries in a ho...

Page 12: ...etailed instruction for each one Tightening torques are included in the text as necessary and in table format in 05 5 Spanner Torques When assembling the engine use the same type of lubricating oil as used in the engine to spray all moving parts during assembly All bearings and bushes must be well lubricated during assembly Renew all joints gaskets connecting rod nuts and bolts and the cylinder he...

Page 13: ... CONTAIN CARBON MONOXIDE WHICH IS A COLOURLESS ODOURLESS AND POISONOUS GAS THAT CAN CAUSE UNCONSCIOUSNESS AND DEATH 2 3 1 The Inlet Manifold Restrictor Some builds as shown in the table below are fitted with an inlet manifold restrictor The restrictor is secured in position with Hylosil 303 Builds LPW2 18 27 28 41 57 58 74 79 81 177 LPW3 18 27 28 41 74 79 81 113 177 LPW4 18 27 28 41 57 74 79 81 LP...

Page 14: ... seconds before stopping to allow the heat from the bearing to dissipate 2 5 1 Removing the Turbocharger 1 Disconnect and remove the turbocharger oil feed pipe A and oil return pipe B 2 Remove the air cleaner exhaust silencer and associated parts 3 Support the turbocharger and remove the three mounting stud nuts C 4 The turbocharger can be dismantled by removing the four nut D Note If the turbo is...

Page 15: ...l housing and attached to the air inlet and No 4 cylinder head cover on industrial engines No 2 on marine engines by flexible pipes A restrictor A is fitted in the outlet hose on some builds and It is important to ensure it is replaced and pushed into the centre of the outlet hose Figure 2 6 1 LPWT4 Oil Separator and Breather The combined oil separator and breather is the same as that fitted to th...

Page 16: ...ufficiently to remove the drive belt 6 Support the alternator and remove the bolt from the slotted section of the adjusting arm 7 Support the alternator and remove the lower pivot bolt and nut 8 Lift the alternator clear Figure 2 8 2 Magnetti Marelli Alternator Adjustment Arm LPW LPWS 2 8 3 Replacing the Alternator 1 Hold the alternator in position and replace the lower pivot bolt and nut 2 Replac...

Page 17: ...he back of the tank 4 Slacken or remove the two setscrews securing the straps to the mounting bracket base 5 Remove the tank 2 10 2 Maintenance of the Fuel Tank Remove any sediment from the tank and if necessary flush the tank with clean kerosene and allow it to drain 2 10 3 Replacing the Fuel Tank 1 Support the tank and replace it on the mounting bracket 2 Replace the two setscrews securing the s...

Page 18: ...he fuel is known to be dirty 2 12 1 Changing the Fuel Filter Element The element should be renewed every 500 hours or more frequently if for any reason the fuel is known to be dirty 1 Isolate the fuel supply or drain the tank 2 Unscrew the centre bolt A of the filter assembly 3 Discard the old element B and sealing rings C 4 Fit a replacement element with new sealing rings Figure 2 12 1 Fuel Filte...

Page 19: ...be out of adjustment refer to 2 53 Setting the Governor If the fuel pump tappet has been removed it must be replaced with the longer slot A facing outwards This will ensure it is correctly located over the end of stud B which is fitted inside the crankcase Figure 2 13 3 Fuel Pump Tappet and Stud The tappet can be placed into the crankcase with the aid of long nosed pliers held open against the top...

Page 20: ...ermine TDC 3 Rotate the flywheel clockwise to beyond the specified piston displacement as given in 2 15 Fuel Pump Timing Values from TDC The correct figure for the type and build of engine must be used 4 Carefully rotate the flywheel anti clockwise until the correct piston displacement figure is reached 5 Use a probe to measure dimension X which is from the top face of the crankcase to the top of ...

Page 21: ...4 Variable 850 2500r min LPW 20º 3 097 10 83 Fixed 3600r min LPW 24º 4 428 104 Variable up to 3600 18 173 174 Fixed 1800 or 2000r min LPW 16º 1 994 177 Dual 1500 1800r min LPW 16º 1 994 70 Variable up to 3000r min set at 2800r min LPW3 20º 3 097 LPWS4 22º 3 735 71 Fixed 2000r min LPW2 4 18º 2 519 72 Fixed 1800r min LPW2 4 18º 2 519 73 Variable up to 2500r min LPWS4 18º 2 519 76 Variable up to 3000...

Page 22: ... 57 58 74 81 308 358 374 379 380 681 754 45260 MARINE High Speed 42 44 46 47 48 842 844 846 847 848 751 45250 Low Speed 41 841 754 45261 LPWS LPWST4 ENGINES LPWS ENGINES Pre Nov 1998 Engine Type Build Number Part Number INDUSTRIAL LPWS 2 01 02 03 51 751 40760 LPWS 3 01 07 09 57 LPWS 4 01 07 57 MARINE LPWS 2 42 47 751 40920 LPWS 3 42 47 LPWS 4 42 47 49 LPWS300SERIESENGINES AfterNov1998 Engine Type ...

Page 23: ...n LPW injectors should have the same appearance and the same length of penetration in the air If one spray is shorter or weaker than the others this indicates that the corresponding hole is partially blocked and best engine performance results will not be obtained If one hole is totally blocked or the nozzle dribbles it must be replaced If the nozzle only is replaced the injector spring pressure m...

Page 24: ...he pump through a drilling in the crankcase to the hole nearest the outside of the cartridge type oil filter base Filtered pressure oil passes through the centre of the filter into the oil gallery in the crankcase door and from the oil gallery it is delivered to the crankshaft and bearings The connecting rod big end bearings are pressure fed through internal drilling in the crankshaft from the sup...

Page 25: ...he precautions on the previous page 2 21 1 Draining the Oil Sump Industrial 1 Run the engine to warm the oil 2 Remove the oil filler cap 3 Remove the oil sump drain plug and allow the oil to run into a suitably sized container 4 Clean the drain plug threads and coat them with Hylomar PL32 M Loctite 572 or Hylogrip 760 5 Replace the plug and tighten it 2 21 2 Refilling the Oil Sump Before refilling...

Page 26: ...55370 751 10620 and 751 12870 refer to 7 2 Oil and Filter Change Periods Refer to 7 2 Oil and Filter Change Periods for revised oil change periods 2 22 1 Oil Filter Identiﬁcation Figure 2 22 1 Oil Filter Identiﬁcation and Part Numbers A 751 12870 E 328 21600 B 751 10620 F 751 43850 C 201 55370 G 751 43860 D 328 11500 2 22 2 Oil Filter Capacity Illustration Code litre pint US pint A 0 14 0 25 0 30 ...

Page 27: ...r joint just makes contact with the crankcase or filter mounting bracket facing 4 Screw the filter on a further quarter to half of a turn 5 Start the engine and run it for a few minutes to circulate the oil 6 Stop the engine and allow time for the oil to drain down and check the level on the dipstick 7 Add more oil if necessary 2 22 5 Filter Mounting Bracket Care must be taken to ensure the instru...

Page 28: ...d 5 Remove the injector copper sealing washers from the cylinder head taking care not to damage the seating area The washer should be captive on the spark plugs 6 On LPW S T4 engines remove the breather flexible pipe from the cylinder head cover 7 Remove the lifting eye 8 Remove the cylinder head covers and gaskets 9 Remove the valve rocker retaining nuts A and washers 10 Remove the valve rockers ...

Page 29: ...Boss cylinder barrels On earlier barrels the bosses and threads are below the top fin On the High Boss arrangement the bosses and threads A are at the top of the barrel Figure 2 24 5 Cylinder Head Bolt Torque Sequence A LPW LPWS2 B LPW LPWS3 C LPW LPWT LPWS LPWST4 5 Lightly oil the push rods and replace them 6 Press down on the top of the push rods while very slowly turning the crankshaft until th...

Page 30: ... least 15 seconds before attempting to start it Figure 2 25 1 Hydraulic Tappet A 751 11730 When fitting the cylinder head valve to piston contact can be avoided when tightening the valve rocker lever nut by depressing the push rod end of the rocker lever using the tappet compressing tool 317 50107 CAUTION Extreme care must be taken not to bend the push rod by using excessive force If the tappet co...

Page 31: ...r processing is required and they are sunk below the combustion surface of the head to the figures given in 2 27 3 The Valve Seats Care must be taken to ensure that all valve associated items are retained in their respective cylinder orientation 2 27 1 Removing a Valve 1 Lay the head upright on a bench and place a suitable circular block of wood under the head of the valve 2 Fit the adaptor A onto...

Page 32: ...ool and check that the collets are correctly located 2 27 3 The Valve Seats Valve seat inserts are only fitted to LPWT4 and LPWST4 and LPWS Bio engines The valve seats must be precision ground so that the valves are sunk below the combustion surface of the head as shown Theseatsarecutata45 angleanda1 interference angle between the face and the seat provides a high contact pressure seal Valve Seat ...

Page 33: ...tool B Figure 2 28 2 Valve Guide Tool and Depth Stop Lister Petter Service Tool 317 50033 317 50108 317 50057 317 50075 6 Place the sleeve C onto the tool 7 Fit the bevelled adaptor D into the sleeve C and locate the bevel into the valve seat 8 Locate the mandrel through the guide from the valve seat side 9 Screw the small threaded sleeve E onto the mandrel at the valve rocker side 10 Holding the ...

Page 34: ...over is located on two dowels and secured to the crankcase on seven bolts If the two dowels are being replaced care must be taken to ensure the flat end enters the crankcase fully the taper end provides engagement with the end cover The crankshaft oil seal is of the lip type and a joint is fitted between the end cover and the crankcase face The oil seal tool 317 50103 is used to protect the oil se...

Page 35: ...d cover lip side ﬁrst and position it squarely on the shoulder of the seal boss 3 Using the seal tool 317 50103 drive the seal into position in the end cover 2 30 3 Fitting the End Cover A solid mounted end cover has replaced the earlier type that was secured with studs and cup washers which also had a thicker joint The two types of cover and joint are not interchangeable Full details for all end ...

Page 36: ... shims that are fitted 8 Gently remove the governor lever assembly from the crankcase 9 Remove the governor weights 10 Remove the governor sleeve F and the thrust washer 11 Use a suitable socket and remove the two thrust plate bolts 12 Gently ease the camshaft out of the crankcase keeping it square at all times 2 31 2 Inspection of the Camshaft a Examine the camshaft bush for scars or wear b Check...

Page 37: ...shaft towards the flywheel end 3 Fix a clock gauge in position against the camshaft gear wheel Figure 2 31 6 Checking Camshaft End float 4 Zero the gauge 5 Move the camshaft as far as it will go towards the gear end The movement recorded on the gauge is the end float 2 32 The Camshaft Bush 2 32 1 Removing the Bush 1 Fit the guide A into the bush from inside the crankcase 2 Fit the slide hammer B o...

Page 38: ... LPWST4 engines have only been fitted with controlled expansion piston assemblies and these are not interchangeable with any other All Other Engines Mono metal piston assemblies were fitted on early engines but from the engines given below controlled expansion piston assemblies have been fitted Either type of piston with the correct rings can be used but the two piston types must not be mixed with...

Page 39: ...ensure the circlips are correctly and securely located 3 Fit the piston rings using a piston ring expander taking care to ensure they are fitted in the correct order Figure 2 33 7 Piston Ring and Gap Positions A Firing ring B Compression ring C Oil control ring X Piston ring gap positions 4 Turn the crankshaft journal to TDC If necessary fit new connecting rod big end bearing shells ensuring they ...

Page 40: ...he bearing 3 Remove the bearing shell and use the scale to check the width of the flattened Plastigauge the width at the widest point establishes the minimum clearance and at the narrowest point the maximum clearance The difference between the two readings is the journal to bearing clearance and is compared with the figures given in 5 7 4 Dimensions of Wearing Parts 2 36 The Flywheel The flywheel ...

Page 41: ...tted with a backplate in place of a flywheel housing 2 37 1 Removing the Flywheel Housing 1 Remove the flywheel 2 Remove the four housing retaining bolts 3 Lift off the housing 2 37 2 Fitting the Flywheel Housing 1 Replace the bolts finger tight 2 Align the previously scribed marks 3 Torque the retaining bolts to 79 0Nm 58 0lbf ft 2 38RearMainBearingHousing The two halves of the main bearing are s...

Page 42: ... With the oil seal removed reﬁt the housing ensuring the metal shim remains in position and the oil drain will be located towards the bottom of the crankcase on ﬁnal assembly 4 Torque the housing bolts to 27 0Nm 20 0lbf ft in the sequence shown Figure 2 38 2 Bearing Housing Tightening Sequence 5 Check the crankshaft end ﬂoat as described in 2 42 Crankshaft End ﬂoat 6 Replace the oil lip seal as de...

Page 43: ...ng shells are plain with no circumferential grooves but both halves have an oil feed hole Two grooved half bearing shells are fitted in the crankcase at the gear end and in the centre main bearing housings An interference fit gear is keyed onto the gear end of the crankshaft and engages with the camshaft gear The balance weights are an integral part of the shaft and the centre bearing housing is i...

Page 44: ...lignment with the hole in the crankcase on final assembly CAUTION Take special care when passing the crankshaft through the gear end bearing as it is quite easy to score the bearing shell with the crankshaft 5 With a suitable 6mm bolt or an inlet manifold bolt inserted in the centre bearing dowel insert the dowel through the crankcase wall and into the centre bearing housing CAUTION Ensure the dow...

Page 45: ... 3 Fit the bolt and dolly into the bearing from the oil seal side crankcase outside face 4 Fit the bridge C over the bolt threads until the two legs are against the housing face crankcase at the gear end 5 Fit the nut E onto the bolt 6 Using a suitable spanner tighten the nut until the bearing shells are withdrawn 2 43 2 Fitting New Bearings The main bearing shells are steel backed copper lead or ...

Page 46: ...nd face the correct way 5 Replace the capscrews and torque them to 21 0Nm 15 5lbf ft 2 44 The Oil Strainer and Pump Access to the pump is only possible after removing the end cover The crankcase door must be removed to gain access to the oil strainer A higher capacity pump 750 12020 is fitted to engines which have controlled expansion pistons and it is interchangeable with the earlier pump for eng...

Page 47: ...iator applications 2 45 2 Engine Block Coolant Capacity It is advisable to ascertain the coolant capacity before determining the amount of coolant concentrate to be added to maintain a 40 concentration Aluminium radiators require 50 mix of water and coolant When topping up or reﬁlling the engine s water system do not use tap water typical minerals and ions found in tap water can be corrosive to in...

Page 48: ...iller cap See 2 45 2 Engine Block Coolant Capacity 4 Replace the filler cap and vent plug 5 Run the engine for a few minutes and check the coolant level 2 46 Coolant Concentrate Refer to 03 3 Engine Fluids coolant concentrate WARNING Coolant concentrate must not be allowed to come into contact with the skin adhere to the manufacturers instructions and precautions WARNING Extreme care must be taken...

Page 49: ...ble and if they are outside those given the thermostat must be replaced ºC ºF 74º Thermostat Starts to Open Fully Open 72 76º 162 169º 85 88º 185 190º 88º Thermostat Start to Open Fully Open 86 90º 187 194º 99 102º 210 216º 2 48 THE RADIATOR Care must be taken to ensure the air ﬂow is unobstructed and has not been re circulated from the driven equipment The radiator ﬁns should be checked for damag...

Page 50: ... in encapsulated installations as this arrangement draws radiated heat from the enclosure The fan blades should be checked for damage every 2000 hours or more frequently if the application demands To maintain adequate cooling extreme care must be taken to ensure that the fan is the correct one 2 49 1 The London Fan These fans are mounted directly onto the water pump being retained by a torque load...

Page 51: ...50 The Water Circulating Pump If an early type pump is being replaced with the later type it will be necessary to change the water pipes and the original thermostat refer to the Master Parts Manual The water pump assembly can be removed from the engine without the need to remove the thermostat radiator fan or fan pulley London and Fral water pumps and their respective radiator fans are not interch...

Page 52: ...pivot on the following engines LPW3 Build 113 LPW Build 84 1 Turn the camshaft until Number 1 cylinder fuel pump tappet is in its lowest position 2 Replace the governor sleeve and washer refer to 2 51 3 Governor Sleeve and Washer Combinations 3 Gently place the governor lever assembly into the crankcase taking care to ensure that the innermost end of the governor rack is located in its housing at ...

Page 53: ...7 458 481 751 12823 751 10288 751 13130 407 408 457 458 481 Thrust Collar 751 12823 Thrust Washer 751 15950 Governor Sleeve 750 12660 Thrust Washer 751 15940 2 52 Governor Weights and Springs 2 52 1 Changing Governor Weights The weights are held by pins which are retained by plates bolted to the camshaft gearwheel On Builds 10 83 and 104 a special weight retaining plate is used and this can be ide...

Page 54: ... Build Part Number of Weight Number of Weights Part Number of Speeder Spring Spring Colour Code 1 2 14 51 602 846 848 751 11091 2 751 15720 Green White 7 57 751 12980 4 751 12894 Black White 79 751 12980 4 751 12895 Black 9 59 82 109 844 751 15460 4 751 16612 Yellow 10 83 751 15460 4 751 17790 Red 27 28 81 581 627 841 751 12983 4 751 47100 Blue Red 71 72 91 92 750 12684 4 751 40906 Green Silver 74...

Page 55: ...409 444 751 15460 4 751 16613 Blue 411 751 46760 4 751 15720 Green White 474 750 12684 4 751 19130 Yellow Green 2 52 7 Governor Weights and Springs LPWST4 Build Part Number of Weight Number of Weights Part Number of Speeder Spring Spring Colour Code 407 408 458 481 751 12983 4 751 19130 Yellow Green 2 53 Setting the Governor 2 53 1 Governor E Setting 1 Move the lever assembly until it abuts agains...

Page 56: ...le rod lever or solenoid The setscrew B is adjusted until it makes contact with the speed control quadrant at the required maximum speed and then locked in position with the locknut Rotating the setscrew anti clockwise increases the engine speed Figure 2 54 2 Variable Speed Adjustment 2 55 Setting the Stop Run Lever To ensure the control lever is positively stopped by the control lever stop screw ...

Page 57: ... 58 81 84 25 5 03 04 25 0 02 05 09 37 42 44 46 52 59 76 82 26 0 2 56 Adjusting the Engine Speed The speed adjustments must only be made after the governor has been correctly set The locations of the two adjusting setscrews are given in 2 56 2 Speed Adjustment Setscrews Caution On some engines a tamperproof setscrew nut is fitted to prevent changes being made to the engine stop run control settings...

Page 58: ...ines in good condition the vacuum increases slightly with engine speed but not proportionally A fluctuating vacuum may indicate faulty oil seals valves or piston blow by troubles Crankcase pressure can cause serious oil leaks and often occurs in engines which need overhauling 2 57 1 Engines Running up to 1800 r min For engines running at these speeds the vacuum may be as low as 10 0mm WG 0 4in WG ...

Page 59: ...mended 3 1 4 The Oil Classiﬁcation System The information contained in this section has been extracted from Lubricant and Fuel Performance with the permission of The Lubrizol Corporation CAUTION Past and Current US API Grade Oils API Service Category CD Service typical of certain naturally aspirated turbocharged or supercharged diesel engines where highly effective control of wear and deposits is ...

Page 60: ... and contaminants is of the utmost importance 3 2 2 Low Temperature Fuels Special winter fuels are often available for use at ambient temperatures below 0 C 32 F These fuels have a lower viscosity and limit the formation of wax at low ambient temperatures CAUTION Wax formation can rapidly reduce the flow of fuel through the fuel filter element 3 3 Engine Fluids coolant concentrate Traditionally th...

Page 61: ... 3 3 2 Concentration A 40 concentration must be maintained under all operating conditions To determine the amount of coolant concentrate to be added it will be necessary to calculate the total coolant capacity by adding together that of the engine as given in 2 45 2 Engine Block Coolant Capacity the radiator or heat exchanger and associated pipework capacities ...

Page 62: ...knob fitted to the control and other variants for automatic or remote operation are available Engines not fitted with a fuel control solenoid have a spring clip to hold the engine control in the stop position Oil Pressure Switch If an oil pressure switch bypass button is fitted it must be depressed during engine cranking and until the engine attains full speed If the Engine Fails to Start Should t...

Page 63: ...ed anti clockwise to the Preheat position until the engine has attained full speed 5 When the engine has attained full speed the key must be moved anti clockwise to the Run position 6 On variable speed engines reduce the speed as necessary 4 1 4 Starting LPWS 400 Series CAUTION These instructions only apply to 400 Series engines Refer to 4 1 1 Preliminary Instructions 1 Move the engine control lev...

Page 64: ... to the STOP position CAUTION Turning the key to the STOP position alone will not stop the engine unless a fuel control solenoid is fitted Figure 4 1 6 Stopping 4 1 7 Preliminary Instructions WARNING Starting any engine can be dangerous in the hands of inexperienced people Before attempting to start any engine the operator should read the Safety Precautions and be conversant with the use of the en...

Page 65: ...ns In particular nuts and or bolts from the connecting rods should be renewed The fuel injector can only be checked 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 UNPROTECT...

Page 66: ...flat tappets 5 3 Routine Maintenance Schedule Hours Both schedules are based on average operating conditions and cover the minimum requirements to keep an engine running at peak performance with trouble free operation 5 3 1 All Engines Also refer to 5 2 Oil and Filter Change Periods Daily Check the coolant level Check the supply and level of fuel Check the level and condition of the lubricating oi...

Page 67: ...hoses Check water pump replace if necessary Every Year LPW and LPWS Drain flush and refill the cooling system adding new coolant concentrate to a 40 concentration Every Year All Engines Drain and replace the lubricating oil and filter irrespective of their condition if the engine has run for less than 250 hours in the preceding twelve months On marine engines change the air cleaner element if it w...

Page 68: ...ubricant To aid fitting lightly coat the exposed part of the O ring Fuel pump tappet stud Loctite 270 Coat the stud end thread which fits into the crankcase Thermostat housing cover Camshaft journals and bores Hylomar PL32 M Molydisulphide Achesons Colloids Compound Grade 1168 or equivalent Coat both joint faces Coat all of the camshaft journals except the gear end Flywheel housing drain plug RTV ...

Page 69: ...ntre bearing housing bolts Exhaust manifold stud LPW S T4 Turbocharger fixing nuts Turbocharger exhaust flange nuts Turbocharger oil feed plugs Breather separator bolts LPW S T4 5 5 1 Stator Motor Terminal Torques Figure 5 5 1 Starter Motor Terminal Identification A Lucas Magnetti Marrelli B Denso Description of Component Nm lbf ft Injector pipe nuts LPWS 22 0 16 0 Glow plug LPWS 27 0 20 0 Oil str...

Page 70: ... good running order it is therefore recommended that when the Maximum Clearance figure is reached one or more components affecting the clearance be replaced The wear to be allowed in parts refitted to an engine depends on the life required to the next overhaul and the relative cost of labour and materials If labour costs are high it may pay to replace parts before the maximum wear condition is rea...

Page 71: ...g groove width 1 830 1 850 2nd piston ring width 1 978 1 990 0 050 0 082 0 14 2nd piston ring groove width 2 040 2 060 Oil control piston ring width 3 978 3 990 0 050 0 082 0 14 Oil control piston ring groove width 4 040 4 060 Non Controlled Expansion Pistons Piston ring gaps 0 260 0 510 0 260 0 589 1 40 Top piston ring width 1 710 1 740 0 060 0 115 0 16 Top piston ring groove width 1 800 1 825 2n...

Page 72: ...thickness replace if less than 2 20mm 2 310 2 360 Gear end camshaft bush bore 34 990 35 085 0 010 0 120 0 17 Gear end camshaft journal diameter 34 965 34 980 Centre camshaft bush bore 35 030 35 070 34 965 34 980 0 17 Centre camshaft journal diameter 34 965 34 980 Flywheel end camshaft bush bore 35 030 35 070 34 965 34 980 0 17 Flywheel end camshaft journal diameter 34 965 34 980 Camshaft thrust pl...

Page 73: ...s again required for service The inhibition fluid should be left in the fuel system e Seal all openings on the engine with tape f Remove the batteries and store them fully charged after coating the terminals with petroleum jelly g Grease all external bright metal parts and the speed control linkage h Tie labels on the engine clearly stating what steps have been taken to inhibit the engine during s...

Page 74: ... procedure the following should be considered a Do you know and understand the engine and all the related systems b Do you have sufﬁcient electrical and mechanical knowledge and skills to understand the symptoms c Do you have suitable electrical diagnostic equipment available d Do you have or access to the necessary Lister Petter spare parts before you commence dismantling 6 2 METHOD OF TROUBLESHO...

Page 75: ...e your load management programme White Exhaust Smoke Water entering the cylinder Check the thermostat and cylinder head gasket Light Blue Exhaust Smoke Generally as a result of light load Investigate the load management programme Heavy Blue Exhaust Smoke Lubricating oil passing the piston rings Check the crankcase vacuum Check for wear Stuck worn or broken piston rings Check for damage decarbonise...

Page 76: ...ect type of fuel Drain the system add fuel of the correct specification Overload Reduce the load Dirty or faulty injector Clean or replace Choked air filter Dismantle and clean the cap and element Undercharging Excessive electrical load from added accessories Remove accessories or fit higher output alternator Poor electrical connections to alternator or battery Inspect clean and rectify the cause ...

Page 77: ...load Class B1 57 Constant speed 1500r min 110 load Class A1 58 Constant speed 1800r min 110 load Class A1 59 Constant speed 3000r min 110 load Class A1 71 Constant speed 2000r min 100 load Class A1 72 Constant speed 1800r min 100 load Class A1 74 Dual speed 1500 1800r min set at 1800r min Onan Genset Build 78 Constant speed 1800r min 110 load Class A1 79 Constant speed 1800r min 110 load Class A1 ...

Page 78: ...ed 3000r min 110 load std crankcase e cover for water pump drive Class A1 Marine Auxiliary 446 Variable speed 850 3000r min 110 load standard crankcase e cover for water pump drive Marine Auxiliary Propulsion 448 Variable speed 850 3000r min 110 load crankcase with cut off feet e cover for water pump drive Marine Propulsion 457 Fixed speed 1500r min 110 load deep sump Class A1 458 Fixed speed 1800...

Page 79: ...ariable speed 850 3000r min 110 load std crankcase e cover for water pump drive Marine Auxiliary Propulsion 848 Variable speed 850 3000r min 110 load crankcase with cut off feet e cover for water pump drive Marine Propulsion 848S Variable speed 850 3000r min 110 load crankcase with cut off feet e cover for water pump drive short lubricating oil strainer for life boat duties Sabb Marine Propulsion ...

Page 80: ...re relief valve setting bar 2 6 3 2 2 6 3 2 2 6 3 2 2 6 3 2 lbf in 37 7 46 4 37 7 46 4 37 7 46 4 37 7 46 4 Number of ﬂywheel ring gear teeth 96 96 96 96 Idling speed Build 73 Build 76 LPW4 Build 84 All other Builds r min 800 850 r min 1025 1050 r min 950 1000 r min 850 900 Minimum full load speed r min 1500 Fuel lift pump maximum lift mm 3048 3048 3048 3048 in 120 120 120 120 Fuel lift pump maximu...

Page 81: ...dle bar 1 0 1 0 1 0 1 0 lbf in 14 5 14 5 14 5 14 5 Oil pressure relief valve setting bar 3 4 4 1 3 4 4 1 3 4 4 1 lbf in 48 0 60 0 48 0 60 0 48 0 60 0 Number of ﬂywheel ring gear teeth 96 96 96 96 Idling speed Build 73 Build 76 Build 84 All other Builds r min 800 850 r min 1025 1050 r min 950 1000 r min 850 900 Minimum full load speed r min 1500 Fuel lift pump maximum lift mm 3048 3048 3048 in 120 ...

Page 82: ...e radiator support bracket 19 Remove the oil filter 20 Remove the dipstick and crankcase door 21 Remove the oil pressure relief valve and the oil strainer 22 Remove the connecting rod caps 23 Carefully remove the carbon build up from the top of the cylinder bore 24 Turn the crankshaft until the piston is at TDC 25 Lift out the piston and connecting rod 26 Fit the flywheel locking tool 27 Remove th...

Page 83: ... the hydraulic tappets 17 Replace the governor weights and governor sleeve 18 Replace the governor lever assembly and springs 19 Set the governor 20 Replace the fuel pumps 21 Replace the gear end cover 22 Adjust the engine control 23 Fit the crankshaft pulley left hand thread 24 Replace the piston and connecting rod 25 Replace the oil pump relief valve and strainer 26 Replace the crankcase door an...

Page 84: ...on A Specific Gravity of 0 886 is assumed litres 24hours g kWh x kW 4922 pints 24hours lb bhp h x bhp 0 15 Piston Speed metres second stroke mm x r min 30000 feet minute stroke in x r min 6 Mechanical Efficiency bhp x 100 ihp Cyclic Irregularity max flywheel speed min flywheel speed mean flywheel speed Power kW r min x torque Nm 9549 bhp r min x torque lb ft 5252 10 2 CONVERSION FACTORS The conver...

Page 85: ...timetre kgf cm2 pound force per square in lbf in2 1 bar 0 9869 1 0197 14 5038 1 atm 1 0132 1 0332 14 6959 1 kgf cm2 0 9807 0 9678 14 2233 1 lbf in2 0 0689 0 0680 0 073 Pressure Table 3 inch of water in H2 O foot of water ft H2 O millimetre of mercury mm Hg inch of mercury in Hg 1 in H2 O 0 0833 1 8683 0 0735 1 ft H2 O 12 000 22 4198 0 8827 1 mm H2 O 0 5352 0 0446 0 0394 1 in Hg 13 5951 1 1329 25 4...

Page 86: ...1055 06 3 9301 x 10 4 251 996 Power Table 1 kilowatt kW metric horsepower CV brake horsepower bhp British thermal unit per hour Btu h 1 kW 1 3596 1 3410 3412 14 1 CV 0 7355 0 9863 2509 63 1 bhp 0 7457 1 0139 2544 43 1 Btu h 0 00029 3 9846 x 10 4 3 9301 x 10 4 Power Table 2 watt W kilo calorie per hour k cal h British thermal unit Btu 1 watt 0 08598 3 4121 1 k cal h 1 1630 3 9683 1 Btu 0 2930 0 251...

Page 87: ...87 ...

Page 88: ...Lister Peter Power Systems Limited Unit 14 Estuary Court Broadmeadow Industrial Estate Teignmouth TQ14 9FA T 44 0 1285 702211 Production Facility Lister Peter Power Systems Limited Units 13 15 Quadrant Distribution Centre Hardwicke Gloucester GL2 2RN sales listerpetter com www listerpetter com ALPHA SERIES ENGINE WORKSHOP MANUAL P027 08240 EDITION 15 NOVEMBER 2017 LISTER PETTER POWER SYSTEMS ...

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