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alpha series

LPW/LPWS/LPWX ENGINE
Operators' Handbook
ORIGINAL INSTRUCTIONS

P027-08270
Associated Publications
Master Parts Manual P027-08041
LPWX4 Master Parts Supplement P027-10641
Workshop Manual P027-08240
Technical Handbook P027-08247

Statement of Indemnity
The information, specifications, illustrations, is based upon results obtained from tests
instructions and statements contained carried out at the place of manufacture. This
within this publication are given with our Company does not guarantee that the same
best intentions and are believed to be results will be obtained elsewhere under
correct at the time of going to press. different conditions.
Our policy is one of continued development Parts that have not been approved by the
and we reserve the right to amend any Lister Petter Power Systems organisation
tech­nical information with or without prior cannot be relied upon for correct material,
notice. dimensions or finish. The Company cannot
Whilst every effort is made to ensure the therefore be held responsible for any
accuracy of the particulars contained within damage arising from the use of such parts,
this publication, neither the Manufacturer, and the guarantee will be invalidated.
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
Company’s current Conditions of Tender P027-08270
and Sale; is for the assistance of users; and Copyright © Lister Petter Power Systems

2
Contents

Introduction................................................................................... 5

1. Safety Information.................................................................... 7
2. Technical Data........................................................................ 13
3. Starting and Stopping............................................................. 14
4. Engine Fluids.......................................................................... 17
5. Routine Maintenance............................................................. 19
6. Troubleshooting...................................................................... 27
7. Maintenance Record.............................................................. 29
8. Warranty................................................................................. 37
9. Index....................................................................................... 39

3
LPW
LPW // LPWS
LPWS // LPWX
LPWX ENGINE
ENGINE operators'
OPERATORS' handbook
HANDBOOK

Glow
Plugs
Inlet
Manifold Exhaust
Manifold
Radiator Fan
(may have 6 blades) Fuel
Filter
Flywheel
Housing

Oil
Filter
LPWS2
Sump
Drain Plug

Exhaust
Manifold
Inlet
Manifold

Alternator

2.1 Features of the LPW


Starter series diesel engines
Motor

Flywheel
LPW(X)3
Lifting Eye
Turbocharger

Radiator
Fan
Fuel
Filter

LPW(S)T4
Oil Filter
Adaptor
Oil Filter

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LPW / LPWS / LPWX ENGINE operators' handbook

Introduction
This handbook explains the operation LPWS3............................. Engine model
and routine maintenance of Lister Petter A..........................Anti clockwise rotation
Power Systems water cooled diesel 402.................................... Build number
engines in the Alpha (LPW, LPWX) and
New Alpha (LPWS) series. The illustrations on page 4 show features
Please note that If your engine is part of the different engine models. When
of a generating set, there is a separate following the instructions in this handbook
operators' handbook for the genset, you will need to be familiar with the parts
to explain such features as the control labelled.
module.
Using this Handbook
Engine Identification Operating or servicing a diesel engine
To identify which model of Lister Petter is ­potentially dangerous. You must not
Power Systems LPWX/LPW(S) diesel attempt it unless you have the necessary
engine you are using refer to the engine knowledge and experience.
serial number, which is stamped on a Read each section thoroughly and
plate attached to the engine. It identifies carefully, taking note of all the information
the type and build of the engine (see table and instructions given. This is for
below) to enable the correct maintenance your safety and to ensure the correct
procedures to be carried out. Here is a maintenance of your engine. For specific
sample serial number: aspects of operation and maintenance,
06 001234 LPWS3 A 402 use the table of contents (page 3) or the
index (page 40) to find the section you
06........................Year code (06 = 2006) need. Where instructions are numbered
001234...............Unique engine number in sequence, they must be followed in

LPW Diesel Engine Models


Model Characteristic features
LPW2 Two cylinders, water cooled, naturally aspirated, direct injection
LPW3 Three cylinders, water cooled, naturally aspirated, direct injection
LPW4 Four cylinders, water cooled, naturally aspirated, direct injection
LPWT4 Four cylinders, water cooled, direct injection, turbocharged
LPWX2 Two cylinders, water cooled, naturally aspirated, direct injection
LPWX3 Three cylinders, water cooled, naturally aspirated, direct injection
LPWX4 Four cylinders, water cooled, naturally aspirated, direct injection
LPWS2 Two cylinders, water cooled, naturally aspirated, indirect injection, emission compliant
LPWS3 Three cylinders, water cooled, naturally aspirated, indirect injection, emission compliant
LPWS4 Four cylinders, water cooled, naturally aspirated, indirect injection, emission compliant
LPWST4 Four cylinders, water cooled, naturally aspirated, indirect injection, turbocharged, emission compliant

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LPW / LPWS / LPWX ENGINE operators' handbook

that order. This applies in particular to Running-in


maintenance and repair procedures To assist running-in all engines are
(sections 5 and 6). despatched with an initial fill lubricating
In cases of difficulty, or to obtain spare oil which must be changed after 100
parts, please consult your local Lister hours. Your engine does not require
Petter Power Systems distributor or gradual ­light-load running-in. Extended
dealer. light-load running should be avoided, as
this could damage the cylinder bore and
allow lubricating oil to enter the exhaust
system.

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LPW / LPWS / LPWX ENGINE operators' handbook

1. Safety Information
Read the information in this section Carefully read and follow all safety
carefully and follow all the advice information and instructions in this
given. Pay especial attention to the manual.
cautions and warnings demonstrated Observe the safety and informative
below, which are used throughout this symbols on your engine and
handbook. equipment.

CAUTION Emergency Precautions


This caution draws attention to • Be prepared with suitable equipment
special information or procedures and knowledge in case a fire starts.
which must be correctly observed,
• Identify a location from which calls
to avoid damage to, or destruction
to the emergency services can be
of, equipment.
made if necessary.
WARNING • Ensure a third party knows where
This warning draws attention to you are working and when you leave
special information or procedures the working area.
which must be strictly observed.
Failure to do so may result in General Precautions
personal injury. • Ensure the engine is securely
mounted.
WARNING • Ensure that there is a generous
This WARNING DRAWS ATTENTION supply of cooling and combustion air
TO S P E C I A L i n f o r m a t i o n O R available.
PROCEDURES WHICH must be
• Keep the engine and surrounding
strictly OBSERVED. Failure to do
so may result in serious injury or area clean.
death. • Some accessories may require
guards which must be supplied and
fitted by the purchaser. Keep all safety
1.1 General Safety guards in position.
Information • Do not make any unauthorised
Starting and operating any diesel modifications as these may affect the
engine is potentially dangerous. Do not safe operation of the engine and put
attempt to do so unless you have the the operator at risk.
necessary knowledge and experience.
Ensure that anyone attempting to start 1.2 Personal Safety
and operate your diesel engine has • Wear personal protective clothing
been properly trained and instructed and safety equipment appropriate to
in the correct procedures. the work being done.
• Keep clear of moving parts at all
Caution times.
Follow all safety instructions
accurately.

7
operators' HANDBOOK
LPW / LPWS / LPWX ENGINE OPERATORS' handbook

•• Wear suitable ear protection against


WARNING objectionable or uncomfortable loud
Keep THE
KEEP the BODY
body AND
and CLOTHING
clothing
clear OF
CLEAR of MOVING
moving OR
or HOT
hot PARTS
parts noise.
atALL
AT all TIMES.
times. CONTACT
Contact OF
of MOVING
moving •• To avoid loss of concentration, do
parts WITH
PARTS with UNPROTECTED
unprotected SKIN
skin not use music or radio headphones
can CAUSE
CAN cause SEVERE
severe BURNS.
burns. while operating an engine.
Entanglement WITH
ENTANGLEMENT with ROTATING
rotating •• When undertaking maintenance, do
equipment CAN
EQUIPMENT can CAUSE
cause SERIOUS
serious not work under any plant that is only
injury OR
INJURY or DEATH.
death. held by overhead lifting equipment.
•• Where appropriate, make sure that
•• Tie long hair back securely.
guards are properly fifitted.
tted.
•• Wear close-fi
close-fitting
tting clothing.
•• Do not wear a necktie, scarf, loose
clothing or necklace when working Precautions WITH
1.3 PRECAUTIONS with
close to a running engine. Chemicals
CHEMICALS
•• Where possible, remove rings and Protect yourself from exposure to
other jewellery to prevent entanglement hazardous chemicals at all times, as
in moving parts. These items could also this can cause serious injury. Potentially
cause a short circuit if any part of the hazardous chemicals include lubricants,
electrical system is being worked on. fuel, coolant concentrate, battery acid,
paint and adhesives.
WARNING Manufacturers' safety data sheets
Prolonged exposure to loud noise will provide specific details of the
can cause impairment, or loss, of physical and health hazards, safety
hearing. and emergency procedures and
1. Safety Symbols
1. Safety
This Symbols
figure This
identifies thefigure identifisymbols
ISO 8999 es the ISO 8999 symbols
currently used bycurrently usedPower
Lister Petter by Lister Petter
Systems

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LPW / LPWS / LPWX ENGINE operators' handbook

any necessary personal protection 1.4 Fuel System


equipment required while working with Precautions
hazardous materials.
• Handle fluids with care at all WARNING
times. Never ALLOW ANY UNPROTECTED
• Rectify any fuel, coolant or oil leak SKIN TO COME INTO CONTACT WITH
as soon as is practicable and clean up THE INJECTOR SPRAY AS FUEL
any spillages when they occur. MAY ENTER THE BLOODSTREAM
• Remove any build-up of grease, oil WITH FATAL RESULTS.
or debris.
• If any fluid other than lubricating WARNING
Never make unauthorised
oil comes into contact with the skin,
adjustments to the emission-
clean off immediately. In the case of compliant fuel injection pumps.
lubricating oil, clean off as soon as is This could be dangerous and
practicable. invalidates warranty claims. In the
USA unauthorised adjustment of
Fuel and High Pressure Fluids emission critical components is
• Store fuel and other flammable prohibited by Federal Law, incurring
liquids away from fire hazards. civil penalty.
• Always stop the engine before • When priming or checking the fuel
refuelling. injection pump timing, care must be
• Do not overfill the fuel tank. taken to wipe any spilled fuel from the
• When working with fuel do not outside of the engine.
smoke or work near to heaters or other • Always fit a new joint when a union
fire hazards. has been disturbed.
• High pressure fluids are extremely • Special care must be taken to
hazardous. Never allow any part of the see that there is no leakage from the
body to come into contact with high- joints of the fuel pipe connection to the
pressure fuel oil, compressed air or pump.
hydraulic oil, for example when testing • When tightening or loosening fuel
fuel injection equipment. injection pump delivery connections
use two spanners to ­prevent unsealing
WARNING of fuel pump delivery valve holders.
Do not expose pressurised
containers to heat, and do not • When refitting the fuel pipe from the
incinerate or puncture them. pump to the injector, the connection to
the injector must be tightened before
WARNING the connection to the fuel pump. This
Never touch or ingest high- procedure will ensure that there is no
pressure fluids such as leakage from these joints.
hydraulic oil, compressed • It is most important that all fuel
air or fuel oil. This could joints are tight and leak proof.
lead to serious injury, or • Always fill the fuel tank through
death. a fine strainer. It is best to do this at
the end of the engine work period so

9
LPW / LPWS / LPWX ENGINE operators' handbook

that any sediment stirred up has time 1.6 Precautions with Oil
to settle before the engine is used Seals
again, and the risk of condensation
Some engines may be fitted with seals
contaminating the fuel is minimised. If
or 'O' rings manufactured from Viton
using a can, avoid tipping out the last
or a similar material. When these
few drops.
substances are exposed to abnormally
• Funnels are very difficult to keep
high temperatures, in excess of 400°C
clean in dusty conditions. Wash them
(752°F), an extremely corrosive acid is
before and after use and wrap them up
produced.
when not required, or fill the tank direct
from a small-mouthed screw-capped
can.
WARNING
If an oil seal containing
• The fuel injection equipment is viton (or similar material)
manufactured to very accurate limits degenerates, it produces
and the smallest particle of dirt will an extremely corrosive acid
destroy its efficiency. that cannot be removed from
the skin. IF you see SIGNS
caution OF DECOMPOSITION, OR are
Keep the fuel free from water and IN DOUBT, WEAR DISPOSABLE
contaminants. HEAVY DUTY GLOVES.
• If in any doubt about an oil seal,
1.5 Precautions with Filters always wear disposable heavy duty
and Elements gloves.
• Used filters and elements contain
some of the filtered liquid and should be
1.7 Precautions with
handled and disposed of with care. Batteries
• After handling new or used elements, Batteries contain hazardous sulphuric
wash your hands thoroughly. acid. Great care therefore needs to be
taken when using them.
WARNING • Do not smoke near batteries and
Do not allow fuel or new or used keep sparks and flames away from
lubricating oil to come into contact them. Do not work near to heaters or
with unprotected skin. It is dangerous other fire hazards.
and could cause skin irritation. • Switch off the battery charger
before connecting or disconnecting
WARNING the charger leads. Disconnect the
Take careful precautions with filters
battery negative (earth) lead first and
and elements. The materials used in
the manufacture and treatment of reconnect last.
some types may cause irritation or • Keep the top of the battery well
discomfort if they come into contact ventilated during charging.
with the eyes or mouth, and they • Never 'flash' connections.
may give off toxic gases if burnt. • Never use a damaged battery.
• Do not attempt to charge a frozen
battery; it may explode. Instead, warm
the battery to 16°C (60°F).

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LPW / LPWS / LPWX ENGINE operators' handbook

• Never connect a battery into the


WARNING system without checking that the
Take especial care with batteries,
which contain highly corrosive voltage and polarity are correct.
sulphuric acid which is poisonous, • Never remove any electrical cable
will burn skin and clothing, and will while the battery is connected in the
cause permanent damage including circuit.
blindness if splashed into the eyes. If • Never disconnect the battery
acid accidentally comes into contact unless the engine has stopped and all
with skin, eyes or clothes, flush it switches are in the off position.
away with copious amounts of fresh • Always ensure that cables are fitted
water and seek medical aid. to their correct terminals.

1.8 Precautions with Caution


Electrical Systems A short circuit or reversal of polarity
will ruin d
­ iodes and transistors.
• Ensure that the battery is of sufficient
capacity to start the engine down to its • Never 'flash' any connection to
minimum operating temperature, taking check the current flow.
into account any drag that may be • N e v e r e x p e r i m e n t w i t h a n y
imposed on the engine by the type of adjustments or ­repairs to the system.
trans­mission that is attached to it. • Always disconnect the battery and
• Ensure that the battery and all alternator before commencing any
engine wiring cables are of sufficient electric welding when a pole strap
size to carry the currents required. is directly or indirectly connected to
• Check that the engine-mounted engine.
alternator is of sufficient output to cope
with the total electrical load required by 1.9 Waste Disposal
the machine to which it is fitted. Precautions
• Extreme care must be taken
Wiring Cables to ensure that waste oil, fuel, filter
Ensure that the engine wiring cables are: elements, coolant concentrate, battery
• Bound together in a loom and electrolyte, solvents or other toxic
adequately supported. wastes are disposed of in accordance
• Routed to avoid any hot surfaces, with local regulations to prevent
particularly the exhaust system. contamination.
• Not in contact with any rough
surfaces or sharp corners so as to avoid WARNING
any possibility of chafing taking place. To avoid contamination and personal
injury, never dispose of toxic or
Alternator other waste except in accordance
The following points must be strictly with official regulations.
observed when an alternator is fitted,
otherwise serious damage can be
done.

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LPW / LPWS / LPWX ENGINE operators' handbook

1.10 Precautions before • Ensure that the lifting equipment


Starting is designed to give a vertical lift from
directly above the engine lifting eye.
WARNING • Check that the engine lifting eyes
Starting any diesel engine can are not damaged and that they are
be dangerous in the hands of secure.
inexperienced people. Engine • The engine lifting eyes are suitable
operators must be instructed in for lifting the engine and accessory
the correct procedures before assemblies originally fitted by Lister
attempting to start any engine. Petter Power Systems.
• Ensure that the engine is free to
turn without obstruction. WARNING
• Check that the lubricating oil level Engine lifting eyes must not be used
is correct. The oil sump must be filled to lift the complete plant.
to the ‘full’ mark on the dipstick; do not
overfill.
WARNING
Do not work under any plant
• Check that the radiator is filled to that is only held by overhead
within 13-25 mm (0.5-1.0 in) below the lifting equipment.
neck of the radiator filler.
• Check that the fuel supply is
adequate and the system is primed. 1.12 Precautions before
• Ensure that the battery is connected, Maintenance
fully charged and serviceable. • Understand the service procedures
• Where possible, disengage the before commencing any work.
driven equipment while starting. • Ensure all starting devices are
removed or isolated before beginning
1.11 Lifting Precautions any work on engine or plant.
Engine lifting eyes are fitted to Alpha • Ensure the work area is clean,
and New Alpha engines. The following dry, well ventilated and has adequate
points must be considered before lighting.
attempting to lift the engine. • Ensure that all persons using
• Ensure any lifting equipment to be equipment or processes in ­connection
used has the correct capacity to lift the with the maintenance of plant and
engine. mach­inery have received adequate
and suitable training.

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LPW / LPWS / LPWX ENGINE operators' handbook

2. Technical Data
Table 2 gives technical data for all Lister Petter Power Systems LPW,
the engines in the Lister Petter Power LPWX, LPWT, LPWS and LPWST
Systems Alpha (Lpw, LPWX) and New engines are able to run satisfactorily
Alpha (LPWS) range. at ambient temperatures up to the
standard engine reference condition
2.1 Combustion Air of 25°C (77°F) without derating. If
Engine performance is affected by the combustion air temperature rises
ambient temperature, which is taken above this temperature, the rated
to mean the temperature of the air power must be reduced in accordance
entering the engine. with the relevant standard:
The temperature of the combustion air LPW/LPWX/LPWT ISO 3046
is measured at the air inlet manifold, or LPWS ISO 14396
the air cleaner, and the temperature Generating Sets ISO 8528
of the cooling air is measured at the The maximum permitted ambient
radiator fan inlet. The higher of these temperature is 52°C (125°F).
two temperatures is taken as being
ambient temperature as far as engine 2.2 The Cooling System
ratings are concerned. Cooling is by a radiator with water
Every effort should be taken to ensure circulation being assisted by an engine
that the air cleaner draws in combustion mounted, centrifugal, belt driven water
air at a consistent ambient temperature. pump using a single belt.

2. Technical data for Lister Petter Power Systems LPW(X) and LPWS engines.

Technical Data
LPW series model LPW(X)2, LPW(X)3, LPW(X)4 LPW(S)T4 LPWS2, LPWS3, LPWS4
Rotation Anti clockwise (when looking on the flywheel)
Type of injection Direct Indirect
2 cylinders 1-2 n/a 1-2
Firing order: 3 cylinders 1-2-3 n/a 1-2-3
4 cylinders 1-3-4-2 1-3-4-2 1-3-4-2
Electrical system 12V negative earth
Starter battery charging 12V engine mounted alternator
at idle 1.0 bar (14.5 lbf in2)
Oil pressure 3000 2.0 bar 2.5 bar 2.0 bar
r/min1 (29.0 lbf in2) (36.3 lbf in2) (29.0 lbf in2)
Oil sump capacity Refer to table 5.6.3a: Sump Capacity (page 19).
Coolant capacity Refer to table 5.5: Engine Block Coolant Capacity (page 18).

Note: 1. Oil Pressure at 3000 r/min is with the oil at 110°C (230°F).

13
LPW / LPWS / LPWX ENGINE operators' handbook
LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

3.
3. Starting
STARTINGand
AND Stopping
STOPPING
The
The following
following information
information isis ofof aa Engines
Enginesnotnotfitted
fittedwith
withaafuel
fuelcontrol
control
general
general nature andshould
nature and shouldbe
beread
readinin sole­
solenoid have a spring clip tohold
n oid have a spring clip to holdthethe
conjunction
conjunctionwith
withthethemanufacturers'
manufacturers' engine
enginecontrol
controlininthe
thestop
stopposition.
position.
instructions
instructionsfor
forany
anyother
otherequipment
equipment
you are using.
you are using.
WARNING
WARNING
Use
Usesuitable
suitablehand
handprotection
protectionwhen
when
WARNING
WARNING stopping
stopping the
the engine,
engine, as
as the
the stop
stop
Do control
controlmay
maybebehot
hotafter
afterprolonged
Donot
notattempt
attempttotostart
startor
oroperate
operateaa running.
prolonged
diesel
diesel engine unless you havebeen
engine unless you have been running.
properly
properlytrained.
trained.Read
Readthe thesafety
safety
information
information inin section
section 11 and
and the
the
information Oil
OilPressure
PressureSwitch
informationbelow
belowononcontrols
controlsand
and IfIfan
Switch
the
thestarting
startingprocedures.
procedures. anoil
oilpressure
pressureswitch
switchbypass
bypassbutton
button
isisfitted
fitted it must be depressedduring
it must be depressed during
CAUTION
CAUTION engine
enginecranking,
cranking,andanduntil
untilthe
theengine
engine
DDoO not attains
attainsfullfullspeed.
N O T us
U SeE EETTHHEERR BBAASSEEDD speed.
COLD
COLD START AIDS
START AIDS UNDER
UNDER ANY ANY
CIRCUMSTANCES. Heater
CIRCUMSTANCES. Heaterand
andGlow
GlowPlugs
Plugs
LPW,
LPW,LPWX:LPWX:aa345 345W Wheater
heaterplug
plug(A)
WARNING
WARNING may
(A)
DDOO N O T B R E AT H EX
N O T B r e ath maybe befitted
fittedtotothe
theinlet
inletmanifold.
manifold.
E XHHAAUUSSTT LPWT4:
LPWT4:aa696 696W Wheater
heaterplug
plug(A) (A)isis
GASES.
GASES. THEY CONTAINCARBON
THEY CONTAIN CARBON fitted in the inlet manifold.
fitted in the inlet manifold.
MONOXIDE,
MONOXIDE, AA COLOURLESS,
COLOURLESS,
ODOURLESS LPWS:
LPWS:aa12v 12vglow
glowplug
plug(B)
(B)isisfitted
fittedinin
ODOURLESS GAS GAS THAT
THAT CAN CAN each
CAUSE
CAUSEUNCONSCIOUSNESS
UNCONSCIOUSNESSAND AND each cylinder and a 696 W heaterplug
cylinder and a 696 W heater plug
DEATH. (A)
(A)isisalso
alsofitted
fittedininthe
theinlet
inletmanifold
manifoldas as
DEATH. standard.
standard.
CAUTION
CAUTION
On
OnLPWT4
LPWT4engines,
engines,ensure
ensurethatthatthe
the
turbocharger
turbocharger housing is fullof
housing is full ofoil.
oil.
Failure
Failuretotodo
dososocan
canresult
resultininserious
serious
damage
damageto tothe
thebearing.
bearing.Run Runon on'no
'no
load'
load'after
afterstarting
startingfor
for30
30seconds,
seconds,to to
ensure
ensurean anadequate
adequateoil oilsupply
supplyto tothe
the
turbocharger,
turbocharger,and andforfor3030seconds
seconds 3.1Heater
3.1 Heaterand
andglow
glowplugs
plugs- -A.A.Manifold
Manifold
before
before stopping to allowthe
stopping to allow theheat
heat heaterplug;
heater plug;B.B.Cylinder
Cylinderglow
glowplug.
plug.
from
fromthe
thebearing
bearingto todissipate.
dissipate.
3.2Key
3.2 KEYStart
START
3.1
3.1General
GENERALInformation
INFORMATION Beforestarting
Before startingyour
yourengine
engineread
readthe
the
Start/Stop Control
Start/Stop Control cautions,warnings
cautions, warningsand
andthe
thegeneral
general
The
Thebasic
basicengine
enginehas
hasaaplastic
plasticknob
knob informationabove.
information above.
fitted
fitted to the control. Other variants
to the control. Other variants
for
forautomatic
automaticororremote
remoteoperation
operationare
are
available.
available.

14
14
LPW / LPWS / LPWX ENGINE operators' handbook

position for 5 to 10 seconds before


turning it to the START position.
For ambient starting temperatures
below -10°C (14°F) turn the key
clockwise to the PREHEAT position
for 15 to 20 seconds before turning
the key to the START position.
Immediately the engine starts the key
must be turned anti clockwise to the
3.2.1 Start control RUN position.
4. On variable speed engines reduce
Starting LPW(X)2, LPW (X) 3 and the engine speed as necessary.
LPW (X) 4
1. With reference to Figure 3.2.1, move Starting LPWT4
the engine control lever (A) clockwise 1. With reference to figure 3.2.1, move
until it is against the stop screw (B). the engine control lever (A) clockwise
2. On variable speed engines move the until it is against the stop screw (B).
speed control to the fast position. 2. On variable speed engines move the
3. Turn the key clockwise to the START speed control to the fast position.
posi­t ion. Immediately the engine 3. For ambient starting temperatures
starts the key must be turned anti above -10°C (14°F) turn the key
clockwise to the RUN position. clockwise and hold it in the preheat
4. On variable speed engines reduce position for 10 to 15 seconds before
the engine speed as necessary. turning it to the start position.
For ambient starting temperatures
below -10°C (14°F) turn the key
clockwise to the preheat position for
15 to 20 seconds before turning the
key to the start position.
Immediately the engine starts the key
must be turned anti clockwise and
held in the preheat position until the
engine has attained full speed.
4. When the engine has attained full
3.2.2 Key start speed turn the key anti clockwise to
the run position.
Starting LPWS2, LPWS3, LPWS4 5. On variable speed engines reduce
1. With reference to figure 3.2.1, move the engine speed as necessary.
the engine control lever (A) clockwise
until it is against the stop screw (B). 3.3 Failure to Start
2. On variable speed engines move the Should the engine fail to start within
speed control to the fast position. 30 seconds, release the key and, after
3. For ambient starting temperatures allowing sufficient time for all moving
above -10°C (14°F) turn the key parts to stop, attempt to restart.
clockwise and hold it in the PREHEAT

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LPW / LPWS / LPWX ENGINE operators' handbook

3.4 Stopping (All Engines) CAUTION


Turning the key to the off position
CAUTION alone will not stop the engine unless
It is recommended that LPWT4 a fuel control solenoid is fitted.
engines run on 'no load' for 30
seconds before stopping to allow
the heat from the turbocharger
bearing to dissipate.
1. If possible, remove the load from the
engine.
2. If a variable speed control is fitted
reduce the engine speed.
3. On engines fitted with a fuel control
solenoid turn the key to the OFF
3.4 Stop control
position.
On engines not fitted with a fuel
control solenoid move the engine
control lever anti clockwise into the
STOP position (figure 3.4) and turn
the key to the OFF position.

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LPW / LPWS / LPWX ENGINE operators' handbook

4. Engine Fluids
4.1 Fuel Specification 4.3 are the ambient temperatures at
The engine must be used only with the time when the engine is started
diesel fuel oil that conforms to one of (see 2.2 Combustion Air). If monograde
the following: oils are used and running ambient
• BS 2869:1988 Class A2; temperatures are significantly higher
• BS EN590:1995 Class A1; than starting temperatures, a higher
• USA Specification ASTM D-975-77 viscosity oil should be selected, subject
Grades 1-D and 2-D; to satisfactory starting performance.
• BSMA 100 Class M1 for marine use. Multi­g rade oils may be used to
The fuel must be a distillate and not a overcome the problem.
residual oil or blend. • Where ambient temperatures
Vaporising oils are not suitable as are variable and it is not practical to
fuels for Lister Petter Power Systems continually change oils accordingly, a
engines. suitable multigrade oil is recommended
to ensure adequate starting performance
at the lowest temperature likely to be
4.1.1 LPWS Bio
encountered.
LPWS Bio is a specially developed
• The engines must be run on heavy-
engine range that will run on B100
duty lubricating oils. Straight mineral
(100% biofuel) as well as on those fuels
oils are not suitable, neither are oils of
specified above.
less detergency than specified.
CAUTION • API CF-4, API CG-4, API CH or API
CI oils must be used in all engines.
Although the engines may operate
o n ­f u e l s o u t s i d e t h e a b o v e • For engines in long-running
specifications, such operation may installations Lister Petter Power
result in excessive wear and damage. Systems should be consulted.

CAUTION Oil Viscosity


It is of the utmost importance to Figure 4.3 shows the recommended
keep fuel free from water and other oil viscosity ranges for various °C
contaminants. The fuel injection ambient temperatures from cold start
equipment is manufactured to very
to maximum running.
accurate limits, and the smallest
particle of dirt will destroy its Non-synthetic oils at very low
efficiency. temperatures will suffer from wax
crystallisation, so synthetic oils are
recommended for these conditions.
4.2 Oil Specification
SAE 5W-20 oils are recommended on
To assist running-in, all engines are the basis that they are fully synthetic
despatched with an initial fill lubricating and are technically suitable for use up
oil which must be changed, with the to 25°C (77°F). (Monograde SAE 5W is
filter, after the first 100 hours. not normally available as a synthetic oil
All subsequent oil changes must be as therefore does not appear in the chart).
specified in 5. Routine Maintenance. SAE 30 and 10W-30 oils may be used at
• The temperatures cited in Figure up to 52°C (126°F), but oil consumption
17
LPW / LPWS / LPWX ENGINE operators'
OPERATORS' handbook
HANDBOOK

4.2 Recommended oil viscosity grades for different temperature ranges.


Note A: intermittent running; Note B: synthetic oils only. NB. The formula for conversion
from degrees Fahrenheit to degrees Centigrade is°F = (1.8 x °C) + 32.

may
20W-40be affected.
multigrades 10W-40, 15W-40 and
are recommended 4.3.1 (see 5.5.4 Coolant Capacity).
volumes
20W-40 multi­grades
for continuous areoperation
full-load recommendedat this 4.3.1
For engines with aluminium core
for continuous(Monograde
temperature. full-load operation
SAE 40 at this
oils radiator:
For engines with aluminium core
temperature. (Monograde SAE 40 oils
are not recommended.) Do not use tap water, the minerals
radiator:
are not recommended.)
In order to maintain the cold-starting andnot
Do ionsusetypically
tap water,found in tap
the minerals
In order to maintain
characteristics of anythe cold-starting
recommended waterions
and can typically
be corrosive found to internal
in tap
characteristics
grade it is essentialof anythat recommended
oil changes e n g i n can
water e c obe m pcorrosive
o n e n t s toi n cinternal
luding
grade
are madeit is essential
within the thatLister
oil changes
Petter radiators,
e n g i n e c oandm p ocan
n e ncause
t s i n cal umore
ding
are made within the Lister
recommendations (see Petter Power
5. Routine rapid depletion
radiators, and of thecause
can anti-corrosion
a more
Systems
Maintenance).recommendations (see 5. additives
rapid found ofin the
depletion most antifreeze.
anti-corrosion
An oil Maintenance).
Routine change is recommended A 50% concentration
additives found in most of coolant
antifreeze.
An oil change
immediately is recommended
if the engine fails to reach additives
A by volume must beofmaintained
50% concentration coolant
immediately
its normal cold if thestart
engine fails tospeed
cranking reach under allbyoperating
additives volume must conditions.
be maintained If a
its normal
owing cold start
to excessive oilcranking
viscosity.speed component
under fails dueconditions.
all operating to an incorrect If a
owing to excessive oil viscosity. coolant concentration
component fails due being
to anused it will
incorrect
CAUTION not be covered
coolant by thebeing
concentration LP warranty.
used it will
CAUTION
Dilution of the lubricating oil with When
not toppingbyup
be covered thecoolant
LP warranty. please
fuel will adversely
Dilution affect cold oil
of the lubricating starting
with ensure that
When the “top
topping upup” is of theplease
coolant correct
and will
fuel willadversely
increase affect
oil consumption.
cold starting concentrate
ensure mix“top
that the andup”
notis just
of thewater.
correct
and will increase oil consumption.
The specification
concentrate mix and notof the coolant
just water.
4.3 COOLANT * MIXTURE concentrate
The should comply
specification of the with one
coolant
4.3 Coolant * Mixture
CONCENTRATION of the following:
concentrate should comply with one
Concentration
To determine the amount of coolant BS6580
of the : 1985;
following:
To determine
concentrate theadded,
to be amountfirstofcalculate
coolant MIL-A-11755D;
BS6580 : 1985;
concentrate to be added,
the total coolant firstbycalculate
capacity adding MIL-A-46153/B.
MIL-A-11755D;
the total coolant
together capacity
the engine andbyradiator
adding MIL-A-46153/B.
together
volumes (seethe5.5.4
engine andCapacity).
Coolant radiator
* Coolant defined
defined as the combination of water, corrosion inhibitor and antifreeze
18
LPW / LPWS / LPWX ENGINE operators' handbook

5. Routine Maintenance
This section is designed primarily for use • Do you know and understand the
by trained technicians but it does contain engine and all the related systems?
sufficient information, illustrations • Do you have sufficient electrical
and detail to allow the operator to and mechanical knowledge and skills
perform basic maintenance work. to understand the symptoms?
• Do you have suitable electrical
WARNING diagnostic equipment available?
Routine maintenance must be • Do you have, or have access to, the
performed by qualified personnel necessary Lister Petter Power Systems
who are conversant with the spare parts?
hazards of oil, fuel, electricity and
machinery.
5.2 Important Instructions
This work can be carried out only if • Remove the battery before carrying
the necessary hand and service tools out any maintenance work on an
are available. When the user has engine.
insufficient tools, experience or ability • D i s c o n n e c t t h e b a t t e r y a n d
to carry out adjustments, maintenance alternator before commencing any
and repairs this work should not be electric welding when a pole strap is
attempted. directly or indirectly connected to the
Where accurate measurements engine.
or torque values are required they • Fuel pumps and injectors can only
can only be made using calibrated be checked and set off the engine using
instruments. suitable specialist test equipment.
Caution 5.3 Maintenance Schedule
Under no circumstances should
makeshift tools or equipment be The table on page 17 sets out the
used, as their use may adversely frequency with which maintenance and
affect safe working procedures and servicing tasks should be performed.
engine operation. This is the minimum frequency
These recommendations and required to keep your engine running
instructions cover several engine models, at peak performance with trouble-free
therefore they are of a general nature. operation.
The engine may include optional The instructions are based on average
equipment not specifically covered in operating conditions. Air cleaners,
this book. lubricating oil and fuel filters will require
more frequent attention if conditions
are very dusty. De carbonising may
5.1 Before Starting
be required more often if the engine
Before starting any dismantling has been running on light loads for
procedure read 1. Safety Information long periods.
and Pre­c au­t ions. Consider the
following:

19
LPW / LPWS / LPWX ENGINE operators' handbook

How to Service your Engine Renew the oil filter.


Instructions are given in the remaining Every 125 hours1
sections of this chapter. Do all the above, and the following:
Clean the air cleaner if the engine is operating
After Servicing under moderately dusty conditions.
• It is essential to ensure that nuts Check for fuel, coolant and oil leaks.
and bolts are tightened to the torques Check the serviceability of the battery.
specified in the Workshop Manual. Every 250 hours1
• When re-assembling an engine Do all the above, and the following:
lubricate all moving parts with engine oil. Check the condition and tension of the radiator
• Renew nuts and bolts that have drive belt.
been taken from high-stress locations. Check the radiator fins for contamination or
In particular nuts and/or bolts from the blockage.
connecting rods should be renewed. Clean the fuel injector nozzles if exhaust is dirty.
Renew the fuel filter element if the fuel is not
Caution perfectly clean.
Long periods of light or ‘no load’ Every 500 hours
running early in the engine’s life Do all the above, and the following:
may lead to cylinder bore glazing Renew the fuel filter element.
and high oil consumption. Renew the air cleaner element.
Check the air induction systems for leaks, damage
Maintenance Schedule and restrictions.
At all times Change the lubricating oil1.
Continuously monitor engine performance. Renew the oil filter1.
Observe the correct oil and filter change periods as LPWT4: Clean the crankcase breather canister
specified below. and hoses.
Every 1000 hours
1. Oil and Filter Change Periods (hours)
Do all the above, and the following:
Ambient LPWS(T) LPWT LPW(X) Check all external nuts, bolts and unions for
temperature Every tightness.
Above 35°C (95°F) 125 hrs 125 hrs 250 hrs Ensure that all guards are firmly attached and are
Up to 35°C (95°F) 250 hrs 250 hrs 500 hrs not damaged.
Replace the fuel-lift pump diaphragm.2
Every Day
Every 2000 hours
Check the level and condition of lubricating oil.
Check the coolant level. Do all the above, and the following:
Check the level and supply of fuel. Drain and clean the engine-mounted fuel tank, if
Examine the cooling fan for damage. fitted.
Clean the air cleaner if the engine is operating Check the engine and speed controls for free
under very dusty conditions. movement.
After the first 100 hours Clean and check, and if necessary replace, the fuel
injector nozzles.
Marine propulsion engines: check idling speed and
reset if necessary. Check the radiator fins and radiator fan blades for
damage.
Change the initial fill lubricating oil1.

1. See also Table 1 above. 2. Inspect more frequently if fuel is contaminated. Inspect regularly
on engines in low duty cycle applications, for example, stand-by generating sets.

20
LPW
LPW/ /LPWS
LPWS/ /LPWX
LPWXENGINE
ENGINEoperators'
OPERATORS'handbook
HANDBOOK

Maintenance
MAINTENANCESchedule
SCHEDULE
Replace
Replacethe theradiator
radiatorfan
fandrive
drivebelt,
belt,irrespective
irrespectiveofof
itsitscondition.
condition.
Check
Checkthethelubricating
lubricatingoiloilpressure.
pressure.
Renew
Renewthe theairaircleaner
cleanerelement.
element.
Every
Everyyear year
Drain,
Drain,flush
flushand andrefill
refillthe
thecooling
coolingsystem,
system,adding
adding
newnewcoolant
coolantconcentrate
concentratetotoa a50% 50%concentration.
concentration.
If Ifyour
yourengine
engineisisfitted
fittedwith
withananaluminium
aluminiumradiatorradiator
youyouareareadvised
advisedtotoDrain,
Drain,flush
flushand andrefill
refillthe
thecooling
cooling 5.4
5.4 Checking
Checkingdrive
drivebelt
belttension.
tension.
system
systemwith withde-ionized
de-ionizedorordistilled
distilledwater,
water,adding
adding FFdenotes
denotesforce
forceand
anddddenotes
denotesdistance.
distance.
newnewcoolant
coolantconcentrate
concentratetotoa a50% 50%concentration.
concentration.
SeeSee4.3.1.
4.3.1.
5.5
5.5Cooling
COOLINGSystem
SYSTEM
Drain
Drainandandreplace
replacethe thelubricating
lubricatingoiloilandandfilter,
filter,
irrespective
irrespectiveofoftheirtheircondition,
condition,if ifthe
theengine
enginehas hasrun
run Draining
Draining the CoolingSystem
the Cooling System
forforless
lessthan
than250 250hours
hoursininthethepreceding
precedingtwelve twelve
months.
months. WARNING
WARNING
On Onmarine
marineengines,
engines,change
changethe theairaircleaner The
cleaner Thecooling
coolingsystem
systemisispressurised
pressurised
element,
element,if ifit itwas
wasnot
notchanged
changedatatthe theprescribed
prescribed and
andextreme
extremecare caremust
mustbe betaken
taken
intervals.
intervals. when
whenremoving
removingthe theradiator
radiatorcap capifif
Every
Everytwo twoyears
years the
theengine
engineisishot.
hot.
Replace
Replacethe thecoolant
coolanthoses,
hoses,irrespective
irrespectiveofoftheir their 1. Place
1. Place a suitablecontainer
a suitable containerunder
underthe
the
condition.
condition.
radiator
radiator bottom hose if the coolantisis
bottom hose if the coolant
When
Whennecessary
necessary totobeberetained.
retained.
Undertake
Undertakea adecake/major
decake/majoroverhaul.
overhaul. 2. Slacken
2. Slackenthe theclips
clipsofofthethehose
hoseand
and
slide the hose off.
slide the hose off.
5.4
5.4Drive
DRIVEBelt
BELT 3. Remove
3. Removethe theradiator
radiatorfiller
fillercap.
cap.
The
Thetension
tensionofofthethedrive
drivebelt
belt(see
(seefigure
figure 4. Allow
4. Allowsufficient
sufficienttime
timefor forthe
thesystem
system
5.4)
5.4)must
mustbe be checked:
checked: totodrain.
drain.
1. After
1. Afterthe
thefirst
first50 50hours;
hours;
2. Every
2. Every250 250hours; Flushing
hours; Flushingthe
theCooling
CoolingSystem
System
3. After
3. Afteran anoverhaul
overhaulwhen whenthe thebelt
beltisis 1. With
1. With the
the bottom
bottom hose
hose removed,
removed,
refitted
refittedororreplaced.
replaced. flush
flushthe
theradiator
radiatorthrough
throughthe thefiller
filler
4.4.The
Thedrive
drivebeltbeltmustmustbe bereplaced
replaced with clean fresh water, preferably
with clean fresh water, preferably
every
every2000
2000hours,
hours,irrespective
irrespectiveofofits its using
usingaahose
hosepipe,
pipe,until
untilclean
cleanwater
water
condition.
condition. emerges.
emerges.
When
Whenaanew newbelt beltisiscorrectly
correctlyfitted
fittedandand 2. With
2. With the
the top
top and
and bottom
bottom hoses
hoses
tensioned,
tensioned,aaforce force(F) (F)ofof31.0­
31.0-33.5
-33.5NN removed
removed from
from the
the engine,
engine, flush
flush
(7.0-7.5
(7.0-7.5lbf)lbf)isisrequired
requiredtotodeflect
deflectititaa the
theengine
enginethrough
throughthethetop tophose
hose
distance
distance(d) (d)ofof3.5mm
3.5mm(0.14in).
(0.14in). with
withclean
cleanfresh
freshwater,
water,preferably
preferably
OOnn ssuubbsseeqquueennt t cchheecckki ni ngg aanndd using
usingaahose
hosepipe,
pipe,until
untilclean
cleanwater
water
adjustment
adjustmentaaforce force(F) (F)ofof22.0-24.0N
22.0-24.0N emerges.
emerges.
(5.0-5.4lbf)
(5.0-5.4lbf)isisrequired
requiredtotodeflect
deflectititaa 3. Replace
3. Replacethethehoses.
hoses.
distance
distance(d) (d)ofof3.5mm
3.5mm(0.14 (0.14in).
in).

21
21
LPW / LPWS / LPWX ENGINE operators' handbook

Filling the Cooling System For these reasons it is advisable to


ascertain the radiator capacity which
CAUTION must then be added to that given in the
Under some circumstances an table above under Engine Block before
air lock can occur when filling determining the amount of coolant
the system, causing a false level concentrate to be added to maintain a
indication. 50% concentration.
1. Ensure the hoses have been The capacity of hoses on remote
replaced. radiator applications must also be
2. Refill the system with clean fresh taken into consideration.
water and coolant concentrate to a
50% concentration while bleeding air 5.6 Lubricating Oil
from the system at a suitable point. Check the lubricating oil daily using the
If your engine is fitted with an dipstick, and top up when necessary
aluminium radiator you are advised with oil of the correct type and
to Drain, flush and refill the specification (see section 4.2 Oil
cooling system with de-ionized or Specification). Table 5.6.3 gives the
distilled water, adding new coolant capacity between the dipstick marks of
concentrate to a 50% concentration. all engines in the LPW range.
The radiator should be filled to within
Table 5.6.1.
13.0-25.0mm (0.5-1.0 in) below the
neck of the radiator filler. Capacity Between Dipstick
3. Run the engine for a short time and Marks
check the coolant level. LPW4
LPW2 LPW3
LPWX4
LPWX2 LPWX3
LPWT4
Coolant Capacity: Engine Block LPWS2 LPWS3
LPWS(T)4
Table 5.5.
All builds except 28, 51, 52, 57, 58, 59
Engine Block Coolant
litres 0.90 0.95 1.20
Capacity
LPW4 pints 1.58 1.67 2.11
LPW2 LPW3
LPWX4 US gallons 0.24 0.25 0.32
LPWX2 LPWX3
LPWT4
LPWS2 LPWS3 Builds 28, 51, 52, 57, 58, 59
LPWS(T)4
litres 2.1 2.5 3.0 litres 1.50 1.75 2.20
pints 3.7 4.4 5.3 pints 2.64 3.08 3,87
US gallons 0.55 0.66 0.79 US gallons 0.39 0.46 0.58

Coolant Capacity: Radiator Change the lubricating oil and filter for
There are a number of radiator options the first time at 100 hours and then as
available for LPW, LPWX, LPWT specified in 5.3. Maintenance Schedule
and LPWS engines, including some (Table 1).
which may not have been originally
fitted by Lister Petter Power Systems.

22
LPW / LPWS / LPWX ENGINE operators' handbook

CAUTION
Continuous operation under heavy
loads in ambient temperatures
above 35°C (95°F) causes the oil to
deteriorate more quickly.
Draining the Oil Sump
Before draining the oil read 1.5
Precautions with Filters and Elements 5.6.1. The oil filler (A) and dipstick handle
and 1.6 Precautions with Oil Seals.
The oil sump drain plugs are located 1. Ensure the new oil meets the correct
on the oil filter side and the gear end of specification and viscosity, as given
the crankcase. It is better if the engine in 4.2 Oil Specification.
has been run immediately before 2. Fill the sump through the oil filler (A)
draining, as the warm oil will drain to the upper mark on the dipstick.
more quickly. 3. Start the engine and run it for a few
1. Remove the oil filler cap. minutes to circulate the oil.
2. Remove the drain plug and allow the 4. Stop the engine and allow time for
oil to run into a suitable retainer. the oil to drain down. Check the level
3. Clean the drain plug threads and coat on the dipstick.
them with Hylomar PL32/M, Loctite 5. Add more oil if necessary.
572 or Hylogrip 760.
4. Replace the plug and tighten it. CAUTION
Do not overfill with oil. If a cylinder-
Refilling the Oil Sump head oil filler is fitted the oil must
Table 5.6.3 gives the sump capacity only be poured into the filler at a
(excluding the filter) of all engines in rate which enables it to drain into the
the LPW range. crankcase. If the oil is poured in too
quickly it can flood the crankcase
Table 5.6.3 breather holes and escape into the
Sump Capacity inlet manifold and cylinders.
(Figures exclude the filter)
LPW4 Changing the Oil Filter
LPW2 LPW3
LPWX2 LPWX3
LPWX4 The full flow filter is a spin-on cartridge
LPWT4 type located on the crankcase door.
LPWS2 LPWS3
LPWS(T)4 Only approved filters should be used,
All builds except 28, 51, 52, 57, 58, 59 as these have high temperature
litres 3.00 3.75 5.50 resistant joints, adequate filter paper
pints 5.28 6.60 9.68 characteristics and a rigid case. Other
US gallons 0.79 0.99 1.45
filters may have the same external
dimensions and thread as the genuine
Builds 28, 51, 52, 57, 58, 59
one but may fail in service.
litres 5.85 8.25 11.5 Before changing the filter read
pints 10.29 14.52 20.23 1.5 Precautions with Filters and
US gallons 1.55 2.18 3.03 Elements.

23
LPW / LPWS / LPWX ENGINE operators' handbook

1. Use a band-type gripping tool to Changing the Agglomerator


remove the filter from the engine. Before starting, read 1.5 Precautions
2. Lightly grease or oil the face of the with Filters and Elements and study
rubber joint on the new filter. figure 5.7.2.
3. Screw the new filter onto the 1. Before removing the agglomerator
crankcase filter adaptor, or filter cartridge (A) from the agglomerator
mounting bracket facing, until the head (B) you should first drain the
rubber joint just makes contact with water from the agglomer­a tor by
the crankcase facing of mounting unscrewing the drain tap (C).
bracket. 2. Using a suitable strap wrench,
4. Screw the filter on a further quarter unscrew the cartridge (A) from the
to half a turn. head (B).
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.

5.7 Fuel System


Priming the Fuel System
1. Ensure there is sufficient fuel.
5.7.2. The agglomerator: cartridge (A);
2. Figure 5.7.1 shows the two types of
head (B); drain tap (C).
filter. Release the bleed screws (A)
on the filter and re-tighten when no
3. Screw a new cartridge onto the head
further air bubbles are expelled.
and hand tighten it.
3. On variable speed engines move the
speed control to the fast position.
4. Move the engine stop/run control
Changing the Fuel Filter
The element should be renewed every
from the stop to the run position
500 hours, or more frequently if for any
(figure 3.3.2, page 13).
reason the fuel is known to be dirty.
5. Operate the fuel-lift pump by hand.
Before changing the filter read
1.5 Precautions with Filters and
Elements.
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 fit a
replacement.
5.7.1 Priming the fuel filter: the bleed 4. Fill the fuel tank and prime the
screws are denoted by A. system (see 5.7.1 Priming the Fuel
System).

24
LPW / LPWS
LPW / LPWX
/ LPWS ENGINE
/ LPWX operators'
ENGINE handbook
OPERATORS' HANDBOOK

5. Run
5. Runthethe
engine
engine and andcheck
check to tosee that Cyclonic
that
see Cyclonic Air AirCleaner
Cleaner
nonofuel is is
fuel leaking
leaking fromfrom thethefilter.
filter. AA cyclonic
cyclonic airaircleaner
cleaner can can bebe remote
remote
or or
engine-mounted
engine-mounted overover thethe flywheel
flywheel
housing.
housing. In Ineither
eithercasecase it is connected
it is connected
to to
thethe engine
engine bybya moulded
a moulded rubber
rubber hose
hose
secured
secured byby jubilee
jubilee clips.
clips.
1. Regularly
1. Regularly remove
remove thethe dustdust capcap(A)(A)
and and empty
empty outout
allall
thethe dust.
dust.
2. Gain
2. Gain access
access to to
thethe paper
paper element
element byby
undoing
undoing thethetwo over-centre
two over-centre clips (B).
clips (B).
3. Remove
3. Remove thetheelement.
element.
4. Clean
4. Clean thethe element
element bybydirecting
directing a low-
a low-
5.7.3 Changing
5.7.3 Changing thethe
fuelfuel
filter. The
filter. Thecentre boltbolt
centre
is denoted
is denoted bybyA and
A andthethe oldoldelement
element byby
B B pressure
pressure compressed-air
compressed-air nozzle
nozzle upup
and and downdown thethepleats
pleats fromfrom inside
insidethethe
element.
element.
5.85.8Air
AIR Cleaner
CLEANER
5. Inspect
5. Inspect thethe element
element forfor damage
damage byby
Every
Everyefforteffortshould
shouldbebetaken takento to placing
placing a suitable
a suitable light
lightsource
source inside
inside
ensure
ensurethat thatthetheairaircleaner
cleanerdraws draws it. it.
If the
If theelement
element is found
is found to tohave
haveanyany
in incombustion
combustionairairat atthetheprevailing prevailing holes
holes it must
it must bebe replaced.
replaced.
ambient
ambient temperature.
temperature.
AnyAnyincrease
increasein incombustioncombustionairair
temperature
temperature above
abovethethe standard
standard engine
engine
reference
reference condition
condition of of25°C
25°C (77°F)
(77°F)willwill
incur anan
incur engine
engine derate
derate factor.
factor.

Light Duty
Light Air
Duty Cleaner
Air Cleaner
TheThesnoutsnoutis isnormallynormallyfitted
fittedlying
lying
horizontally
horizontally andand pointing
pointingtowards
towards thethe
gear
gearend,end, although
although thethecleaner
cleaner itself
itself
cancanbebe rotated
rotated through
through 360°.
360°. 5.8.2 The cyclonic
5.8.2 The cyclonic airair cleaner
cleaner
1. 1.Release
Release thethethree cover
three coverclips
clips(A).(A).
2. 2.LiftLift
offoffthethe
cover
cover (B).
(B).
5.95.9 BATTERY
Battery
3. 3.LiftLift
outout thethe
element
element (C).
(C).
4. 4.FitFit
a new
a new element.
element. Check thethe
Check battery
battery asas follows.
follows.
5. 5.Replace
Replace thethecover and
cover andclips.
clips. 1. We a r p r o t e c t i v e g l g
1. We a r p r o t e c t i v e o lvoevse sa nadn d
goggles.
goggles.
2. Clean
2. Clean thethetoptopof of
thethe filler-plug
filler-plug area.
area.
3. Remove
3. Remove thethe filler
filler plugs
plugs and and check
check
that
that thethe electrolyte
electrolyte level
level is is 6.0-9.0
6.0-9.0
mm mm (0.25-0.37
(0.25-0.37 in)in)
aboveabove thethe tops
tops of of
thethe separators.
separators.
4. If
4. If necessary,
necessary, toptop upup with
with distilled
distilled
water.
water. In In cold
cold weather
weather distilled
distilled water
water
should
should onlyonlybebe added
added immediately
immediately
5.8.1
5.8.1The light
The duty
light airair
duty cleaner
cleaner before
before running
running thethe engine.
engine.

2525
LPW / LPWS / LPWX ENGINE operators' handbook

5. Replace and tighten the filler plugs. 4. Stop the engine, drain the cooling
6. Check that the terminal connections system and drain the lubricating oil
are tight; petroleum jelly will help to from the sump.
protect them from corrosion. The crankshaft should not be turned
until the engine is again required for
CAUTION service.
BATTERIES CONTAIN SULPHURIC The inhibition fluid should be left in
ACID WHICH CAN CAUSE the fuel system.
SEVERE BURNS AND PRODUCE 5. Seal all openings on the engine with
EX P L O S I V E G A S E S . I f acid tape.
is splashed on the skin, eyes
6. Remove the batteries and store
or clothes flush with copious
amounts of fresh water and them fully charged after coating the
seek immediate medical aid. terminals with petroleum jelly.
7. Grease all external bright metal parts
and the speed control linkage.
5.10 Long Term Engine 8. Tie labels on to the engine, clearly
Storage stating what steps have been taken
If the engine is not required for a period to inhibit the engine during storage.
of a few weeks it should be run on full
load for approximately 45 minutes once Returning the Engine to Service
a month Refer to the appropriate sections
If the engine will not be required for for the relevant detailed instructions
some months, prepare it for storage necessary to complete this work.
as follows. 1. Remove the tie-on labels and all the
protective coverings from openings
CAUTION and apertures.
As a direct result of combustion the 2. Check the drive belt for deterioration
lubricating oil may contain harmful and correct tension.
acids and therefore it should not be Check to ensure that the drive-
left in the sump if it is known that the belt pulley grooves are free from
engine will not be used for extended corrosion.
periods. 3. Fill the fuel tank.
1. Replace the fuel in the tank with a 4. Refill the cooling system, adding new
small supply of suitable inhibition coolant to a 40% concentration.
fluid. 5. Refill the oil sump with new oil of the
2. Drain the lubricating oil from the correct specification and viscosity.
sump and refill with new oil. 6. Remove the batteries from store
3. Run the engine for a period to and recharge them if necessary.
circulate the oil through the system Reconnect them to the engine.
and to ensure the inhibition fluid is Coat the terminals with petroleum jelly.
passed through the fuel pumps and 7. Start the engine and check for
injectors. coolant, fuel and oil leaks before
applying load.

26
LPW / LPWS / LPWX ENGINE operators' handbook

6. Troubleshooting
When an engine does not operate as procedure please read 1. Safety
expected it can be difficult to diagnose Information and Precautions, taking
the cause. The table in this chapter especial note of 1.8.
suggests a number of possible causes
of various problems, together with 6.1 Method of Fault
recommended solutions. The operator Diagnosis
should check carefully which of these
1. Diagnose the problem by checking
applies in a particular case. Many
and eliminating the easiest causes
of the suggested solutions can be
first. In the case of electrical problems
carried out by the operator, guided by
always check the battery first.
section 5. Routine Maintenance. Where
2. Double check your observations.
indicated1 you should seek assistance
3. Carry out the recommended solution,
from an experienced engineer (who
or request an engineer to do this.
must refer to the Workshop Manual).
A comprehensive list of problems and
The list is of a general nature as it
the methods of correction is given in
covers the basic engine; your particular
the Workshop Manual. If you are in any
application may be different.
doubt, contact your Lister Petter Power
Before starting any maintenance
Systems distributor.

Troubleshooting
Problem Cause Solution
Incorrect starting procedure. Refer to section 3.
Unsuitable lubricating oil or fuel. Refer to section 4.
Refill the tank and prime the fuel system or
No fuel in the tank or the filter is choked.
replace the filter.
Air in the fuel system. Prime the fuel system.
Difficulty
starting or Water or dirt in the fuel system. Drain, flush, refill and prime the fuel system.
failure to start Replace the injector or pump or have it
Faulty injector or pump.
serviced.
Discharged battery or poor battery Recharge or replace the battery. Check the
connections. terminals are tight.
Check the shutdown devices of the
Fuel control solenoid not energised.
electrical system.1
Loose or corroded connections. Clean and tighten the connections.
Starter motor
Worn out battery. Replace the battery.
does not
operate Adjust the connections and/or replace the
Faulty starter panel or connections.
panel.
Loose or corroded connections. Clean and tighten the connections.
Battery will not
Worn-out battery. Replace the battery.
charge
Loose alternator drive belt. Replace or re-tension the drive belt.
1. Requires an experienced engineer.

27
LPW / LPWS / LPWX ENGINE operators' handbook

Troubleshooting
Problem Cause Solution
Poor quality fuel. Drain, flush, refill and prime the fuel system.
Engine speed Fuel system restriction. Replace fuel filter.
unstable Restriction in induction system. Replace air cleaner element.
Fault in fuel lift pump. Replace diaphragm and/or pump.1
Radiator fan belt too slack. Adjust belt tension.
Overload. Reduce the load.
Lubricating oil level too low. Refill the sump.
Overheating Recirculation of exhaust gases or cooling air. Redesign exhaust and ventilation system.1
Radiator cooling fins blocked. Clean the fins of all obstruction.
Low level of coolant. Check for leaks and refill.
Cooling system obstructed. Drain, flush and refill the system.
Lack of fuel. Check the system.1 Refill the tank.
Air in the fuel system. Prime the fuel filter.
Water in the fuel system. Drain, flush, refill and prime the fuel system.
Choked fuel filter. Replace the filter.
Choked air filter. Dismantle and clean the cap and element.
Engine stops Overload. Reduce the load.
Overheating. See Overheating section.
Loss of compression. Check the piston rings and the valves.1
Loss of electrical supply to the fuel pump solenoid. Check the electrical feed.1
Automatic shutdown, if protective devices are
Investigate the cause and rectify.1
fitted.
Loss of compression. Check the piston rings and the valves.1
Choked air filter. Dismantle and clean the cap and element.
Poor quality fuel. Drain, flush, refill and prime the fuel system.
Lack, or loss,
Choked exhaust system. Dismantle and clean.1
of power
Overload. Reduce the load.
Choked fuel filter. Replace the filter.
Worn engine. Give the engine a major overhaul.1
Excessive electrical load from added Remove accessories or fit higher output
accessories. alternator.1
Poor electrical connections to alternator or
Undercharging Inspect, clean and rectify the cause.
battery.
Faulty battery. Test and recharge or replace.
Faulty alternator. Test and if necessary replace.
Overcharging Faulty alternator. Test and if necessary replace.
Battery Battery case leaking. Clean surrounding area and replace the battery.
requires Defective battery. Test or replace the battery.
excessive
amounts of Check the alternator output and battery
Battery charging rate is too high.
water charging system.1
1. Requires an experienced engineer.

28
LPW / LPWS / LPWX ENGINE operators' handbook

7. Maintenance Record
Your Lister Petter Power Systems of the maintenance work carried out
engine must be properly maintained on the engine during the first 5000
using the timings and procedures hours, except the daily checks, must
described in this manual. You must be recorded in the spaces allocated in
be familiar with the routine tasks set this section: pages 29-33 for routine
out in 5. Engine Servicing, and their maintenance and pages 34-36 for
correct frequency as described in records of non-routine maintenance.
5.3 Maintenance Schedule. Details

7.1 Routine Maintenance


Hours run Work done by Details of service Distributor/Dealer Stamp Date

29
LPW / LPWS / LPWX ENGINE operators' handbook

Hours run Work done by Details of service Distributor/Dealer Stamp Date

30
LPW / LPWS / LPWX ENGINE operators' handbook

Hours run Work done by Details of service Distributor/Dealer Stamp Date

31
LPW / LPWS / LPWX ENGINE operators' handbook

Hours run Work done by Details of service Distributor/Dealer Stamp Date

32
LPW / LPWS / LPWX ENGINE operators' handbook

Hours run Work done by Details of service Distributor/Dealer Stamp Date

33
LPW / LPWS / LPWX ENGINE operators' handbook

7.2 Non-Routine Maintenance


Hours run Work done by Details of service Distributor/Dealer Stamp Date

34
LPW / LPWS / LPWX ENGINE operators' handbook

Hours run Work done by Details of service Distributor/Dealer Stamp Date

35
LPW / LPWS / LPWX ENGINE operators' handbook

Hours run Work done by Details of service Distributor/Dealer Stamp Date

36
LPW / LPWS / LPWX ENGINE operators' handbook

8. Warranty
On receipt of your engine please • Only genuine Lister Petter Power
fill in the section on page 38. This Systems service parts must be used.
information will be required in the • When Lister Petter Power Systems
event of a claim under your two-year parts are purchased from a dealer,
warranty, according to the conditions this must be noted, with the dealer's
set out below. stamp, in 7. Maintenance Record, and
receipts for the parts must be retained.
8.1 Standard Warranty The dealer is authorised to stamp the
Cover maintenance record only following the
sale of genuine parts, to a competent
The standard warranty includes
engineer, intended to be used on
two-year / 2000-hour (or 1000-hour
the warrantable Lister Petter Power
for 3600 r/min engines) cover for
Systems engine.
all non-serviceable 1 components,
• Evidence will be required of engine
parts and labour, beginning on the
hours run and should be entered in
date of delivery to the original retail
7. Maintenance Record. Evidence
purchaser, and is transferable. It is
of equipment used to record engine
subject to the conditions set out below
hours may be requested in the event
in 8.2 Conditions of Warranty and the
of a warranty claim. If no hour recorder
limitations set out in 8.3 Limitations of
is fitted, twelve hours per calendar day
Warranty.
will be used as a basis for the hours-run
calculation.
8.2 Conditions of Warranty • The installation should be in
For the warranty to be valid, servicing accordance with data supplied by
must be carried out in accordance the Lister Petter Power Systems
with 5. Routine Maintenance and with Applications Department.
the timings set out in 5.3 Maintenance • Long term light load and cold engine
Schedule. Detailed records of servicing running will invalidate the warranty.
must be kept; see 7. Maintenance
Record. Servicing must be by approved 8.3 Limitations of Warranty
dealers or competent engineers. The
• T h e s e l l e r d o e s n o t a c c e p t
conditions of warranty are:
responsibility for any business costs
• The maintenance record must be
or other losses which may result from
completed.
the warrantable failure.
• Oils and other fluids must be to
• The seller is not responsible for
the specifications/grades given in 4.
Engine Fluids or as instructed in the Continued
Workshop Manual.
Notes:
1. Serviceable items (unless defective) include, but are not limited to: air filters, fuel filters, oil filters,
injector nozzles, drive belts and lubricants and coolants (unless used on an authorised repair).
2. This warranty gives the purchaser specific legal rights; the purchaser may also have other
rights, which vary by country or state.

37
LPW / LPWS / LPWX ENGINE operators' handbook

failures resulting from misapplication, 8.6 Contacting Lister


abuse or neglect, including: operating Petter Power Systems
with inadequate cooling; the use of
Head Office
non-approved or contaminated fuels
Lister Petter Power Systems Limited
or lubricants; lack of, or incorrect,
Unit 14 Estuary Court, Broadmeadow
maintenance; incorrect repair; improper
Industrial Estate, Teignmouth
storage; incorrect starting, stopping or
TQ14 9FA
operating procedures; the use of non-
T: +44 (0) 1285 702211
approved parts; fair wear and tear; and
serviceable items (see note 1). Production Facility
Lister Petter Power Systems Limited
8.4 Purchase and Units 13-15 Quadrant Distribution
Registration Details of Centre, Hardwicke, Gloucester
your Engine GL2 2RN
Please fill in the section below with your sales@listerpetter.com
purchase and registration details. This www.listerpetter.com
information will be required in the case
of a claim under warranty.

8.5 Repairs under


Warranty
• Lister Petter Power Systems
must be contacted and authorisation
given before any warrantable work is
commenced.

Engine Serial Number: ..........................................................................................

Purchased from: ...................................................................................................

Purchase Date:.......................................................................................................

Date Registered with Lister Petter Power Systems:...............................................

Plant Type:..............................................................................................................

Plant Number:........................................................................................................

38
LPW / LPWS / LPWX ENGINE operators' handbook

9. Index
A O
Agglomerator.................................. 24 Oil filter........................................... 23
Air cleaner - cyclonic...................... 25 Oil pressure switch......................... 14
Air cleaner - light duty..................... 25 Oil specification.............................. 17
Oil Sump - filling............................. 23
Other Publications............................ 2
B
Battery............................................ 25
P
Priming the fuel system.................. 24
C Publications...................................... 2
Cooling system.......................... 13,21
Cooling System - filling................... 22
Cooling System - flushing............... 21 R
Routine maintenance..................... 19

D
Drive belt tension............................ 21 S
Safety precautions
Waste disposal . ........................ 11
F Safety symbols................................. 8
Fuel filter element........................... 24 Start/stop control............................ 14
Fuel system - priming..................... 24 Stopping......................................... 16
Storage........................................... 26

G
T
Glow plug....................................... 14
Troubleshooting.............................. 27

M
W
Maintenance record........................ 29
Warranty definitions........................ 37

39
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.

ALPHA (LPW, LPWX, LPWS & LPWS BIO) ENGINE


Operators' Handbook,
p027-08270, EDITION 6, January 2019
© Lister Petter POWER SYSTEMS

Head Office
Lister Petter Power Systems Limited
Unit 14 Estuary Court, Broadmeadow Industrial Estate
Teignmouth, TQ14 9FA
T: +44 (0) 1285 702211

Production Facility
Lister Petter Power Systems Limited
Units 13-15 Quadrant Distribution Centre
Hardwicke, Gloucester, GL2 2RN

sales@listerpetter.com
www.listerpetter.com