Gamma Engines Operators Handbook PDF

GAMMA SERIES
GW3, GWT3, GW4, GWT4, GWT6-1A

GWT6-2A, GWTA6 ENGINEs
Operators' Handbook
ORIGINAL INSTRUCTIONS
P027-08199
Associated Publications
Master Parts Manual P027-08557
Workshop Manual P027-08220
Technical Handbook P027-08315
WARNING
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNING
MENTIONED IN THIS MANUAL.
WARNING
IMPROPER OPERATION OR MAINTENANCE PROCEDURES COULD
RESULT IN SERIOUS ACCIDENT OR DAMAGE TO THE EQUIUPMENT
CAUSING INJURY OR DEATH.
WARNING
NON-COMPLIANCE WITH THESE INSTRUCTIONS MAY INVALIDATE THE
WARRANTY.
WARNING
MAKE CERTAIN THAT THE ENGINE CANNOT BE STRTED IN ANY WAY
BEFORE UNDETAKING ANY MAINTENANCE, PARTICULARLY IN THE CASE
OF AUTOMATICALLY STARTING GENERATING SETS.
Statement of Indemnity
The information, specifications, illustrations, instructions and statements contained within
this publication are given with our best intentions and are believed to be correct at the time
of going to press.
Our policy is one of continued 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 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 Petter Power Systems organisation cannot
be relied upon for correct material, dimensions or finish. The Company cannot therefore
be held responsible for any damage arising from the use of such parts, and the guarantee
will be invalidated.
P027-08199 Copyright © Lister Petter Power Systems
2
CONTENTS
Introduction ...............................................................................................6
Engine Identification 6
Engine lifting 7
Care of your engine 7
Service literature 7
Training 7
1. Safety Information and Precautions ............................................8

1.1 Personal Safety 9
1.2 General Precautions 9
1.3 Care with Lubricating Oil 11
1.4 Precautions with Diesel Fuel 11
1.5 Precautions with Coolant 11
1.6 Precautions with Batteries 12
Battery Charge Alternator 12
1.7 Care with Electrical Systems 13
Wiring Cables 13
1.8 Lifting Precautions 13
1.9 Care with Filters and Elements 14
1.10 Waste Disposal 14
2. Engine Parts and Technical Data ...................................................15

2.1 Front and Left Side 15
2.2 Rear and Right Side 15
3. Operating instructions .....................................................................17

3.1 Starting the Engine 17
3.1.1 Starting a Warm Engine 17
3.1.2 Starting a Cold Engine without Starting Aids 17
3.1.3 Starting a Cold Engine with Starting Aids 18
3.2 Stopping the Engine 18
3.3 Adjustment of Engine Speed 18
3
3.4 Running-In 19
3.5 Altitude 19
4. Engine Fluids ..........................................................................................20

4.1 Fuel Specification 20
4.1.1 Low Temperature Fuels 20
4.2 Lubricating Oil Specification 21
4.3 Coolant Specification 22
5. Routine Maintenance ..........................................................................23

5.1 Maintenance Schedule 23
5.2 Draining the Cooling System 24
5.3 Checking the Drive Belts 25
5.3.1 Adjusting the Belt Tension 25
5.4 Cleaning the Fuel Lift Pump 26
5.5 Checking the Fuel Pre-Filter 27
5.6 Renewing the Fuel Filter Element 27
5.6.1 Renewing a Separate Type Fuel Filter Element 27
5.6.2 Renewing a Canister Type Fuel Filter Element 28
5.6.3 Renewing a Quick Release
Canister Type Fuel Filter Element 28
5.7 Renewing a Fuel Injector 30
5.8 Eliminating Air from the Fuel System 31
5.8.1 Standard Method 31
5.8.2 Method Using In-Line PB Type Injection Pump 33
5.9 Changing the Lubricating Oil 34
5.10 Replacing the Oil Filter Canister 34
5.11 Cleaning the Breather system 35
5.12 Servicing the Air Cleaner 36
5.12.1 Air Filter 37
5.12.2 Restriction Indicator 38
4
GAMMA SERIES ENGINES operators' handbook
5.13 Checking Valve Clearances 38

5.13.1 Three Cylinder Engines 38
5.13.2 Four Cylinder Engines 39
5.13.3 Six Cylinder Engines 40
5.13.4 Valve Positions 40
6. Fault Diagnosis .....................................................................................41

6.1 Problems and Possible Causes 41
6.2 Code List of Possible Causes 42
7. Engine Storage .....................................................................................43

7.1 Preparing the Engine for Storage 43
7.2 Returning the Engine to Service 43
8. Maintenance Record ..........................................................................44

8.1 Routine Maintenance 44
8.2 Non-Routine Maintenance 48
9. Warranty .................................................................................................52
9.1 Standard Warranty Cover 52
9.2 Conditions of Warranty 52
9.3 Limitations of Warranty 53
9.4 Repairs under Warranty 53
9.4.1 Contact Details 53
Appendix: Fuel Pumps and Governors ..............................................54

PB Pump 54
Adjustment and Use of the PB Pump 55
Adjustment of Static Fuel Supply 55
RSV Governor - PB Pump 56
Rotary Type Fuel Pumps 57
Electronic Governor 58
5
Introduction
Your Gamma engine should be correctly operated and serviced in accordance
with this handbook.
To obtain the best performance and the longest life from your engine you must
ensure that maintenance operations are carried out at the intervals indicated in
5. Routine Maintenance. For example, it is essential to renew the filter elements and
lubricating oil regularly in order to ensure that the engine components remain clean.
If the engine operates in a very dusty environment or other adverse conditions
some of the maintenance intervals will be shorter. Ensure that all adjustments and
repairs are done by properly trained personnel. Your Lister Petter Power Systems
distributor can assist in this matter and will also supply the genuine Lister Petter
Power Systems parts needed for your engine.
To ensure that you use the correct information for your specific engine type, refer
to the section below.
Engine Identification
In this handbook the different engine types are indicated by code letters.
The meanings of these codes are as indicated below:
GAMMA Models
Model Number Cylinders Aspiration
GW3 3 Natural
GWT3 3 Turbocharged
GW4 4 Natural
GWT4 4 Turbocharged
GWT6-1A 6 Turbocharged
GWT6-2A 6 Turbocharged
Turbocharged
GWTA6 6
and Intercooled
The engine number is stamped on a label fastened to the left side (1) or rear (2)
of the cylinder block (see figure).
Example of the engine numbers are:
09300158GW40015 or 09300021GWT62A18RP
It is identified as follows:
09. ..................................... Year code (09 = 2009)
3 ....................................... Factory code
00158 ............................... Unique engine number
GW ................................... Engine model (GWT)
6
4 ....................................... Number of cylinders

00 ..................................... Reserved for 6 cylinder turbocharged variant 1A or 2A
15 ..................................... Engine speed 1500 r/min or
18 ..................................... Engine speed 1800 r/min or
22 ..................................... Engine speed 2200 r/min
RP .................................... Rotary fuel injection pump
This should be quoted when requesting parts, service or information from your
Lister Petter Power Systems distributor.
Engine lifting
In different applications of the engine the maximum dry weight (without coolant
or lubricating oil) will vary. The maximum recommended weight of the engines
for lifting is as follows:
3-cyIinder engines: 420 kg (925 Ib)
4-cyIinder engines: 500 kg (1100 Ib)
6-cylinder engines: 600 kg (1320 Ib)
Before lifting the engine, read 1.8 Lifting Precautions.
Care of Your Engine

Your engine must receive the correct routine maintenance as described in section 5.
If faults do occur they can usually be diagnosed and corrected using the information
in section 6.
In case of queries about your engine or its installation contact your Lister Petter
Power Systems distributor. Your distributor can undertake repairs and will ensure
that only the correct parts are fitted and the work is done correctly.
Service literature
Workshop manuals and other service publications are available from your Lister
Petter Power Systems distributor.
Training
Local training for the correct operation, service and overhaul of engines is available
at certain Lister Petter Power Systems distributors. If special training is necessary,
your distributor can advise you how to obtain it.
7
• Wear suitable ear protection against
WARNING objectionable or uncomfortable loud
KEEP THE BODY AND CLOTHING
GAMMA SERIES ENGINES
CLEAR OF MOVING OR HOT PARTS operators' noise.
handbook
AT ALL TIMES. CONTACT OF MOVING • To avoid loss of concentration, do
not use music or radio headphones
1. Safety Information
PARTS WITH UNPROTECTED SKIN
CAN CAUSE SEVERE BURNS. while operating an engine.
and Precautions
ENTANGLEMENT WITH ROTATING
EQUIPMENT CAN CAUSE SERIOUS
• When undertaking maintenance, do
not work under any plant that is only
INJURY OR DEATH. held by overhead lifting equipment.
Carefully read and follow all safety messages in thisappropriate,
• Where manual (some makeitems only
sure that
• Tietolong
apply hair applications).
specific back securely.Familiarise yourself with the safety and informative
guards are properly fitted.
• Wearon
symbols close-fi
your tting clothing.You must also refer to the local regulations in the
equipment.
• Do not
country wear a necktie, scarf, loose
of use.
clothingthat
or you
necklace whenwithworking 1.3 PRECAUTIONS WITH
Ensure are familiar the safety symbols used by Lister Petter Power
close to a(Figure
running1).engine. CHEMICALS
Systems
•TakeWhere possible, remove rings and
especial care when handling potentially Protect yourself
hazardous from These
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include
other jewellery to prevent entanglement hazardous chemicals at all
lubricants, fuel, coolant concentrate, battery acid (see sect ion 1.4 Precautions times, as
in moving
with parts. paint
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adhesives. this can cause serious injury. Potentially
cause a short circuit
Manufacturers' safetyifdata
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the physical and
electrical system is being worked on. fuel, coolant concentrate,
health hazards, safety and emergency procedures and any necessary personal battery acid,
protection equipment required while working paint and
with adhesives.
hazardous materials.
WARNING Manufacturers' safety data sheets
Prolonged exposure to loud noise will provide specific details of the
CAUTION
can cause impairment, or loss, of physical and health hazards, safety
hearing.
Follow all safety instructions accurately. and emergency procedures and
1. Safety Symbols This figure identifies the ISO 8999 symbols currently used by Lister Petter
1. This figure identifies the ISO 8999 symbols

8 currently used by Lister Petter Power Systems.
8
1.1 Personal Safety

• Ensure that you have access to fire extinguishers and have knowledge of
emergency procedures.
• Identify a location from which calls to the emergency services can be made if
necessary.
• Ensure that someone knows where you are working and is informed when you
leave the working area.
• Wear personal protective clothing and safety equipment appropriate to the
work being done.
• Ensure that guards are properly fitted.
• Keep your body and clothing clear of all moving or hot parts.
WARNING
Be aware that the fan cannot be seen clearly while the engine is running.
• Tie long hair close to your head.

• Do not wear loose clothing or jewellery.
WARNING
KEEP CLEAR OF ALL ROTATING PARTS. DO NOT WEAR A NECKTIE, A
SCARF, LOOSE CLOTHING OR A NECKLACE WHEN WORKING CLOSE TO
A RUNNING ENGINE. ENTANGLEMENT WITH ROTATING PARTS COULD
CAUSE SERIOUS INJURY OR DEATH.
• Remove rings and other jewellery if working on any part of the electrical system,
to avoid causing a short circuit.
• Wear ear protection against loud noise.
WARNING
Prolonged exposure to loud noise can cause impairment or loss of hearing.
• To avoid loss of concentration, do not use music earphones while working.
1.2 General Precautions

Engine operators must be instructed in the correct procedures before attempting
to start any engine.
WARNING
It is dangerous to permit an inexperienced person to start any diesel engine.
9
• Use these engines only in the type of application for which they have been
designed.
• Ensure the engine is securely mounted.
• Ensure that the area around the engine is well ventilated.
WARNING
LACK OF VENTILATION CAN RESULT IN THE BUILD-UP OF TOXIC, AND
POTENTIALLY FATAL, EMISSIONS.
• Only one person must control the engine.

• Other persons must be kept at a safe distance while the engine or equipment
is in operation.
• Ensure that the engine is operated only from the control panel or from the
operator's position.
• Ensure that the control lever of the transmission drive is in the "out-of-drive'
position before the engine is started.
• Fit guards on any accessories that require them (these must be supplied and
fitted by the purchaser). Keep all safety guards in position.
• Never attempt to change the specification of the engine as this could affect its
safe operation and put the operator at risk.
• Never work under any plant that is only held by overhead lifting equipment.
• Check that the brakes are in good condition before moving mobile
equipment.
• While the engine is running never attempt to clean it, add fuel or lubricating
oil, or adjust it in any way.
• Keep the engine and surrounding area clean.
WARNING
NEVER ALLOW ANY PART OF THE BODY TO COME INTO CONTACT WITH
HIGH PRESSURE FUEL OIL, COMPRESSED AIR OR HYDRAULIC OIL.
CONTACT WITH, OR INGESTION OF, THESE SUBSTANCES CAN CAUSE
SERIOUS INJURY OR DEATH.
• Handle fluids with care at all times.

• Rectify any fuel, coolant or oil leak as soon as is practicable and clean up any
spillages immediately.
• Remove any build-up of grease, oil or debris.
• Wear gloves or use suitable barrier creams when doing anything that could
soil your hands.
WARNING
Diesel fuel and lubricating oil can damage the skin.
10
WARNING
Do not expose pressurised containers to heat. Do not incinerate or puncture
them.
• Fit only genuine Lister Petter Power Systems parts.
1.3 Care with Lubricating Oil

• Wear gloves or barrier cream.
• Clean up any spillages.
• Do not wear clothing that is contaminated by lubricating oil. Do not put material
that is contaminated with oil into your pockets.
• To prevent environmental contamination, always discard used lubricating oil
strictly in accordance with local regulations. Preferably take to a recycling site.
1.4 Precautions with Diesel Fuel

• Store fuel and other flammable liquids away from sources of ignition.
• Always switch off the engine before adding fuel.
• Never smoke when you are filling the tank with fuel.
• Do not handle fuel near to heaters or other sources of ignition.
• Do not overfill the fuel tank.
• Clean up any spillages.
WARNING
Material that has been contaminated by diesel must be kept away from all
sources of ignition and safely disposed of.
• Never attempt to adjust the fuel system while the engine is running or still hot.
• If skin comes into contact with high pressure fuel, obtain medical assistance
immediately.
WARNING
HIGH PRESSURE FUEL CAN CAUSE SERIOUS INJURY OR DEATH.
1.5 Precautions with Coolant

• Do not remove the filler cap of the cooling system while the engine is hot and
while the coolant is under pressure, because dangerous hot coolant can be
discharged.
• Do not use salt water or any other coolant which can cause corrosion in the
closed cooling circuit.
11
1.6 Precautions with Batteries

Batteries contain hazardous sulphuric acid.
Great care therefore needs to be taken when using them.
WARNING
BATTERY ACID IS HIGHLY CORROSIVE AND POISONOUS, AND WILL BURN
SKIN AND CLOTHING. IT WILL CAUSE PERMANENT DAMAGE, INCLUDING
BLINDNESS, IF SPLASHED INTO THE EYES.
• If acid accidentally comes into contact with skin, eyes or clothes, flush it away
with copious amounts of water and seek medical aid.
WARNING
The electrolyte gases are highly flammable.
• Do not smoke near batteries and keep sparks and flames away from them.
• Do not work near to heaters or other fire hazards.
• Disconnect the main battery terminals before making any repair to the electrical
system.
• Keep the top of the battery well ventilated during charging.
• Do not attempt to charge a frozen battery; it may explode. Instead, warm the
battery to 16°C (60°F).
• Switch off the battery charger before connecting or disconnecting the charger
leads. The negative (earth) battery lead must be disconnected first and
reconnected last.
• Never use a damaged battery.
Battery Charge Alternator

The following points must be strictly observed when an alternator is fitted, otherwise
serious damage can be done.
• Never connect a battery into the system without checking that the voltage and
polarity are correct.
• Never remove any electrical cable while the battery is connected in the circuit.
• Only disconnect the battery with the engine stopped and all switches in the
off position.
• Always ensure that cables are fitted to their correct terminals.
CAUTION
A short circuit or reversal of polarity will ruin diodes and transistors.
12
• Never 'flash' any connection.

• Never experiment with any adjustments or repairs to the system.
• Always disconnect the battery and alternator before commencing any electric
welding when a pole strap is directly or indirectly connected to engine.
1.7 Care with Electrical Systems

• Ensure that the battery is of sufficient capacity to start the engine at its minimum
operating temperature, taking into account any drag that may be imposed on
the engine by the type of transmission that is attached to it.
• Ensure that the battery and all engine wiring cables are of sufficient size to
carry the currents required.
• Check that the engine-mounted alternator is of sufficient output to cope with
the total electrical load required by the machine to which it is fitted.
Wiring Cables
Ensure that 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 rough surfaces or sharp corners to avoid chafing.
1.8 Lifting Precautions

The engine lifting eyes are suitable for lifting only the engine and accessory
assemblies originally fitted by Lister Petter Power Systems. They must not be
used to attempt to lift an entire generating set.
1.8 Lifting a Gamma series engine using overhead lifting eyes.
WARNING
Do not attempt to lift the complete plant using the engine lifting eyes.
13
Preparations required before lifting an engine:

• Check that the lifting eyes or lugs are not damaged and ensure they are
secure.
Note:
The torque setting for the lifting eyes is 44 Nm (33 ft Ib or 4.5 kgf m).
• Use the correct type of lifting appliance with the correct lifting capacity. The
lifting appliance shown in Figure 1.8 is recommended for use when lifting
vertically and should be connected directly to the lifting eyes.
• In order to protect the rocker cover, ensure there is clearance between the
lifting equipment and the cover.
WARNING
DO NOT WORK UNDER ANY PLANT THAT IS HELD ONLY BY OVERHEAD
LIFTING EQUIPMENT.
1.9 Care with Filters and Elements

• The combustion material of some components of the engine (for example
certain seals) can become extremely dangerous if burned. Never allow burnt
material to come into contact with the skin or eyes.
WARNING
The materials used in the manufacture and treatment of some filters and
elements may cause irritation or discomfort. If they come into contact with the
eyes or mouth, and they may give off toxic gases if they are burnt.
• Used filters and elements contain some of the filtered liquid and should be
handled and disposed of with care.
• After handling new or used elements, hands should be thoroughly washed.
1.10 Waste Disposal

Ensure that waste oil, fuel, filter elements, coolant concentrate, battery electrolyte,
solvents and other toxic wastes are disposed of in accordance with official
regulations to prevent contamination.
14
2. Engine Parts and Technical Data

Lister Petter Power Systems engines are built for many applications. The views
which follow do not necessarily match your engine specification.
2.1 Front and Left Side 2.2 Rear and Right Side
1. Filler cap for lubricating oil 15. Turbocharger
2. Fuel filter 16. Exhaust manifold
3. Lubricating oil cooler 17. Radiator
4. Fuel injection pump 18. Alternator
5. Lubricating oil dipstick 19. Bracket
6. Lubricating oil filter 20. Lubricating oil sump
7. Drain plug for lubricating oil 21. Starter motor
8. Crankshaft pulley 22. Flywheel housing
9. Drive belt 23. Flywheel
10. Water pump 24. Air filter
11. Fan 25. Rear lift bracket
12.Water outlet 26. Induction manifold
13. Front lift bracket
14. Injector
2.1 Engine type GWT6: front and left side
15
2.2 Engine type GWT4: rear and right side
TECHNICAL DATA
Engine cycle 4-stroke
General Engine Data Cylinder arrangement Inline

Anti clockwise viewed from
Direction of rotation
flywheel end
GW3, GW4 Naturally aspirated
Induction System GWT3, GWT4, GWT6 Turbocharged
GWTA6 Turbocharged and Intercooled
Bore (nominal) 100 mm (3.94 in.)
Combustion System
Stroke 127 mm (5 in.)
GW3, GW4 16.5:1
Compression Ratio
GWT3, GWT4, GWT6, GWTA6 17.5:1
3-cylinder engines 2.99 litres (183 in3)
Cubic Capacity 4-cylinder engines 3.99 litres (243 in3)
6-cylinder engines 5.99 litres (365 in3)
3-cylinder 1-2-3
Firing Order 4-cylinder 1-3-4-2
6-cylinder 1-5-3-6-2-4
Inlet 0.20 mm (0.008 in.)
Valve Clearance
Exhaust 0.45 mm (0.018 in.)
Lubricating Oil Pressure Engine without piston cooling jets 207 kN/m2
(min. when at max. speed and
normal engine temperature) Engine with piston cooling jets 280 kN/m2
16
3. Operating instructions
3.1 Starting the Engine
Several factors affect engine start, for example:
• Battery power
• Starter motor performance
• Lubricating oil viscosity
• Cold start system installation
Diesel engines need a cold start aid in very cold conditions. Normally, your
vehicle or your machine will be fitted with the correct equipment for your region
of operation.
Lister Petter Power Systems engines can be equipped with various cold starting
systems. For the Gamma engine range these systems are:
• Fuel Start Aid: An electrically operated device which ignites a specific amount
of diesel fuel in the induction manifold in order to heat the induction air.
3.1.1 Starting key positions: 3.1.2 Starting key positions:

R=run; H=heat; S=start R=run; S=start
3.1.1 Starting a Warm Engine

1. If the engine is equipped with a manual stop control, ensure that it is in the run
position (R).
2. Adjust the engine speed control to the quarter open position.
3. Turn the key to the start position (HS/S) to engage the starter motor (Figures
3.1.1 and 3 .1.2).
4. Allow the start key to return to position R as soon as the engine starts. Always
ensure that the engine and starter motor are stationary before the starter motor
is engaged again.
3.1.2 Starting a Cold Engine without Starting Aids

1. lf the engine is equipped with a manual stop control, ensure that it is in the run
position (R).
2. Adjust the engine speed control to the maximum speed position.
17
3. Turn the start key to the start position (S) to engage the starter motor (Figure
3.1.2). Allow the key to return to position R when the engine starts. Adjust the
speed control to get an even idle speed.
4. lf the engine does not start in 30 seconds, allow the start key to return to the
R position for another 30 seconds. Then engage the starter motor again for a
maximum period of 30 seconds.
3.1.3 Starting a Cold Engine with Starting Aids

1. If the engine is equipped with a manual stop control, ensure that it is in the
run position.
2. Turn the start key to position H and leave there for 15 seconds (Figure 3.1.1).
3. Adjust the engine speed control to the maximum speed position.
4. Turn the start key to position HS to engage the starter motor (Figure 3.1.1).
Allow the start key to return to position R as soon as the engine starts. Adjust
the speed control to get an even idle speed.
5. lf the engine does not start in 15 seconds, turn the start key to the H position
and hold it there for 10 seconds then engage the starting motor again.
CAUTION
A short circuit or reversal of polarity will ruin diodes and transistors.
3.2 Stopping the Engine

According to the equipment fitted, either turn the start key to position 0 or operate
the manual stop control. If a manual stop control is used, ensure that the control
returns to the run position after the engine has stopped. Also, ensure that the
engine start key is turned to the 0 position.
CAUTION
It is recommended that a turbocharged engine is run at approximately 1000
r/min at a reduced load for 2-3 minutes before it is shut down. This allows the
turbocharger to cool.
3.3 Adjustment of Engine Speed

The idle or maximum speed setting must not be changed by the engine operator
as this may damage the engine or transmission.
The warranty of the engine is invalidated if the seals on the fuel injection pump
are broken during the warranty period by a person who is not approved by Lister
Petter Power Systems.
18
3.4 Running-In
A gradual running-in of a new engine is not necessary.
CAUTION
Prolonged operation at fight load during the early life of the engine can cause
lubricating oil to enter the exhaust system.
Maximum load can be applied to a new engine as soon as the engine is put into
service and the coolant temperature has reached a minimum of 60°C (140°F).
The engine will benefit if the load is applied as soon as possible after the engine
is put into service.
CAUTION
Do not operate the engine at high speeds without load.
CAUTION
Do not overload the engine.
3.5 Altitude
If the naturally aspirated engine is to run at an altitude above 600 m (2000 ft)
the fuel delivery can be changed to reduce fuel consumption and smoke. Lister
Petter Power Systems can give the percentage of fuel reduction necessary if
details of engine application and ambient conditions are provided. Information for
turbocharged engines can be obtained from Lister Petter Power Systems. Changes
to the settings of the fuel injection pump must be made by a Lister Petter Power
Systems distributor or by an approved distributor for the fuel injection pump.
19
4. Engine Fluids
4.1 Fuel Specification
To get the correct power and performance from your engine, use good quality fuel.
The recommended fuel specification for Lister Petter Power Systems engines is
indicated below.
Fuel Specification
Factor Specification
Cetane Number 50 minimum
Viscosity 2.0 / 4.5 centistoke at 40°C
Density 0.835-0.855 kg/litre
Sulphur 0.2% of mass maximum
Distillation 85% at 350°C
• Cetane Number
This indicates ignition performance. A fuel with a low cetane number can cause
starting problems and affect combustion.
• Viscosity
Engine performance can be affected if viscosity (resistance to flow) is outside
the given limits.
• Density
A low-density fuel reduces engine power. A high density fuel increases engine
power and exhaust emissions
• Sulphur
A high sulphur content (not normally found in Europe, North America or
Australasia) can cause engine wear. Where only high sulphur fuels are
available, it is necessary to use highly alkaline lubricating oil or to renew the
lubricating oil more frequently (see sections 5.1 and 5.9).
• Distillation
This is an indication of the mixture of different hydrocarbons in the fuel. A high
ratio of lightweight hydrocarbons can affect the combustion characteristics.
4.1.1 Low Temperature Fuels

Special winter fuels may be available for engine operation at temperatures below
0°C. These fuels have a lower viscosity and also limit the wax format ion in the
fuel at low temperatures. If wax formation occurs, this could stop the fuel flow
through the filter.
20
CAUTION
The quality of the fuel affects the type of lubricating oil required. See 4.1 above.
4.2 Lubricating Oil Specification

Use only a good quality lubricating oil, to the relevant specification, as shown in
the following table:
Lubricating oil specification

Specification
Engine Type
API CF4 API CF-4
Naturally Aspirated • • (Note 1)
Engines in Heavy Duty Applications •
Earthmoving Equipment •
Turbocharged •
Note 1: Not recommended during the first 40 hours of operation, nor for light load applications.
Always ensure that the correct viscosity grade of lubricating oil is used for the
ambient temperature range in which the engine will run as shown in Figure 4.2.
For advice on adjustments to an engine setting or to the lubricating oil change
periods which may be necessary because of the standard of available fuel, consult
you nearest Lister Petter Power Systems distributor.
4.2 Oil viscosity
21
4.3 Coolant Specification

The quality of coolant used affects the efficiency and life of the cooling system.
The recommendations in the table below will help to maintain the cooling system
in good condition and to protect it against frost and/or corrosion.
Coolant Specification
Description Ethulene (% volume) Water (% volume) Solidifying Point (°C)
60 40 -55
55 45 -40
Antifreezing Fluid
50 50 -30
40 60 -22
• If possible, use clean soft water in the coolant mix.

If an antifreeze mixture other than that recommended by Lister Petter Power
Systems is used, it must be ethanediol (ethylene glycol) based with a corrosion
inhibitor. It is recommended that the corrosion inhibitor is of the sodium nitrite/
sodium benzoate type. The antifreeze mixture must be an efficient cool ant at all
ambient temperatures and it must provide protection against corrosion.
It must also have a specification at least as good as the requirement of the
standard BS6580: MOD AL39. Lister Petter Power Systems antifreeze exceeds the
requirements of this standard. The quality of antifreeze coolant must be checked
at least once a year, for example, at the beginning of the cold period. The coolant
must be renewed every two years. The antifreeze mixture must contain equal
quantities of antifreeze and water. Concentrations of more than 50% antifreeze
must not be used as this can affect the performance of the coolant adversely.
When frost protection is not necessary, it is still an advantage to use an approved
antifreeze mixture because this gives protection against corrosion and also raises
the boiling point of the coolant.
CAUTION
Failure to follow the correct coolant specification and procedures may lead to
damage by frost or corrosion.
If an antifreeze mixture is not used, add the correct mixture of corrosion inhibitor
to the water. Renew the mixture of water and corrosion inhibitor every six months
or check it according to the inhibitor manufacturer's recommendations.
CAUTION
Certain corrosion inhibitor mixtures can cause damage to some engine
components. It is recommended that you consult the service department at
Lister Petter Power Systems if a corrosion inhibitor is to be used.
22
GAMMA SERIES ENGINES OPERATORS' HANDBOOK

5. ROUTINE MAINTENANCE
5. Routine Maintenance
5.1 MAINTENANCE SCHEDULE frequent maintenance than those
Routine maintenance should be with average running times. The
5.1 Maintenance Schedule
undertaken regularly at the intervals intervals are therefore expressed
Routine maintenance should be undertaken both regularly
as runningathours
the intervals stated
and as months.
stated in Figure 5.1.1. Engines with
in Figure 5.1.1. Engines with long daily Yourunning times require more frequent
should undertake the work at
long daily running times require more
maintenance than those with average running times. The intervals are therefore
expressed both as running 5.1.1.
hoursMaintenance
and as months. You should undertake the work
Schedule
at whichever limit is reached first.
MAINTENANCE SCHEDULE
Every day or every 8 hours, whichever is sooner
First service at 40 hours
Every 200 hours or every six months, whichever is sooner
Every 400 hours or every 12 months, whichever is sooner; see note (3)
Every 2000 hours
● ● Check the amount of coolant
● ● Check the drive belt(s)
● ● Check for water in the fuel pre-filter (1)
● Check the idle speed and adjust if necessary (2)
● Clean the sediment chamber and the strainer of the fuel-lift pump
● Renew the fuel filter element(s)
● Check the atomisers (2)
● Check the amount of lubricating oil in the sump
● ● Check the lubricating oil pressure at thegauge (1)
● ● Renew the engine lubricating oil (3) (4)
● ● Renew the canister(s) of the lubricating oil filter (3)
● ● Clean the air cleaner or empty the dust bowl of the air filter (very dusty conditions)
● Clean the air cleaner or empty the dust bowl of the air filter (normal conditions)
● Clean or renew the air filter element if this has not been indicated earlier
● Clean the closed breather system (1)
Clean the turbocharger impeller and the turbocharger compressor casing
●
(if applicable) (2)
● ● Check the valve clearances, and adjust if necessary (2)
● Check the alternator and starter motor (2)
(1) If fitted (2) By a competent person
(3) The lubricating oil and the filter canister(s) must be renewed every 250 hours or 12 months for
applications where the engine normally runs at full load for periods of more than 20 minutes e.g. generating
sets or water pumps.
(4) The oil change interval will vary according to the sulphur content of the fuel (see table 5.1.2 and section
4.1 Fuel Specification).
The interval for changing the canister of the lubricating oil filter is not affected.
5.1.1 Maintenance Schedule

19
23
The intervals apply only to engines operating under normal conditions and
using fuel and lubricating oil that conform to the specifications given in this
handbook. If the engine is running in dusty or otherwise adverse conditions,
the maintenance intervals must be more frequent. Check also the maintenance
periods recommended by the manufacturer of the equipment in which the engine
is installed. If these intervals are shorter, you should observe them.
Oil Change Periods

Fuel sulphur content (%) Oil change period
< 0.5 normal
0.5 - 1.0 0.75% of normal
> 1.0 0.50% of normal
OPERATORS' HANDBOOK 5.1.2 The effect of sulphur content on oil change periods
If there are local regulations affecting the operation of the engine, it may be
rst. 2.Removetothe
necessary fillerthe
adapt cap of the cooling
maintenance periods accordingly.
o engines system.
It is advisable to check for leakage and loose components at each service.
conditions 3.Remove the drain plug from the side
ng oil that of the cylinder block (there are two
5.2 Draining the Cooling System
ons given possible locations; see Figure 5.2)
engine is 1. Ensure
in orderthat the engine
to drain is onEnsure
the engine. level ground and that it has had time to cool
e adverse down.
that the drain hole is not restricted.
e intervals
ck also the
mmended
WARNING
Never drain the coolant while the engine is still hot and the system Is under
equipment whichever
pressure.limit
ThisisIsreached first.and could cause
dangerous 2.Remove
injury the
fromfiller cap of the
discharged cooling
coolant.
nstalled. If The intervals apply only to engines system.
you should operating under normal conditions 3.Remove the drain plug from the side
2. Remove the filler cap of the cooling system.
and using fuel and lubricating oil that of the cylinder block (there are two
3. Remove the drain plug from the side of the cylinder block (there are two possible
conform to the specifications given possible locations; see Figure 5.2)
ODS locations; see Figure 5.2) in order to drain the engine. Ensure that the drain
in this handbook. If the engine is in order to drain the engine. Ensure
ange period hole is not restricted.
running in dusty or otherwise adverse that the drain hole is not restricted.
normal conditions, the maintenance intervals
must be more frequent. Check also the
% of normal
maintenance periods recommended
% of normal by the manufacturer of the equipment
ntent on oil in which the engine is installed. If
these intervals are shorter, you should
observe them.
s affecting
OIL CHANGE PERIODS
it may be
aintenance Fuel sulphur content (%) Oil change period
5.2 alternative
5.2 The< 0.5
two The two alternative
normallocations
locations of the of the cooling system drain plug
akage and cooling system drain plug
0.5 - 1.0 0.75% of normal
service.
24
4.Open >the
1.0 tap or remove
0.50% ofthe
normal
drain
OLING plug
5.1.2 Theat the ofbottom
effect sulphur of the radiator
content on oil
in order change
to drain the radiator. If the
periods
GAMMA SERIES ENGINES OPERATORS' HAND
5.3 CHECKING THE DRIVE

4. Open the tap or remove the drain plug at the bottom of the radiator in order to
BELTS
drain the radiator. If the radiator does not have a tap or a plug, disconnect the
hose at the bottomAlways renew a belt if it is worn or
of the radiator.
5. If necessary, flush damaged.
the system with clean water.
6. Fit the drain plugsIf andtwinthe
belts arecap.
filler fitted, theythemust
Close be tap or connect the
radiator
radiator hose. renewed together.
To ensure maximum belt life, it is
5.3 Checking the recommended
Drive Belts that a belt tensioner
gauge is used to check the belt
Always renew a belt if it is worn or damaged.
tension. Fit the gauge (Figure 5.3) at
If twin belts are fitted, they must be renewed together.
the centre of the longest free length
To ensure maximum belt life, it is recommended that a belt tensioner gauge is used
and check the tension. If a Burroughs
to check the belt tension. Fit the gauge (Figure 5.3) at the centre of the longest free
gauge is used, the correct tension is
length and check the tension. If a Burroughs gauge is used, the correct tension
355N (80 Ibf or 36 kgf). If the tension
is 355N (80 Ibf or 36 kgf). If the tension is below 220N (50 Ibf or 22 kgf) adj st to
is below 220N (50 Ibf or 22 kgf) adj st
355N as indicated below.
to 355N as indicated below.
5.3.1 Checking drive belt tension
a gauge. (1) Pivot fasteners of al
(2) Adjustment link fastene
2.Change the position of the al

to give the correct tension, tig
pivot fasteners of the alternator
adjustment link fasteners.
3.Check the belt tension a
ensure that it is st ill correct.
belt is fitted, the belt tension
5.3 Using
5.3 Using the
the belt
belt tensioner
tensioner gauge
gauge
checked again.
If a gauge
If a gauge is not available, pressis down
not available,
the belt press
with a down
thumb at the centre of the
5.4 CLEANING THE FUEL
longest free length and thecheck
belt with
the adeflection
thumb at(Figure
the centre
5.3).ofWith moderate thumb
pressure, 45N (10 Ibfthe longest
or 4.5 kgf), free length and
the correct checkisthe
deflection
PUMP
10 mm 3/8 in).
If twin belts are fitted, deflection
check and(Figure 5.3). With
if necessary adjustmoderate
the tension on Refer to Figure
the tighter belt.5.4.
thumb pressure, 45N (10 Ibf or 4.5 kgf), 1.Remove t he fuel lift pump an
5.3.1 Adjusting thetheBelt correct deflection is 10mm 3/8in).
Tension into clean fuel.
Refer to Figure 5.3.1 Ifbelow.
twin belts are fitted, check and if
necessaryofadjust
1. Loosen the pivot fasteners the tension
the alternator on the
(1) and also the adjustment link
fasteners (2). tighter belt.
5.3.1 Adjusting the Belt Tension

Refer to Figure 5.3.1 below.
1.Loosen the pivot fasteners of the
alternator (1) and also the adjustment
link fasteners (2).
5.4 The fuel lift pump
25
renew a belt if it is worn or
ed.
GAMMAGAMMA SERIES ENGINES operators' handbook
belts are fitted, they must SERIES
be ENGINES OPERATORS' HANDBOOK
d together.
ure
ECKING maximum
THE belt
DRIVE life, it is
mended that a belt tensioner
is used to check the belt
renew a belt if it is worn or
Fit the gauge (Figure 5.3) at
d.
tre of the longest free length
belts are fitted, they must be
ck the tension. If a Burroughs
d together.
s used, the correct tension is
ure maximum belt life, it is
80 Ibf or 36 kgf). If the tension
ended that a belt tensioner
w 220N (50 Ibf or 22 kgf) adj st
is used to check the belt
as indicated below.
Fit the gauge (Figure 5.3) at
5.3.1 Checking drive belt tension without
tre of the longest free length a gauge. (1) Pivot fasteners of alternator;
ck the tension. If a Burroughs (2) Adjustment link fasteners.
s used, the correct tension is
0 Ibf or 36 kgf). If the tension 2.Change the position of the alternator
220N (50 Ibf or 22 kgf) adj st to give the correct tension, tighten the
as indicated below. pivot fasteners of the alternator and the
5.3.15.3.1 Checking
adjustment
Checking linkdrive
drive belt belt tension
fasteners.
tension without
without a gauge.
a gauge. (1) Pivot fasteners of alternator;
3.Check
(1) Pivot fasteners ofthe belt tension
alternator; againlinktofasteners.
(2) Adjustment
(2) Adjustment link fasteners.
ensure that it is st ill correct. If a new
2. Change the position beltofisthe alternator
fitted, the belttotension
give themust
correct
be tension, tighten the
Using the belt tensioner gauge 2.Change the position of the alternator
pivot fasteners of the alternator
checked again. and the adjustment link fasteners.
to give the correct tension, tighten the
3. Check the belt tension again to ensure that it is st ill correct. If a new belt is
ge is not available, press down pivot fasteners of the alternator and the
fitted, the belt tension
5.4 must
CLEANINGbe checked THE again.
FUEL LIFT
with a thumb at the centre of adjustment link fasteners.
gest free length and check the PUMP
3.Check the belt tension again to
5.4 Cleaning the Refer
ensureFuel Lift
tothat Pump
it is 5.4.
Figure st ill correct. If a new
on (Figure 5.3). With moderate
Refer to Figure
ressure, 45N (10 Ibf or 4.5 kgf), 5.4. 1.Remove
belt is t
fitted, hethefuel lifttension
belt pump and place
must be
Using the belt tensioner gauge
ect deflection1. is Remove t he fuel lift
10mm 3/8in). pump and
into clean
checked place into clean fuel.
fuel.
again.
belts are fitted, check and if
ge is not available, press down
ary adjust the tension on the 5.4 CLEANING THE FUEL LIFT
with a thumb at the centre of
belt.
est free length and check the PUMP
on (Figure 5.3). With moderate Refer to Figure 5.4.
djusting
ressure,the45NBelt
(10 Tension
Ibf or 4.5 kgf), 1.Remove t he fuel lift pump and place
Figure
ect deflection below.
5.3.1 is 10mm 3/8in). into clean fuel.
en
beltsthearepivot fasteners
fitted, check andof the
if
atoradjust
ary (1) andthe
alsotension
the adjustment
on the
steners
elt. (2).
justing the Belt Tension
Figure 5.3.1 2. Carefully wash all sediment from the lift pump body. 21
below.
3. Clean the
n the pivot fasteners of gauze
the strainer, joint and cover.
4. the
ator (1) and also Assemble the lift pump. Ensure that the lift pump body and the cover are fitted
adjustment
steners (2). together correctly because leakage at this point will let air into the fuel system.
If fitted, refit the heat shield.5.4 The fuel lift pump
26 21
heat shield. It Is Important that only genuine
5.Eliminate the air from the fuel system Lister Petter fuel filter elements
through the filter vent point (see are used. The wrong element can
section 5.8). damage the fuel injection pump.
5.5 CHECKING THE FUEL 5.6.1 Renewing a Separate Type Fuel

5. Eliminate the air from the fuel system through Filter Element
the filter vent point (see
PRE-FILTER
section 5.8). Refer to Figure 5.6.1.
Some engines are fitted with a pre- The filter can have one or two
filterChecking
5.5 of the same main thetype Fuel as the fuel
Pre-Filter
elements.
filter element (see 5.6 below). This will
Some engines are fitted with a pre-filter ofWhen twin main
the same elements arethe
type as fitted
fuelboth
filter
normally be fitted between the fuel tank the elements must be renewed at the
element (see 5.6 below). This will normally be fitted between the fuel tank and
and the engine and is connected to the same time.
the engine and is connected to the main filter but before the fuel lift pump. Both
main filter but before the fuel lift pump.
elements must be removed at the same time.
Both elements must be removed at the
Check the fuel bowl for water at regular intervals and drain as necessary.
same time.
Check the fuel bowl for water at regular
5.6 Renewing
intervals and drainthe Fuel Filter Element
as necessary.
There are three fuel filter element types in use (see Figure 5.6).
5.6Separate
1. RENEWING Type THE FUEL
The filter
FILTER element is held between the filter head and the bottom cover.
ELEMENT
2. Canister
There are threeType
fuel filter element types
The filter element
in use (see Figure 5.6). has an internal thread at the top and is fastened to a threaded
1. adaptor
Separate inType.
the filter
Thehead.
filter element is 5.6.1 Renewing a separate type element
Quick
3. held Release
between theCanister
filter headType
and the
This has
bottom been introduced on certain engines.
cover.
A. Separate
A. Separate type
type element
element B.Canister
B. Canistertype
type element
element C.
C. Quick
Quick release
release element
element
5.6 Fuel filter element types
5.6 Fuel filter element types
22
CAUTION
It Is Important that only genuine Lister Petter Power Systems fuel filter elements
are used. The wrong element can damage the fuel injection pump.
5.6.1 Renewing a Separate Type Fuel Filter Element

Refer to Figure 5.6.1.
The filter can have one or two elements.
When twin elements are fitted both the elements must be renewed at the same
time.
27
engines are fitted with a pre- The filter can have one or two
he same main type as the fuel elements.
ment (see 5.6 below). This will When twin elements are fitted both
y be fitted between the fuel
GAMMA tank ENGINES
SERIES operators'
the elements handbook
must be renewed at the
engine and is connected to the same time.
er but before the fuel lift pump.
ments must be removed at the
me.
he fuel bowl for water at regular
s and drain as necessary.
NEWING THE FUEL

R ELEMENT
re three fuel filter element types
see Figure 5.6).
rate Type. The filter element is 5.6.1 Renewing a separate type element
5.6.1 Renewing a separate type element
between the filter head and the
m cover.
1. Clean the outside surfaces of the fuel filter assembly. If a drain tap is fitted to
the bottom of the filter bowl, drain the fuel from the filter.
2. Hold the bottom cover of the filter element and release the setscrew which is
fitted through the filter head above the centre of each element
3. Lower the bottom cover of the filter.
4. Remove the element and discard it.
5. Clean the inside surfaces of the fitter head and cover.
6. Renew the seals and lightly lubricate them with clean fuel.
arate type element
7. Put the B.bottom
Canistercover
type element C. Quick
under the new release
element element
and hold the element square to the
fitter head. Ensure the element is fitted in the centre against the joint in the filter
5.6 Fuel filter element types
head. With the assembly in this position, engage and tighten the setscrew.
8. Eliminate the air from the fuel filter (see Section 5.8).
5.6.2 Renewing a Canister Type Fuel Filter Element

1. Clean t he outside surfaces of the fuel filter assembly.
2. Loosen the drain device at the bottom of the filter and allow the water / fuel to
drain into a suitable container.
3. Use a strap wrench or similar tool to loosen the filter canister and remove the
canister.
4. Ensure that the threaded adaptor is secure in the filter head and that the inside
of the head is clean.
5. Lubricate lightly the top seals between the new canister and the filter head
(1, 2) and tighten by hand only.
6. Eliminate the air from the fuel filter (see Section 5.8).
28
the outside surfaces of the fuel 5.6.2 Renewing a canister type fuel filter
nssembly.
the outside If asurfaces
drain tapofisthe fuel
fitted 5.6.2GAMMA
element.RenewingSERIES
(1, 2) Topaseals
ENGINES
canister operators'
type fuel
between filter
canister
handbook
assembly.
bottom of the If a filter
drainbowl,
tap isdrain
fitted element. (1, 2)
andTop seals
filter between canister
head.
eelbottom of filter.
the filter bowl, drain and filter head.
from the
uel from the
he bottom cover filter. of the filter
theand
ent bottomrelease cover
theofsetscrew
the filter
ent andthrough
is fitted releasethe thefilter
setscrew
head
hthe
is fitted
centre through
of eachtheelement
filter head
ethethebottom
centrecover of each
of element
the filter.
r the
ve thebottom
element cover
andof the filter.
discard it.
ove
the the
insideelement
surfaces andofdiscard
the fitterit.
nand
thecover.
inside surfaces of the fitter
wand cover.and lightly lubricate
the seals
w theclean
with sealsfuel.
and lightly lubricate
with clean fuel.
e bottom cover under the new
he bottom
nt and holdcover under the
the element new
square
ent
fitterandhead.holdEnsure
the element square
the element
edfitter
in thehead.
cent Ensure
re againstthethe
element
joint
ed in the
filter head.cent re against
With the joint
the assembly
e position,
filter head. With the
engage andassembly
tighten
stscrew.
position, engage and tighten
etscrew.
ate the air from the fuel filter
nate the5.8).
Section air from the fuel filter
Section 5.8). 5.6.1 Renew
newing a Canister Type Fuel 5.6.3 Renewing a Quick Release
enewing a Canister
ement 5.6.3 Renewing 5.6.3 Renewing
Type Fuel a Canister
Quick aCanister
Type Fuel
Release Quick
Filter Release
Element
Type Fuel Filter Element
lement Canister
Refer
Figure 5.6.2.Refer to Figure 5.6.3. to Type
Figure Fuel Filter Element
5.6.3.
ot he
Figure
outside 5.6.2.
surfaces of the fuel Refer to Figure 5.6.3.
nssembly.
t he outside surfaces of the fuel
nassembly.
the drain device at the bottom
en theand
filter drain device
allow theatwater/
the bottom
fuel
einfilter
into and allow the
a suitable water/ fuel
container.
ain
strapintowrench
a suitable container.
or similar tool to
a strap
n the wrench
filter or similar
canister tool to
and remove
en the filter canister and remove
nister.
eanister.
that the threaded adaptor is
ereinthat
the thefilterthreaded
head andadaptor
that theis
reofinthe thehead
filterishead and that the
clean.
5.6.3 Renewing a quick release canister
e oflightly
ate the head is clean.
the top seals between
5.6.3 5.6.3a Renewing
Renewing quick fuel afilter
typerelease quick release
element.
canister typecanister
fuel filter element
catecanister
ew lightly the topthe
and seals between
filter head type fuel filter element.
ew canister
and tighten by and the only.
hand filter head
)ateandthe tighten 1. hand
by the outside 1.Clean
Cleanonly. surfacesthe of outside
the fuelsurfaces of the fuel
filter assembly.
air from the fuel filter 1.Clean
filter at the
assembly.outside surfaces of and
the fuel
nate the5.8). 2. Loosen the
air from the fuel filter drain device the bottom of the filter allow the water / fuel to
Section filter
2.Loosen assembly.
the drain device at the bottom
Section 5.8). drain into a suitable container.
3. Turn the sediment bowl 2.Loosen
of the theand
filter
(if fitted) drain device
allow
to the left,theatwater/
and the bottom
fuel
remove.
of the filter
4. Turn the clamp ring to the left and remove.and allow the water/ fuel
5. Remove the canister from the filter head (1) by pulling directly downwards.
Discard the old canister. 23
23
29
filter head (see arrow).
from the fuel injection pump
7.Fit the clamp ring and turn it fully to
bend the pipe. If necessary,
the right to fasten the canister to the
the pipe clamps.
GAMMA SERIES ENGINES filter operators'
head. handbook 3. Remove the injector flange se
8.Remove the cover of the sediment
and remove the flange, the
bowl and clean thoroughly.
6. Ensure the filter head is clean and push the new canister fullyand intothe
theseat
filter washer (Figu
9.Check the two 'O' ring seals of the
head (see arrow). numbers 1, 2 and 3). Rem
sediment bowl cover for damage,
7. Fit the clamp ring and turn it fully to the right to fasten the canister
dusttoseal
the and
filterspacer (4 and
and replace if necessary.
head. fit the spacer and a new dus
10.Clean the threads of the sediment
8. Remove the cover of the sediment bowl and clean thoroughly. the injector.
bowl fastener. To secure the bowl to
9. Check the two 'O' ring seals of the sediment bowl cover for damage,
4. Put the new andinjector in posit
the canister, turn the bowl fully to the
replace if necessary. its spacer, a new dust sea
right. Tighten by hand only.
10. Clean the threads of the sediment bowl fastener. To secure the newbowlseattowasher.
the Ensure
11. Eliminate the air from the fuel filter
canister, turn the bowl fully to the right. Tighten by hand only. leak-off connection is not tow
(see Section 5.8).
11. Eliminate the air from the fuel filter (see Section 5.8). engine. Fit the flange and eng
flange setscrews. Ensure the
5.7 RENEWING A FUEL
5.7 Renewing a Fuel Injector is not tilted and tighten the
INJECTOR setscrews evenly and grad
Refer to Figure 5.7.
Refer to Figure 5.7. 12Nm (9 lbt ft or 1.2 kgfm).
CAUTION
Do not tighten the nuts
high-pressure pipes more t
recommended torque. If t
leakage from the union nut,
that the pipe is correctly align
the injector inlet. Do not tigh
union nut more, as this can
a restriction at the end of t
which in turn will affect t
delivery to the engine.
5.Fit the high pressure fuel p
tighten the union nuts to 22
5.7 Renewing a fuel injector
5.7 Renewing a fuel injector
24
CAUTION
Do not allow dirt to enter the fuel system. Before a connection is disconnected,
thoroughly clean the area around the connection. After a component has been
disconnected, fit a suitable cover to all open connections.
1. Remove the fuel leak-off pipe.

2. Remove the union nuts of the high-pressure pipe from the injector and from
the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe
clamps.
3. Remove the injector flange setscrews and remove the flange, the injector and
the seat washer (Figure 5.7, numbers 1, 2 and 3). Remove the dust seal and
spacer (4 and 5) and fit the spacer and a new dust seal to the injector.
4. Put the new injector in position with its spacer, a new dust seal and a new seat
30
washer. Ensure the fuel leak-off connection is not toward the engine. Fit the
flange and engage the flange setscrews. Ensure the injector is not tilted and
tighten the flange setscrews evenly and gradually to 12 Nm (9 lbt ft or 1.2 kgfm).
CAUTION
Do not tighten the nuts of the high-pressure pipes more than the recommended
torque. If there is leakage from the union nut, ensure that the pipe is correctly
aligned with the injector inlet. Do not tighten the union nut more, as this can
cause a restriction at the end of the pipe which in turn will affect the fuel delivery
to the engine.
5. Fit the high pressure fuel pipe and tighten the union nuts to 22 Nm (16 Ibf ft or
2.2 kgfm). If necessary, fit the pipe clamps.
6. Renew the aluminium washers and fit the leak-off pipe.
7. Operate the engine and check for air or fuel leaks.
5.8 Eliminating Air from the Fuel System

If air enters the fuel system, it must be eliminated before the engine can be started.
Air can enter the system if:
• The fuel tank is drained during normal operation.
• The low pressure fuel pipes are disconnected or damaged / broken.
• A part of the low pressure fuel system leaks during engine operation.
To eliminate air from the fuel system, use one of the following procedures
depending on the fuel system vent set up on your engine.
5.8.1 Standard Method

1. Loosen the vent plug on top of the twin element fuel filter, or, if there is only one
fuel filter element the banjo bolt which is fitted on the top of the fitter (1).
2. Operate the priming lever on the fuel lift pump until air free fuel flows from the
filter venting point (2). Tighten the vent plug of the banjo connection bolt If
the drive cam of the fuel lift pump is at point of maximum cam lift it will not be
possible to operate the priming lever. In this situation, the crankshaft must be
turned one revolution.
3. Ensure that the manual stop control is in the run position. If an electrical stop
control is used turn the start key to the R position.
4. For engine codes AA and VA, loosen the vent screw in the lock screw of the
hydraulic head and the vent screw on the governor cover of the fuel injection
pump.
5. Operate the priming lever of the fuel lift pump until fuel flows from the vent
screws, then retighten the vent screws.
6. Loosen the union nut (3) at the fuel start aid (Figure 5.8.1b) and operate the lift
pump until fuel freely flows from the connection. Retighten the union nut.
31
eliminated before the engine can be which
started.
started. Air
Air can
can enter
enter the
the system
system if: if: which is is fitted
fitted on
on the
the top
top of
of the
the fitter
fitter (1).
(1).
•• The fuel tank is drained during 2.Operate
2.Operate the
the priming
priming lever
lever on
on the
the fuel
fuel
The fuel tank is drained during lift
normal
normal operation
operation .. lift pump
pump until
until air
air free
free fuel
fuel flows
flows fromfrom
•• GAMMA
The lowSERIES ENGINES
pressure fuel operators'
pipes are the
handbook
the filter
filter venting
venting point
point (2).
(2). Tighten
Tighten the
the
The low pressure fuel pipes are vent plug of the banjo connection bolt
disconnected
disconnected or or damaged/broken.
damaged/broken. vent plug of the banjo connection bolt
•• Loosen
A If
If the
the drive cam of the
theoffuel lift pump
pump is
7. A part
part of the
the low
ofthe pressure
union
low nuts (4)
pressure fuel
fuelofsystem
the high pressure
system drive
pipescam at of
two fuel
theliftinjectorsis
(Figure 5.8.1c). Operate the starter motor until air free fuel flows from these
connections, and
5.8.1 re-tighten.
Standard method of eliminating air from the fuel system.
5.8.1 Standard method of eliminating air from the fuel system.
1 3
1 3
(1) The banjo bolt on top of the fuel filter. (3) The union nut of the fuel start aid.
(1)
(1)The
Thebanjo
banjobolt
bolton
ontop
topof
ofthe
thefuel
fuelfilter.
filter. (3)(3) The
The union
union nut
nut ofof
thethe fuel
fuel start
start aid.
aid.
2
2
4
4
(2) Operating the priming lever on the fuel (4) The union nuts of the high pressure
(2) Operating the priming lever on the fuel (4) The union nuts of the high pressure
(2) Operating the priming lever
lift pump. (4) The pipes
unionat
nuts
twoofofthe
thehigh pressure
injectors.
lift pump. pipes at two of the injectors.
on the fuel lift pump. pipes at two of the injectors.
5.8.1 Standard method of eliminating air from the fuel system 25

25
CAUTION
Do not tighten the nuts of the high pressure pipes more than the recommended
torque. If there Is a leakage from the union nut, ensure that the pipe is correctly
aligned with the injector inlet. Do not tighten the union nut more, as this can
cause a restriction at the end of the pipe which in turn will affect the fuel delivery
to the engine.
8. The engine is now ready to start. If the engine runs correctly tor a short time
and then stops or runs roughly, check for air in the fuel system. If there is air
in the fuel system, there is probably a leak in the low pressure section of the
fuel system.
32
at point of maximum cam lift it will not 5.8.2 Method Using In-Line PB Type
nt of maximum cam lift it will not
be possible to operate 5.8.2 the Method primingUsing In-LineInjection PBPump
Type
ossible to operate lever. theInpriming
this situation, the crankshaft
Injection Pump Refer to Figure 5.8.2 and to the
In this situation,must the crankshaft
be turned oneRefer revolution. to Figure 5.8.2 and to
Appendix. the
be turned one3.Ensure revolution. that the manual Appendix. stop control 1. Loosen the vent plug on the top of
e that the manual is instop thecontrol
run position. 1. If an electrical
Loosen the vent plugthe onfuel
the filter
top of(1) by turning It two or
he run position. 5.8.2If anMethod
stop electrical
control is Using
used turn In-Line
the the
fuel startPBkey
filter Type
(1) Injection
by turning Pump
It two or
ontrol is usedRefer turn
to the to R
the Figure
start key5.8.2 and to the Appendix.
position.
R position. 1. Loosen
4.For engine thecodes
vent plug AA and on the VA, top of the fuelFigure
loosen filter (1) by turning
5.8.2 EliminatingIt twoairorfrom
threethe
turns.
fuel
ngine codes AA and Operate
the VA,
ventloosen the
screw fuel in
liftFigure
pump
the until
5.8.2
lock fuel flowssystem
Eliminating
screw without
air from air.
using anRetighten
the in-line
fuel PB type the plug. pump.
injection
OPERATORS' HANDBOOK
ent screw in2.the Loosen
of the connecting
lockhydraulic
the screw head system andscrew
using
theanon the PB
in-line
vent housing at thepump.
type injection driving side (2). Operate
hydraulic headscrew the
andfuel onliftthe
the pump
vent until fuel
governor cover flowsof without
the air from the loosened joint. Re-tighten
t itonwill 5.8.2
notgovernor
the the
fuel coverconnecting
Method
injection Using
of the screws.
pump. In-Line PB Type
e priming
njection pump.3. LoosenPump
Injection
5.Operate the priming
connecting lever nutof onthethefuelfuel start aid (3). Operate the fuel lift pump
rankshaft
ate the primingRefer until
lever
lift pump ofair free
the
until
to Figure fuel fuel flows
flows from
5.8.2 from
andthe the loosened
to vent
the joint. Re-tighten the connecting nut.
tion.until fuel flows
mp Use
froma the
screws,
Appendix. spanner
then vent to prevent
retighten the vent the connecting nut from moving (4).
screws.
op control
s, then 4.
retighten Ensure
1.the
6. that
vent screws.
Loosen
Loosen the the
ventstop
the union nutcontroller
plug (3)
on at thethe isfuel
top inofthe run position and the speed controller is
electrical
en the union nutstart at
the the
(3)fuelat maximum
aidthe filterfuel
(Figure speed
(1)5.8.1b)
by turning position.
and Itoperate
two or Operate the starter motor. After starting the
aidstart key 5.8.1b)
(Figure engine,
the and decrease
lift operate
pump until thefuelengine
freely speed.
flows If after a short period of normal running
t pump until fuel thefreely
from engine flows stops or runs
the connection. roughlythe
Retighten it may be because there is a leak in the low
A,
theloosenconnection. pressure
Figure 5.8.2
Retighten
union section
the of the
nut. Eliminating fuel system.
air from the fuel Check this and
Loosening therectify
vent plugif necessary.
(1) on top of the
ck nut. screw system
7. Loosen usingthe an in-line
unionPB nutstype injection
Loosening
(4) of the pump.
the vent plug (1) on top of the
high fuel filter.
en the thevent
union nutspressure
(4) of thepipes high at two of the injectors fuel filter.
ver
ure of the at two(Figure
pipes of the injectors5.8.1c). Operate the starter 2
e 5.8.1c). Operate the starter 2
motor until air free fuel flows from
ofuntil
the fuelair free fuel
these flows from
connections, and re-tighten.
mconnections,
the vent and re-tighten.
nt screws. CAUTION
AUTION
at the fuel Do not tighten the nuts of the
t operate
d tighten the high nutspressure of thepipes more than the
essure
ely flowspipesrecommended
more than thetorque. If there Is a
mended
ghten thetorque. leakageIf there from Isthe a union nut, ensure
e from the union that
Loosening the vent plug (1)aligned
the
nut, pipe
ensure is correctly on top ofwith the Operating the fuel lift pump; (2) denotes
pipe is the injector
correctly alignedLoosening inlet.
with the
fuel Do vent
filter. not plug
Operating (1)thethe
tighten fuel lift Operating
pump;the (2) the fuelscrew
connecting
denotes lift pump; (2) housing.
on the denotes
f the high
ctor inlet. Dounion not tightennutonmore, top
theof theas fuel thefilter.
this can causescrew on
connecting thethe
connecting
housing. screw on the housing.
injectors 3 4
nut more, asathis restriction
can
2 cause at the end of the pipe
he starter
ction at the which end of in theturn pipewill affect the fuel 3 4
ows
in turn fromwill delivery
affect the to the fuelengine.
ytighten.
to the engine.
8.The engine is now ready to start. If
ngine is now the ready engine to start.runsIf correctly tor a short
sine ofrunsthe correctly
time and tor athen short stops or runs roughly,
dthan thenthe stops check
or runsforroughly, air in the fuel system. If
here
or airIs in a thethere
fuel is system.
air in the If fuel system, there
t,air ensure
in the fuel system, there
is probably a leak in the low pressure
nedawith The connecting nut (3) on the fuel start
ably Operating
leak in section
the low of the fuel
pressure
the fuel lift pump; (2) denotes
system.
hten The connecting nut (3) aid;
on (4)fuel
the denotes
start positioning of spanner.
of thethefuel system.theThe connecting
connecting screw
nuton (3) the housing.
aid;on (4)the fuel start
denotes aid; (4) denotes
positioning positioning of spanner.
of spanner.
an cause
the pipe 3 4
26
Figure 5.8.2 Eliminating air from the fuel system using an in-line PB type injection pump.
the fuel
o start. If
r a short
roughly,
33
ystem. If
em, there
pressure
The connecting nut (3) on the fuel start
CAUTION
Any waste fuel must be collected and disposed of in a responsible manner and
in accordance with local authority guidelines.
5.9 Changing the Lubricating Oil

Refer GAMMA
to FigureSERIES
5.9. ENGINES OPERATORS' HANDBOOK
1. Operate the engine until it is warm.
turns. Operate2.the
Stopfuelthe
liftengine,
pump remove the the
sumpsump
anddrain plugto(Figure
tighten a torque of and O-ring and drain
5.9)
uel flows withoutthe air.lubricating
Retighten oil from the sump.
34Nm (25 Ibf ft or 3.5 kgfm).
ug. 3. Ensure the O-ring is not the
4.Fill damaged.
sump toFitthethe
MAX O-ring
markand drain plug back into the
on the
sump
en the connecting screw on and tighten to a torque of 34 Nm (25 Ibf ft or
dipstick (Figure 5.9) with new, clean3.5 kgfm).
ousing at the4.driving
Fill theside sump(2).to the lubricating
MAX mark oil onoftheandipstick
approved grade5.9) with new, clean
(Figure
lubricating
ate the fuel lift pump oil of an approved
until fuel grade Fluids).
(see 4.Engine (see 4.Engine Fluids).
without air from the loosened
. Re-tighten the connecting
ws.
sen the connecting nut on the
start aid (3). Operate the fuel
ump until air free fuel flows
the loosened joint. Re-tighten
onnecting nut. Use a spanner
event the connecting nut from
ng (4). Figure 5.9 The oil sump,
Figure showing
5.9 The drainshowing
oil sump, plug (1)drain
and dipstick (2).
re that the stop controller is plug (1) and dipstick (2).
e run position5.10 andReplacing
the speed the Oil Filter Canister
oller is at the maximum speed
Refer to Figure 5.10. 5.10 REPLACING THE OIL
on. Operate the starter motor.
The filter can have a single
FILTERor double canister. If two canisters are fitted they must
CANISTER
starting the engine, decrease
both be replaced at the same time.
ngine speed. If after a short Refer to Figure 5.10.
d of normal running the engine The filter can have a single or double
s or runs roughlyCAUTION it may be canister. If two canisters are fitted they
use there is aThe leakcanister
in the contains
low must bothand
a valve be special
replacedtube
at the
to same
ensuretime.
that lubricating oil does
ure section of not
the drain
fuel system.
from the filter. Therefore, ensure that the correct Lister Petter Power
k this and rectify canister is used.CAUTION
if necessary.
Systems
The canister contains a valve
AUTION and special tube to ensure that
aste fuel must be collected lubricating oil does not drain from
sposed of in a responsible the filter. Therefore, ensure that
r and in accordance with local the correct Lister Petter canister
ty guidelines. is used.
HANGING THE
CATING OIL
o Figure 5.9. 34
ate the engine until it is warm.
the engine, remove the sump
The canister contains a valve
AUTION and special tube to ensure that
aste fuel must be collected lubricating oil does not drain from
sposed of in a responsible the filter. Therefore, ensure that
GAMMA SERIES
the correct ENGINES
Lister Petter operators' handbook
canister
r and in accordance with local
ty guidelines. is used.
HANGING THE
CATING OIL
o Figure 5.9.
ate the engine until it is warm.
the engine, remove the sump
plug (Figure 5.9) and O-ring
drain the lubricating oil from
ump.
e the O-ring is not damaged. Fit
Figure 5.10 ReplacingFigure
the oil5.10
filterReplacing thethe
canister: (1) oil adaptor;
filter (2) the canister.
O-ring and drain plug back into canister: (1) the adaptor; (2) the canister.
1. Place a tray under the filter to collect spilt lubricating oil.
2. Remove the filter canister with a strap wrench or similar 27
tool. Ensure that
the adaptor (Figure 5.10) is secure in the filter head, and then discard the
canister.
3. Clean the filter head .
4. Add clean lubricating oil to the new canister. Allow the oil enough time to pass
through the filter element.
5. Lubricate the top of the canister seal with clean lubricating oil.
6. Fit the new canister and tighten it by hand only. Do NOT use a strap wrench.
7. Ensure that there is lubricating oil in the sump. On turbocharged engines, ensure
that the engine will not start and operate the starter motor until oil pressure is
obtained. To ensure that the engine will not start, either put the manual stop
control in the stop position or disconnect the electrical stop control of the fuel
injection pump. Oil pressure is indicated when the warning light is extinguished
or by reading a gauge.
8. Operate the engine and check for leakage from the filter. When the engine
has cooled, check the oil level on the dipstick and put more oil into the sump
if necessary.
5.11 Cleaning the Breather system

Refer to Figure 5.11.
1. Release the hose clip and remove the breather cover (1).
Note: It is necessary to remove the breather body in the rocker cover so that a strainer
can be put into it.
2. Remove the plastic strainer (2) and wash it with clean kerosene.
3. Wash the breather body with clean kerosene.
4. lf necessary, renew the O-ring (3).
35
a tray under the filter to collect wash it with clean kerosene.
ubricating oil. 3.Wash the breather body with clean
ve the filter canister
GAMMAwith aSERIES
strap ENGINES kerosene.
operators' handbook
ch or similar tool. Ensure that 4.lf necessary, renew the O-ring (3).
daptor (Figure 5.10) is secure
filter head, and then discard
anister.
the filter head .
lean lubricating oil to the new
er. Allow the oil enough time to
through the filter element.
ate the top of the canister seal
lean lubricating oil.
he new canister and tighten it
nd only. Do NOTFigureuse5.11aCleaning
strap theFigure
breather5.11system.
Cleaning (1) breather
the breathercover;
system. (2)(1)
plastic strainer; (3) O-ring
breather cover; (2) plastic strainer; (3) O-ring.
ch.
re that there is5.lubricating
Check that oilthe
in inside of the upper pipe is clean. If the pipe is not clean, release
5.Check that the
ump. On turbocharged the flange
engines,setscrews and remove theinside
pipe. of
Washthe theupper pipe with kerosene and
dry with low pressure pipe
air. is clean. If the pipe is not clean,
e that the engine will not start release the flange
6. Fit
perate the starter the until
motor breatheroil cover onto the body and setscrews
ensure thatand it is fitted firmly.
7. To
Fitensure
the upper remove
tighten the hose clip.the pipe with
the pipe. Wash
ure is obtained. thatpipe and kerosene and dry with low pressure air.
ngine will notNote:
start,The either put body6.Fit
breather is fixed
the on the cover
breather with onto
cover screws.theIf body
it is necessary to remove the
anual stop control
breather the stop use a spanner
in assembly, to clamp the flange on the bottom before loosening the
and ensure that it is fitted firmly.
on or disconnect screws.
the electrical 7.Fit the upper pipe and tighten the
control of the fuel injection hose clip.
. Oil pressure 5.12 Servicing
is indicated when the Air Cleaner
Note: The breather body is fixed on the
arning light isAextinguished
typical wet type or air cleaner is shown in Figure 5.12. The wet type air cleaner
cover with screws. If it is necessary to
ading a gauge. must be drained regularly. remove the breather assembly, use a
ate the engine 1. and
The check
container for and spanner
elementto(1) must
clamp thebeflange
cleaned
on the with kerosene or with another
bottom
ge from the filter. When
suitable theDo NOT
fluid. before loosening
use the screws.
gasoline.
e has cooled, check
2. Check the oil level
that the seal (2) is not damaged. Renew GAMMA SERIES ENGINES OPERATORS' HANDBO
it if necessary.
e dipstick and3. putFill
more oil into
to the indicated5.12 levelSERVICING
(3) with cleanTHE engineAIR lubricating oil.
ump if necessary. CLEANER intervals. Do not let dust comp
A typical wet -type air cleaner is shown fill the bowl as this will reduce t
LEANING THE of the filter element (2). The a
in Figure 5.12. The wet type air cleaner
THER SYSTEM must be drained regularly. of dust in the bowl indicates w
Figure 5.11. 1.The container and element (1) must it has been removed early enou
be cleaned with kerosene or with the conditions of operation.
se the hose clip and remove
another suitable fluid . Do NOT use Certain air filters have automati
eather cover (1).
gasoline. valves through which dust is ex
s necessary to remove the breather
2.Check that the seal (2) is not from the filter (Figure 5.12.2)
he rocker cover so that a strainer rubber dust valve (1) must be
ut into it. damaged. Renew it if necessary.
clean. Ensure that the sides
3.Fill to the indicated level (3) with
ve the plastic strainer (2) and valves close completely togethe
clean engine lubricating oil.
that they can separate freely.
Figure
Figure 5.12
5.12AAtypical
typicalwet
wettype
typeair
aircleaner.
cleaner.
5.12.1 Air Filter

36
Environmental conditions have an
important effect on the frequency at
which the air filter needs service Figure 5.12.2 Air filter with dust val
Figure 5.12 A typical wet type air cleaner.
5.12.1 Air Filter
Environmental conditions have an
5.12.1 Air Filter
important effect on the frequency at
Environmental conditions have an important effect on the frequency at which the
which the air filter needs service Figure 5.12.2 Air filter with dust va
air filter needs service. Refer to Figure 5.12.1.
If a restriction indicator is fitte
below) it will indicate precisely w
air filter element needs servicin
prevents the premature remova
filter, which is an unnecessary ex
or late removal which can cau
of power. The filter element m
cleaned or renewed according
manufacturer's recommendatio
5.12.2 Restriction Indicator

GAMMA SERIES ENGINES OPERATORS' HANDBOOK The restriction indicator for
engines must work at a pr
intervals. Do not let dust completely difference of 508/558mm (20/2
fill the bowl as this will reduce the life water gauge.
of the filter element (2). The amount It is fitted on the outlet pipe of
Figure 5.12.1of
The Figure
dust in
5.12.1
air filter, The air
showing
the bowl thefilter,
dustshowing
indicates bowl (1)the
whether cleaner.
and element (2)
dust bowl (1) and element (2). Refer to Figure 5.12.3. When
it has been removed early enough for
Certain air filters havethe
a separate dust warning light (1) is seen throu
conditions
Certain ofbowl (1) which must be cleaned
operation.
air filters have a separate dust
at intervals.
Do not let dust completely fill the clear panel (2) after the engi
Certain
bowl (1) air bowl
filtersas this will
whichhave
reduce the
mustautomatic
be cleaned dustatlife of the filter element
(2). The amount of dust in the bowl indicates whether stopped,
it has been removed early the air filter element m
valves through which dust is expelled
enough for the conditions of operation.
from the filter (Figure 5.12.2). The
Certain air filters haverubber
automatic dustdust valves
valve (1) through
must bewhich kept dust is expelled from
the filter (Figure 5.12.2).
clean.TheEnsure
rubber that
dust the
valve (1) must
sides of the be kept clean. Ensure
that the sides of the valves
valvescloseclosecompletely
completelytogether
togetherand and that they can separate
freely. that they can separate freely.
.12 A typical wet type air cleaner.
ir Filter
nmental conditions have an
nt effect on the frequency at
he air filter needs service Figure
Figure 5.12.2
5.12.2 Air
Air filter
filter with
with dust
dust valve
valve (1).
(1)
Figure 5.12.1.
If a restriction indicator
If ais restriction
fitted (see indicator
below) it will indicate
is fitted (seeprecisely when the air
filter element needs servicing.
below) it willThis prevents
indicate the premature
precisely when the removal of the filter,
which is an unnecessary expense,
air filter or late
element needsremoval whichThis
servicing. can cause loss of power.
The filter element must be cleaned
prevents or renewed
the premature according
removal of theto the manufacturer's
recommendations. filter, which is an unnecessary expense,
or late removal which can cause loss
of power. The filter element must be 37
cleaned or renewed according to the
manufacturer's recommendations.
GAMMA
GAMMA SERIES ENGINES SERIES ENGINES
operators' OPERATORS' HANDBOOK
handbook
5.12.2 Restriction removed for service

Indicator 5.13.1 Three Cylinder Engine
The restriction indicatorAfter
forathese
cleanengines
elementmust has been
work atfitted, 1.Remove
a pressure difference theof cover plate
press
GAMMA the
508 / 558 mm (20/22 in) of water gauge. rubber
SERIES bottom
ENGINES (3) of the
OPERATORS' window
HANDBOOK of the flywheel hou
button (4) of the restriction
It is fitted on the outlet pipe of the air cleaner. indicator to 2. Rotate the crankshaft until th
Refer to Figure 5.12.3. reset the the
When redservice
warning
red warningindicator.
light (1) is seen throughline on the theclearflywheel is in th
removed for 5.13.1 Three Cylinder Engines
panel (2) after the engine
After ahas stopped,
clean element thehasair been
filter element
fitted, must of be
1.Removetheremoved
window the and coverNo.1 pist
plate
for service. press the rubber bottom (3) of the compression stroke
window of the flywheel hous (both va
After a clean elementbuttonhas been fitted, press the rubber
(4) of the restriction indicator to bottom (3)closed).
of the button
2. Rotate the crankshaft until th
(4) of the restriction indicator
reset thetored reset the red
warning warning indicator. 3.Check
indicator. line on the andflywheel
adjustiscleara
in the
specified.
of the window and No.1 pisto
4.Repeat
compression thestroke
procedure
(both val
remaining
closed). valves following
order (3and
3.Check cylinder engines
adjust cleara ha
order
specified. 1 - 2 - 3).
5.Replace the
4.Repeat the rocker
procedurecover
Figure 5.12.3 Restriction indicator: (1)
warning light; (2) clear panel; (3) rubber
that
remainingthe rocker
valves cover
following gast
base; (4) button. good(3condition
order cylinder enginesand ishac
positioned.
order 1 - 2 - 3).
5.13 CHECKING VALVE 5.Replace the rocker cover e
Figure 5.12.3 Restriction indicator: (1) (3) rubber base; (4) button
Figure 5.12.3 Restriction indicator:
CLEARANCES
(1) warning light; (2) clear panel; 5.13.2
that Four
the Cylinder
rocker Engines
cover gask
warning light; (2) clear panel; (3) rubber
base; (4) button.
Thegood sequence
condition of valves
and from
is con
5.13 Checking Valve The valve clearances
Clearances are checked cylinder
positioned.is shown in the table
between the top of the valve stem and Number 1 cylinder
The valve clearances5.13 are CHECKING
checked between VALVE the top of the valve stem and the is at the fro
the rocker lever (Figure 5.13) with the engineFour (fanCylinder
and gearEnginesend).
rocker lever (Figure 5.13) with
CLEARANCES the engine hot or cold. 5.13.2
engine hot or cold.
The sequence of valves from n
The valve clearances are checked cylinder isVALVE shownPOSITIONS
in the table b
between the top of the valve stem and Number 1 cylinder1 is at
2 the fro 3
Cylinder and
the rocker lever (Figure 5.13) with the engine (fan and gear end).
Valve Number 1 2 3 4 5 6
engine hot or cold.
Valve: I=Inlet;
VALVE I EPOSITIONS
E I I E
E=Exhaust
Cylinder and 1 2 3
Valve Numberpositions
The valve 1 2 3are4 shown
5 6
5.13.2.
Valve: I=Inlet;
I E E I I E
E=Exhaust
Figure
Figure 5.13
5.13 Checking
Checking valve
valve clearances.
clearances
The valve positions are shown i
The correct clearancesThearecorrect
0.20 mm clearances areinlet
(0.008 in) for 0.20mm
valves and5.13.2.
0.45 mm (0.018
in) for exhaust valves.(0.008 in) for inlet valves and 0.45mm
(0.018
Figure in) forChecking
5.13 exhaustvalve
valves.
clearances.
Note: Number 1 cylinder is at the front of the engine.
Note:
The correct
Number clearances
1 cylinder arefront
is at the 0.20mm
of the
5.13.1 Three Cylinder Engines Figure 5.13.2 The valve pos
(0.008
engine. in) for inlet valves and 0.45mm (GW4, GWT4)
1. Remove the cover (0.018
plate inin)the
forwindow
exhaustofvalves.
the flywheel housing
2. Rotate the crankshaft until the T.D.C. line on the flywheel is in the centre of the
Note:
Number 1 cylinder is at the front of the Figure 5.13.2 The valve posit
engine. (GW4, GWT4)
38 30
4.Repeat the procedure for the
remaining valves following the firing
order (3 cylinder engines have firing
order
GAMMA1 - 2 -SERIES
3). ENGINES operators' handbook
5.Replace the rocker cover ensuring
5.12.3 Restriction indicator: (1)
window
g light; (2) clear panel;
that inthe
and No.1 piston
(3) rubber therocker cover gasket
compression is in valves fully closed).
stroke (both
good condition
3. Check and adjust clearance as specified.
base; (4) button. and is correctly
4. Repeat the procedure positioned.
for the remaining valves following the firing order
HECKING VALVE
(3 cylinder engines have firing order 1 - 2 - 3).
RANCES 5. Replace 5.13.2
the rocker coverFour Cylinder
ensuring thatEngines
the rocker cover gasket is in good
The sequence
condition and is correctly of valves from number 1
positioned.
ve clearances are checked cylinder is shown in the table below:
n the top of the valve stem and Number 1 cylinder is at the front of the
5.13.2
er lever (Figure 5.13)Four Cylinder
with the Engines
The sequence of engine
valves from(fan and gear
number end). is shown in the table below:
1 cylinder
hot or cold.
Number 1 cylinder is at the front of the engine (fan and gear end).
VALVE POSITIONS
VALVE
Cylinder and 1 POSITIONS
2 3 4
Valve Number 1 2 3 4 5 6 7 83
1 2 4
Cylinder and Valve NumberValve: I=Inlet;
1 I 2 E E3 I I 4 E E5 I 6 7 8
E=Exhaust
Valve: I=Inlet; E=Exhaust I E E I I E E I
The valve positions are shown in Figure
The valve positions are shown in Figure 5.13.2.
5.13.2.
5.13 Checking valve clearances.
rect clearances are 0.20mm

n) for inlet valves and 0.45mm
n) for exhaust valves.
1 cylinder is at the front of the FigureThe

5.13.2 The valve positions
Figure 5.13.2 valve positions (GW4, GWT4)
(GW4, GWT4)
1. Rotate the crankshaft in the normal direction of rotation until the inlet valve
(8) of number 4 cylinder has just opened and the exhaust valve (7) of the
same cylinder has not closed completely. Check the clearances of the valves
(1 and 2) of number 1 cylinder and adjust them, if necessary.
2. Set the valves (3 and 4) of number 2 cylinder as indicated above for number
4 cylinder. Then check and adjust the clearances of the valves (5 and 6) of
number 3 cylinder.
3. Set the valves (1 and 2) of number 1 cylinder. Then check and adjust the
clearances of the valves (7 and 8) of number 4 cylinder.
39
5.13.3 Six Cylinder Engines

The sequence of valves from number 1 cylinder is shown in the table below.
Number 1 cylinder is at the front of the engine (fan and gear end).
VALVE POSITIONS
1 2 3 4 5 6
Cylinder and Valve Number
1 2 OPERATORS'
GAMMA SERIES ENGINES 3 4 5 HANDBOOK
6 7 8 9 10 11 12
Valve: I=Inlet; E=Exhaust I E E I I E E I I E E I
crankshaft in the normal 5.13.4 Valve Positions
otation until the inletValve
5.13.4 valve Positions
The valve positions are shown in Figure
4 cylinder has
Thejust opened
valve positions5.13.4.
are shown in Figure 5.13.4.
aust valve (7) of the same
s not closed completely.
earances of the valves (1
mber 1 cylinder and adjust
essary.
lves (3 and 4) of number Figure 5.13.4 The valve positions (GWT6-
Figure 5.13.4 The valve positions (GWT6-1A, GWT6-2A, GWTA6)
as indicated above for 1A, GWT6-2A, GWTA6).
cylinder. Then check and
1. Rotate the crankshaft in the normal direction of rotation until the inlet valve (12)
clearances of the of valves 1.Rotate
number(56 cylinder theopened
has just crankshaft
and thein the normal
exhaust valve (11) of the same
number 3 cylinder. direction
cylinder has not closed of rotation
completely. Check the until the inletof the valves (1 and
clearances
ves (1 and 2) of2)number
of number valveand
1 1 cylinder (12) of them,
adjust number 6 cylinder
if necessary.
hen check and 2. Set the valves
adjust the (4 and has3)just
of number
opened 2 cylinder
and the as exhaust
indicated above for number
s of the valves (7 6 cylinder.
and 8) ofThen check
valveand adjust
(11) thesame
of the clearances of the
cylinder hasvalves (9 and 10) of
number 5 cylinder. not closed completely. Check the
cylinder.
ves (5 and 6) of number 3 clearances of the valves (1 and 2) of
hen check and adjust the number 1 cylinder and adjust them,
s of the valves (3 and 4) of if necessary.
cylinder. 5. Set the valves (9 andthe
2.Set 10)valves
of number(4 and 3) of number
5 cylinder. Then check I adjust the
2 cylinder
clearances of the valves (3 andas4) ofindicated
number 2 above
cylinder.for
ylinder Engines 6. Set the valves (5 and number6) of6number
cylinder. Then check
3 cylinder. Thenand check and adjust the
ce of valves from clearances adjust(7the
numberof the valves andclearances
8) of number of the valves (9
4 cylinder.
shown in the table below. and 10) of number 5 cylinder.
linder is at the front of the 3.Set the valves (8 and 7) of number 4
and gear end). cylinder. Then check and adjust the
clearances of the valves (5 and 6) of
LVE POSITIONS number 3 cylinder.
1 2 3 4 5 6 4.Set the valves (1 and 2) of number 1
cylinder. Then check and adjust the
2 3 4 5 6 7 8 9 10 11 12 clearances of the valves (11 and 12)
E E I I E E I I E E I of number 6 cylinder.
40
5.Set the valves (9 and 10) of number
5 cylinder. Then check I adjust the
clearances of the valves (3 and 4)
6. Fault Diagnosis
6.1 Problems and Possible Causes
See table below, in conjunction with 6.2 Code List of Possible Causes opposite.
Fault Diagnosis
Possible Cause
Problem
Checks by Operator Checks by Workshop Personnel
The starter motor turns the engine
1, 2, 3, 4 None
too slowly
The engine does not start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 17 33, 34, 35,36, 37, 41, 42, 43
5, 6, 7, 8, 9, 10, 11, 12,
The engine is difficult to start 33, 35, 36, 37, 39, 41, 42, 43
13, 14, 15, 16, 17, 19
8, 9, 10, 11, 12, 13, 16, 33, 35, 36, 37, 38,
Not enough power
17, 18, 19, 20, 21, 31 41, 42, 43, 60, 62, 63
Misfires 8, 9, 10, 12, 13, 15, 20, 22 33, 35, 36, 37, 38, 39, 40, 42
33, 35, 36, 37, 38, 39,
High fuel consumption 11, 13, 15, 17, 18, 19, 21, 22
41, 42, 43, 62
33, 35, 36, 37, 38, 39, 41,
Black exhaust smoke 11, 13, 15, 17, 19, 21, 22
42, 43, 60, 62
35, 36, 37, 38, 41, 43,
Blue or white exhaust smoke 4, 15, 21, 23, 31
44, 51, 52, 61
Low lubricating oil pressure 4, 24, 25, 26 45, 46, 47, 49, 50, 58
The engine knocks 9,13,15,17,20,22,23 35, 36, 39, 41, 43, 45, 51, 52, 59
7, 8, 9, 10, 11, 12, 13,
The engine turns erratically 33, 37, 39, 40, 43, 51, 59
15, 16, 18, 20, 22, 23
Vibration 13, 18, 20, 27, 28 33, 37, 39, 40, 43, 51, 53
High lubricating oil pressure 4, 25 48
High engine temperature 11, 13, 15, 19, 27, 29, 30, 32 33, 35, 36, 38, 51, 54, 55, 56, 63
41
6.2 Code List of Possible Causes

Checks by the Operator Checks by Workshop Personnel
1. Battery of low capacity 33. Fault in fuel injection pump
2. Bad electrical connections 34. Broken drive on fuel injection pump
3. Fault within the starter motor 35.Timing of fuel injection pump is
4. Wrong grade of lubricating oil incorrect
5. Starter motor turning engine too slowly 36. Valve timing is incorrect
6. Fuel tank empty 37. Bad compression
7. Fault in stop control 38. Cylinder head gasket leaks
8. Restriction in fuel pipe 39. Valve stem sticking
9. Fault in fuel lift pump 40. Wrong high-pressure pipes
10. Dirty fuel filter element 41. Worn cylinder bores
11. Restriction in air filter / cleaner or 42. Leakage between valves and seats
induction system 43. Piston rings are not free or are worn
12. Air in fuel system or broken
13. Fault in injector or incorrect type of 44. Valve stems and/or guides are worn
fuel injector 45. Crankshaft bearings are worn or
14. Cold start system used incorrectly damaged
15. Fault in cold start system 46. Lubricating oil pump is worn
16. Restriction in fuel tank vent 47. Relief valve does not close
17. Wrong type or grade of fuel used 48. Relief valve does not open
18.Restricted movement of engine 49. Relief valve spring is broken
speed control 50. Fault in suction pipe of lubricating
19. Restriction in exhaust pipe oil pump
20. Engine temperature too high 51. Piston is damaged
21. Engine temperature too low 52. Piston height is incorrect
22. Incorrect valve clearance 53. Flywheel housing or flywheel is not
23. Too much (or wrong type of) oil aligned correctly
used in a wet-type air cleaner 54. Fault in thermostat, or incorrect type
24. Not enough lubricating oil in sump 55. Restriction in coolant passages
25. Defective gauge 56. Fault in water pump
26. Dirty lubricating oil filter element 57. Valve stem seal (if fitted) is
27. Fan damaged damaged
28. Fault in engine mounting of flywheel 58. Restriction in sump strainer
housing 59. Valve spring is broken
29. Too much lubricating oil in sump 60. Turbocharger impeller is damaged
30. Restrict ion in air or water passages or dirty
of radiator 61. Lubricating oil seal of turbocharger
31. Restriction in breather pipe leaks
32. Insufficient coolant in system 62. Induction system leaks
(turbocharged engines only)
63.Turbocharger waste-gate (if fitted)
does not work correctly
42
7. Engine Storage
If the engine is to be withdrawn from service for a prolonged period you must follow
the procedures below to ensure that damage does not occur.
7.1 Preparing the Engine for Storage

1. Completely clean the outside of the engine.
2. When a preservative fuel is to be used, drain the fuel system and fill it with the
preservative fuel. If preservative fuel is not used, the system can be kept full
with normal fuel but the fuel must be discarded at the end of the storage period
together with the fuel fitter element(s).
3. Operate the engine until warm then correct any leakage of fuel, oil or air. Stop
the engine and drain the lubricating oil from the sump.
4. Renew the canister(s) of the lubricating oil filter.
5. Fill the sump to the mall mark on the dipstick with new, clean lubricating oil.
6. Drain the cooling system (see 5.2). In order to protect the cooling system from
corrosion fill it with an approved antifreeze mixture.
7. Operate the engine for a short period in order to circulate the lubricating oil
and coolant in the engine.
8. Clean the engine breather pipe.
9. Remove the air fitter. If necessary, remove the pipe(s) installed between the air
filter and induction manifold or turbocharger. Seal the manifold with waterproof
tape.
10. Seal the exhaust manifold and air pipe of the fuel tank with waterproof tape.
11. Disconnect the battery. Put the battery into safe storage in a fully charged
condition and protect the terminals against corrosion.
12. Remove the drive belts and put them into storage.
If the above procedure is carried out correctly, there should be no damage due
to corrosion .
Lister Petter Power Systems are not responsible for damage which may occur
when an engine is in storage after a period of service.
7.2 Returning the Engine to Service

After a period in storage, before the engine is started, operate the starter motor
with the engine stop control in the stop position until oil pressure is indicated (oil
pressure can be indicated either by a gauge or when a low pressure warning light
is extinguished). If a solenoid stop control is used on the fuel injection pump it
must be disconnected for this operation.
43
8. Maintenance Record
Your Lister Petter Power Systems engine must be properly maintained using the
intervals and procedures described in this manual. You must be familiar with the
routine tasks set out in 5.Routine Maintenance, and their correct frequency set
out in 5.1 Maintenance Schedule.
Details of the maintenance work carried out on the engine during the warranty
period (the first 5000 hours or first two years, whichever is sooner), except the
daily checks, must be recorded in the spaces allocated in this section: pages 35-39
for routine maintenance and pages 40-44 for non-routine maintenance (see 9.3
Conditions of Warranty). If you purchase an extended warranty you must keep
records for the entire period of the warranty.
It is also recommended that you continue to keep records beyond the warranty
period, to enable you to keep track of work that has been done on the engine.
8.1 Routine Maintenance

Hours run Work done by Details of service Distributor / Dealer Stamp Date
44
45
46
47
8.2 Non-Routine Maintenance

48
Hours run Work done by Details of service Distributor/Dealer Stamp Date
49
50
51
9. Warranty
On receipt of your engine please fill in the section on page 53. This information
will be required in the event of a claim under warranty, according to the conditions
set out below.
9.1 Standard Warranty Cover

The standard warranty includes 2 year / 2000 hour cover for all non-serviceable1
components, parts and labour, beginning on the date of delivery to the original retail
purchaser, and is transferable. It is subject to the conditions set out below in 9.3
Conditions of Warranty and the limitations set out in 9.4 Limitations of Warranty.
9.2 Conditions of Warranty

For the warranty to be valid, servicing must be carried out in accordance with 5.
Routine Maintenance and with the timings set out in 5.3 Maintenance Schedule.
Detailed records of servicing must be kept; see 8. Maintenance Record. Servicing
must be by approved dealers or competent engineers.
• The maintenance record must be completed.
• Oils and other fluids must be to the specifications/grades given in 4.Engine
Fluids or as instructed in the Workshop Manual.
• Only genuine Lister Petter Power Systems service parts must be used.
• When Lister Petter Power Systems parts are purchased from a dealer, this
must be noted, with the dealer's stamp, in 8. Maintenance Record, and
receipts for the parts must be retained. The dealer is authorised to stamp the
maintenance record only following the sale of genuine parts, to a competent
engineer, intended to be used on the warrantable Lister Petter Power Systems
engine.
• Evidence will be required of engine hours run and should be entered in 8.
Maintenance Record. Evidence of equipment used to record engine hours
may be requested in the event of a warranty claim. If no hour recorder is
fitted, twelve hours per calendar day will be used as a basis for the hours-run
calculation.
• The installation should be in accordance with data supplied by the Lister Petter
Power Systems Applications Department.
• Long term light load and cold engine running will invalidate the warranty.
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. The term 'core engine' excludes the radiator/heat exchanger, starter motor and
starting systems, alternator, water pump, exhaust, fan belts, oil seals and fuel injection
equipment.
3. This warranty gives the purchaser specific legal rights; the purchaser may also have
other rights, which vary by country or state.
52
9.3 Limitations of Warranty

• The seller does not accept responsibility for any business costs or other losses
which may result from the warrantable failure.
• The seller is not responsible for failures resulting from misapplication, abuse or
neglect, including: operating with inadequate cooling; the use of non-approved
or contaminated fuels or lubricants; lack of, or incorrect, maintenance; incorrect
repair; improper storage; incorrect starting, stopping or operating procedures;
the use of non-approved parts; fair wear and tear; and serviceable items (see
note 1).
9.4 Repairs under Warranty

Lister Petter Power Systems must be contacted and authorisation given before
any warrantable work is commenced.
9.4.1 Contact Details

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
Engine Serial Number: ..........................................................................................
Purchased from: ...................................................................................................
Purchase Date:.......................................................................................................
Plant Type:..............................................................................................................
Plant Number:........................................................................................................

53
APPENDIX: FUEL PUMPS AND

Appendix: Fuel Pumps
GOVERNORS
and Governors
PB fuel pumps, RSV governors and PB PUMP
electronically
PB fuel pumps,controlled governors
RSV governors andare
electronically controlled
Characteristics governors
of PB are applied
fuel pumps are:
applied
on on of
certain certain of theengines
the diesel diesel engines
manufactured for the
1.Plunger Gamma
and engine series.
barrel assembly (pumping
manufactured for the Gamma engine element) for each cylinder.
series.
PB Pump 2.Camshaft is integrated into the
aluminium pump housing.
Characteristics of PB fuel pumps are:
3.Fuel supply pump to deliver fuel from
1. Plunger and barrel assembly (pumping element) for each cylinder.
the tank.
2. Camshaft is integrated into the aluminium pump housing.
3. Fuel supply pump to deliver fuel from the tank.
Delivery valve holder
Delivery valve
Washer
Front and rear liner bushing
Pump barrel
Pump plunger
Spring upper seat
Rack control
Control sleeve
Plunger return spring
Spring seat
Camshaft
Pump housing
Tappet
PB Pump Structure PB Pump Structure
46
54
Adjustment and Use of the PB Pump

1. Important adjustment of the pump should only be carried out on a special test
bench by trained personnel.
Adjustment of Static Fuel Supply

Advanced Angle of Inline Pump
1. Determine the mark position when the piston of number 1 cylinder is at TDC
on the compression stroke. The mark should be stamped on both the timing
case cover and the pulley.
2. Remove the high pressure pipe of number 1 cylinder, pull the throttle control
lever to the maximum position of fuel supply, turn the crankshaft clockwise from
the front and set the piston of number 1 cylinder to TDC on the compression
stroke.
3. Turn the crankshaft anti clockwise from the front to an angle of more than 60
degrees then turn back clockwise slowly. Observe for the fuel overflow from
the valve seat, when the fuel level fluctuation just appears it indicates the fuel
supply is beginning at number 1 cylinder. At this point stop turning the crankshaft
and check for a difference between the angle on the timing case cover and the
pulley, thus the fuel supply advanced angle can be determined. At this moment,
if the mark on the pulley is ahead of that on the timing case cover it indicates
that the fuel supply is in advance (and vice versa).
4. If the fuel supply advance angle fails to meet the requirement, loosen the nut
on the pump bracket and the flange at the side of the pump and adjust with the
kidney hole on the flange. When moving the pump body close to the cylinder
block it can increase the fuel supply advance angle (or vice versa).
5. The periphery of the flange on the pump body to be turned for 1 mm of arc
length, the fuel supply advance angle can increase or decrease by 1 degree
or crankshaft rotation angle.
6. After the fuel pump supply advanced angle has been set, the nuts on the flange
at the side of the pump and the screws on the pump bracket should be tightened
to the correct torque.
7. Repeat the third step of the operation and check.
Note:
The arc length opposite to 1degree of rotation angle of the crankshaft = πD/360 (mm) where
D is the diameter of the pulley in mm.
55
RSV GOVERNOR - PB PUMP governor lever is equal to the torque

RSV Governor - PB Pump
The RSV governor (see figure) is of of the centrifugal force at the specified
The RSV governoreccentric
the mechanically (see figure) is ofThe
type. the mechanically
speed. eccentric type. The governor
drawbar device can be simplified
governor drawbar device can be into a crank
Theblock
strokedevice,
of theand the break
governor handdevice
lever
can be simplified
simplified into a into a rolling
crank block guide
device,road device.
and flyweight can be transmitted to t e
The loadbreak
and the of thedevice
springcancanbe besimplified
varied by rotating
toothedthebar
spring leverthe
through via lever
the governor
device.
lever, thus changing
into a rolling guide road thedevice.
speed range. When adjusting
The total the speed,
fuel quantity limit the torque
screw and
generated by the load of the
The load of the spring can be variedgovernor spring on the governor lever is equal
calibrator are mounted in the governor to the
torque of thethe
by rotating centrifugal force at
spring lever viathethe
specified
body.speed.
The idle speed stabilising device
The strokelever,
governor of the thus
governor hand lever
changing the and is flyweight
mounted canin thebe rear
transmitted
housing.to The
the
toothed bar through the
speed range. When adjusting the lever device. The total fuel quantity limit screw
adjusting screw on the spring lever is and
calibrator
speed, the aretorque
mounted in the governor
generated by the body. usedThetoidle speedthe
change stabilising device is
speed governing
mounted
load of thein the rear housing.
governor springThe on adjusting
the screw
rate onathe
within spring
certain lever is used to
range.
change the speed governing rate within a certain range.
48
56
Rotary Type Fuel Pumps

Stanadyne rotary pumps DB2 and DB4 are used on certain engine models within
the Gamma range. These have mechanical governing (except GWTA6 engines)
and incorporate an electrical shut off solenoid.
Characteristics of the DB2 / DB4 pump are:
1. Built in automatic advance system.
2. Electric shut off system.
3. Mechanical governing
GAMMA SERIES to 3% OPERATORS'
ENGINES regulation. HANDBOOK
4. Peak injection pressure to 800 bar (11600 lbf/in2).
RY TYPE FUEL PUMPS

yne rotary pumps DB2 and DB4
ed on certain engine models
he Gamma range. These have
nical governing (except GWTA6
) and incorporate an electrical
solenoid.
eristics of the DB2/DB4 pump
n automatic advance system.

ic shut off system.
anical governing to 3%
ation.
injection pressure to 800 bar
0 lbf/in2).
57
ELECTRONIC GOVERNOR
The figure below gives a basic the high pressure fuel pump rack
illustration on the principle of on the engine, thus control ling fuel
Electronic
electronic speed Governor
governing. The delivery to the engine and hence
The figureactuator
solenoid below gives
is ana basic illustration
actuator of on the principle
controlling engine ofspeed.
electronic
The speed
governing.
the electronic The solenoid
governoractuator
which iscan
an actuator of theiselectronic
controller governordevice
a full electronic which
can control
control the the output
output displacement
displacement of of the actuator
which throughthe
can control controlling a coil
engine speed
current in thethrough
the actuator solenoidcontrolling
actuator. a coil with a rapid and accurate response to
The electronic
current actuatoractuator.
in the solenoid drives directly the the
high pressure fuelload
instantaneous pump rack on the
variation.
engine, thus control
The electronic ling drives
actuator fuel delivery
directlyto the engine and hence controlling engine
speed. The speed controller is a full electronic device which can control the engine
speed with a rapid and accurate response to the instantaneous load variation.
Electronically controlled governor
50
58
59
GAMMA series ENGINES Operatrators' Handbook,
p027-08199, EDITION 4, AUGUST 2020
© Lister Petter POWER SYSTEMS
Head Office
Unit 14 Estuary Court, Broadmeadow Industrial Estate
Teignmouth, TQ14 9FA
T: +44 (0) 1285 702211
Production Facility
Units 13-15 Quadrant Distribution Centre
Hardwicke, Gloucester, GL2 2RN
sales@listerpetter.com
www.listerpetter.com
consult you Lister Petter Power Systems distributor. * Optional items standard on most builds.
a specification that matches your requirements; Please
A range of options are available that allows you to select
OPTIONAL ITEMS
Emissions Limits.
This engine does not comply with Harmonised International Regulated
▪ operators hand book (English)* Note:

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GAMMA SERIES

GW3, GWT3, GW4, GWT4, GWT6-1A

1. Safety Information and Precautions ............................................8

2. Engine Parts and Technical Data ...................................................15

3. Operating instructions .....................................................................17

4. Engine Fluids ..........................................................................................20

5. Routine Maintenance ..........................................................................23

5.13 Checking Valve Clearances  38

6. Fault Diagnosis .....................................................................................41

7. Engine Storage .....................................................................................43

8. Maintenance Record ..........................................................................44

Appendix: Fuel Pumps and Governors ..............................................54

4 ....................................... Number of cylinders

Care of Your Engine

1. This figure identifies the ISO 8999 symbols

1.1 Personal Safety

• Tie long hair close to your head.

• To avoid loss of concentration, do not use music earphones while working.

1.2 General Precautions

• Only one person must control the engine.

• Handle fluids with care at all times.

• Fit only genuine Lister Petter Power Systems parts.

1.3 Care with Lubricating Oil

1.4 Precautions with Diesel Fuel

1.5 Precautions with Coolant

1.6 Precautions with Batteries

Battery Charge Alternator

• Never 'flash' any connection.

1.7 Care with Electrical Systems

1.8 Lifting Precautions

1.8 Lifting a Gamma series engine using overhead lifting eyes.

Preparations required before lifting an engine:

1.9 Care with Filters and Elements

1.10 Waste Disposal

2. Engine Parts and Technical Data

2.1 Engine type GWT6: front and left side

2.2 Engine type GWT4: rear and right side

General Engine Data Cylinder arrangement Inline

3.1.1 Starting key positions: 3.1.2 Starting key positions:

3.1.1 Starting a Warm Engine

3.1.2 Starting a Cold Engine without Starting Aids

3.1.3 Starting a Cold Engine with Starting Aids

3.2 Stopping the Engine

3.3 Adjustment of Engine Speed

4.1.1 Low Temperature Fuels

4.2 Lubricating Oil Specification

Lubricating oil specification

4.2 Oil viscosity

4.3 Coolant Specification

• If possible, use clean soft water in the coolant mix.

GAMMA SERIES ENGINES operators' handbook

5.1.1 Maintenance Schedule

Oil Change Periods

5.3 CHECKING THE DRIVE

2.Change the position of the al

5.3.1 Adjusting the Belt Tension

5.5 CHECKING THE FUEL 5.6.1 Renewing a Separate Type Fuel

5.6.1 Renewing a Separate Type Fuel Filter Element

NEWING THE FUEL

5.6.2 Renewing a Canister Type Fuel Filter Element

1. Remove the fuel leak-off pipe.

5.8 Eliminating Air from the Fuel System

5.8.1 Standard Method

1. Safety Information and Precautions ............................................8

2. Engine Parts and Technical Data ...................................................15

3. Operating instructions .....................................................................17

4. Engine Fluids ..........................................................................................20

5. Routine Maintenance ..........................................................................23

5.13 Checking Valve Clearances 38

6. Fault Diagnosis .....................................................................................41

7. Engine Storage .....................................................................................43

8. Maintenance Record ..........................................................................44

Appendix: Fuel Pumps and Governors ..............................................54