Lister Petter LPW2, LPW3, LPW4, LPWT4, LPWX2 Operator's Handbook Manual

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LPW/LPWS/LPWX ENGINE

OPERATORS' HANDBOOK

P027-08270

ALPHA SERIES / NEW ALPHA SERIES

ORIGINAL INSTRUCTIONS

Associated Publications

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

Statement of Indemnity

The information, specications, 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 tech nical 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 th e 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

P027-08270

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 organisation cannot be relied upon for correct material, dimensions or finish. The Company cannot therefore be held resp onsi ble for any damag e arising from the use of such parts, and the guarantee will be invalidated.

CONTENTS

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

1. Safety Information ................................................................... 7

2. Technical Data ....................................................................... 13

3. Starting and Stopping ............................................................ 14

4. Engine Fluids ......................................................................... 17

5. Routine Maintenance............................................................. 19

6. Troubleshooting ..................................................................... 27

7. Maintenance Record ............................................................. 29

8. Warranty ................................................................................ 37

9. Index ...................................................................................... 39

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

2.1 Features of the LPW series diesel engines

Oil Filter

Adaptor

Fuel

Filter

Turbocharger

Lifting Eye

Radiator

Fan

LPW(S)T4

Alternator

Flywheel

Inlet

Manifold

Starter Motor

Exhaust

Manifold

LPW(X)3

Radiator Fan

(may have 6 blades)

Exhaust

Manifold

Flywheel

Housing

Sump

Drain Plug

Inlet

Manifold

Oil

Filter

Fuel

Filter

LPWS2

Glow

Plugs

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

INTRODUCTION

This handbook explains the operation and routine maintenance of Lister Petter water cooled diesel engines in the Alpha (LPW, LPWX) and New Alpha (LPWS) series. Please note that If your engine is part of a generating set, there is a separate operators' handbook for the genset, to explain such features as the control module.

ENGINE IDENTIFICATION

To identify which model of Lister Petter LPWX/LPW(S) diesel engine you are using refer to the engine serial number, which is stamped on a plate attached to

the engine. It identiﬁ es the type and build

of the engine (see table below) to enable the correct maintenance procedures to be carried out. Here is a sample serial number:

06 001234 LPWS3 A 402

06........................Year code (06 = 2006)

001234...............Unique engine number

LPWS3 ............................Engine model

A .........................Anti clockwise rotation

402....................................Build number

The illustrations on page 4 show features of the different engine models. When following the instructions in this handbook you will need to be familiar with the parts labelled.

USING THIS HANDBOOK

Operating or servicing a diesel engine is potentially dangerous. You must not attempt it unless you have the necessary knowledge and experience. Read each section thoroughly and carefully, taking note of all the information and instr uctions given. T his is for your safety and to ensure the correct

maintenance of your engine. For speciﬁ c

aspects of operation and maintenance, use the table of contents (page 3) or the

index (page 40) to ﬁ nd the section you

need. Where instructions are numbered in sequence, they must be followed in

LPW DIESEL ENGINE MODELS

Model Characteristic features

LPW2 Two cylinders, water cooled, naturally aspirated, direct injection

LPW3 Three cylinders, water cooled, naturally aspirated, direct injection

LPW4 Four cylinders, water cooled, naturally aspirated, direct injection

LPWT4 Four cylinders, water cooled, direct injection, turbocharged

LPWX2 Two cylinders, water cooled, naturally aspirated, direct injection

LPWX3 Three cylinders, water cooled, naturally aspirated, direct injection

LPWX4 Four cylinders, water cooled, naturally aspirated, direct injection

LPWS2 Two cylinders, water cooled, naturally aspirated, indirect injection, emission compliant

LPWS3 Three cylinders, water cooled, naturally aspirated, indirect injection, emission compliant

LPWS4 Four cylinders, water cooled, naturally aspirated, indirect injection, emission compliant

LPWST4 Four cylinders, water cooled, naturally aspirated, indirect injection, turbocharged, emission compliant

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

that order. This applies in particular to maintenance and repair procedures (sections 5 and 6).

In cases of difﬁ culty, or to obtain spare

parts, please consult your local Lister Petter distributor or dealer.

RUNNING-IN

To assist running-in all engines are

despatched with an initial ﬁ ll lubricating

oil which must be changed after 100 hours. Your engine does not require gradual light-load running-in. Extended light-load running should be avoided, as this could damage the cylinder bore and allow lubricating oil to enter the exhaust system.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

Read the information in this section carefully and follow all the advice given. Pay especial attention to the cautions and warnings demonstrated below, which are used throughout this handbook.

CAUTION

This caution draws attention to special information or procedures which must be correctly observed, to avoid damage to, or destruction of, equipment.

WARNING

This warning draws attention to special information or procedures which must be strictly observed. Failure to do so may resu lt in personal injury.

WARNING

This WARNING DRAWS ATTENTION TO S PE C IA L in f o rm a t io n O R PROCEDURES WHIC H must be strictly OBSERVED. Failure to do so may result in serious injury or death.

1.1 GENERAL SAFETY INFORMATION

Starting and operating any diesel engine is potentially dangerous. Do not attempt to do so unless you have the necessary knowledge and experience. Ensure that anyone attempting to start and operate your diesel engine has been properly trained and instructed in the correct procedures.

CAUTION

Follow all saf e t y instructi o n s accurately.

Carefully read and follow all safety information and instructions in this manual. Observe the safety and informative s y m b o l s o n y o u r e n g i n e a n d equipment.

Emergency Precautions

• Be prepared with suitable equipment and knowledge in case a ﬁ re starts.

• Identify a location from which calls

to the emergency services can be made if necessary.

• Ensure a third party knows where

you are working and when you leave the working area.

General Precautions

• Ensure the engine is securely

mounted.

• Ensure that there is a generous

supply of cooling and combustion air available.

• Keep the engine and surrounding

area clean.

• Some accessories may require

guards which must be supplied and

ﬁ tted by the purchaser. Keep all safety

guards in position.

• Do not make any unauthorised modiﬁ cations as these may affect the

safe operation of the engine and put the operator at risk.

1.2 PERSONAL SAFETY

• Wear personal protective clothing

and safety equipment appropriate to the work being done.

• Keep clear of moving parts at all

times.

1. SAFETY INFORMATION

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

1. Safety Symbols This  gure identi es the ISO 8999 symbols currently used by Lister Petter

WARNING

KEEP THE BODY AND CLOTHING CLEAR OF MOVING OR HOT PARTS AT ALL TIMES. CONTACT OF MOVING PARTS WITH UNPROTECTED SKIN CAN CAUSE SEVERE BURNS. ENTANGLEMENT WITH ROTATING EQUIPMENT CAN CAUSE SERIOUS INJURY OR DEATH.

• Tie long hair back securely.

• Wear close-ﬁ tting clothing.

• Do not wear a necktie, scarf, loose

clothing or necklace when working close to a running engine.

• Where possible, remove rings and

other jewellery to prevent entanglement in moving parts. These items could also cause a short circuit if any part of the electrical system is being worked on.

WARNING

Prolonged exposure to loud noise can cause impairment, or loss, of hearing.

• Wear suitable ear protection against

objectionable or uncomfortable loud noise.

• To avoid loss of concentration, do

not use music or radio headphones while operating an engine.

• When undertaking maintenance, do

not work under any plant that is only held by overhead lifting equipment.

• Where appropriate, make sure that guards are properly ﬁ tted.

1.3 PRECAUTIONS WITH CHEMICALS

Protect yourself from exposure to hazardous chemicals at all times, as this can cause serious injury. Potentially hazardous chemicals include lubricants, fuel, coolant concentrate, battery acid, paint and adhesives. Manufacturers' safety data sheets will provide specific details of the physical and health hazards, safety and emerg ency proce d ures and

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

any necessary personal protection equipment required while working with hazardous materials.

• Handle fluids with care at all

times.

• Rectify any fuel, coolant or oil leak

as soon as is practicable and clean up any spillages when they occur.

• Remove any build-up of grease, oil

or debris.

• If any ﬂ uid other than lubricating

oil comes into contact with the skin, clean off immediately. In the case of lubricating oil, clean off as soon as is practicable.

Fuel and High Pressure Fluids

• Store fuel and other flammable liquids away from ﬁ re hazards.

• Always stop the engine before

refuelling.

• Do not overﬁ ll the fuel tank.

• When working with fuel do not

smoke or work near to heaters or other

ﬁ re hazards.

• High pressure ﬂ uids are extremely

hazardous. Never allow any part of the body to come into contact with highpressure fuel oil, compressed air or hydraulic oil, for example when testing fuel injection equipment.

WARNING

D o n o t e x p o s e p r e s s u r i s e d containers to heat, and do not incinerate or puncture them.

WARNING

NEVER TOUCH OR INGEST HIGHPRESSURE FLUIDS SUCH AS HYDRAULIC OIL, COMPRESSED AIR OR FUEL OIL. THIS COULD LEAD TO SERIOUS INJURY, OR DEATH.

1.4 FUEL SYSTEM PRECAUTIONS

WARNING

NEVER ALLOW ANY UNPROTECTED SKIN TO COME INTO CONTACT WITH THE INJECTOR SPRAY AS FUEL MAY ENTER THE BLOODSTREAM WITH FATAL RESULTS.

WARNING

N e v er m a k e u n a u th o r i s e d adjustments to the emissioncompliant fuel injection pumps. This could be da n gerous and invalidates warranty claims. In the USA unauthorised adjustment of emission critical components is prohibited by Federal Law, incurring civil penalty.

• When priming or checking the fuel

injection pump timing, care must be taken to wipe any spilled fuel from the outside of the engine.

• Always ﬁ t a new joint when a union

has been disturbed.

• Special care must be taken to

see that there is no leakage from the joints of the fuel pipe connection to the pump.

• When tightening or loosening fuel

injection pump delivery connections use two spanners to prevent unsealing of fuel pump delivery valve holders.

• When reﬁ tting the fuel pipe from the

pump to the injector, the connection to the injector must be tightened before the connection to the fuel pump. This procedure will ensure that there is no leakage from these joints.

• It is most important that all fuel

joints are tight and leak proof.

• Always ﬁ ll the fuel tank through a ﬁ ne strainer. It is best to do this at

the end of the engine work period so

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

that any sediment stirred up has time to settle before the engine is used again, and the risk of condensation contaminating the fuel is minimised. If using a can, avoid tipping out the last few drops.

• Funnels are very difﬁ cult to keep

clean in dusty conditions. Wash them before and after use and wrap them up

when not required, or ﬁ ll the tank direct

from a small-mouthed screw-capped can.

• The fuel injection equipment is

manufactured to very accurate limits and the smallest particle of dirt will

destroy its efﬁ ciency.

CAUTION

Keep the fuel free from water and contaminants.

1.5 PRECAUTIONS WITH FILTERS AND ELEMENTS

• Used ﬁ lters and elements contain some of the ﬁ ltered liquid and should be

handled and disposed of with care.

• After handling new or used elements,

wash your hands thoroughly.

WARNING

Do not allow fuel or new or used lubricating oil to come into contact with unprotected skin. It is dangerous and could cause skin irritation.

WARNING

Take careful precautions with ﬁ lters

and elements. The materials used in the manufacture and treatment of some types may cause irritation or discomfort if they come into contact with the eyes or mouth, and they may give off toxic gases if burnt.

1.6 PRECAUTIONS WITH OIL SEALS

Some engines may be ﬁ tted with seals

or 'O' rings manufactured from Viton or a similar material. When these substances are exposed to abnormally high temperatures, in excess of 400°C (752°F), an extremely corrosive acid is produced.

WARNING

IF AN OI L SEAL CONTAINING VITON (OR SIMILAR MATERIAL) DEGENERATE S, IT PRODUCES AN EXTREMELY CORROSIVE ACID THAT CANNOT BE REMOVED FROM THE SKIN. IF YOU S EE SIG NS OF DEC OMPOS ITION, OR A RE IN DOUBT, WEAR DISPOSABLE HEAVY DUTY GLOVES.

• If in any doubt about an oil seal,

always wear disposable heavy duty gloves.

1.7 PRECAUTIONS WITH BATTERIES

Batteries contain hazardous sulphuric acid. Great care therefore needs to be taken when using them.

• Do not smoke near batteries and keep sparks and ﬂ ames away from

them. Do not work near to heaters or

other ﬁ re hazards.

• Switch off the battery charger

before connecting or disconnecting the charger leads. Disconnect the

battery negative (earth) lead ﬁ rst and

reconnect last.

• Keep the top of the battery well

ventilated during charging.

• Never 'ﬂ ash' connections.

• Never use a damaged battery.

• Do not attempt to charge a frozen

battery; it may explode. Instead, warm the battery to 16°C (60°F).

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

WARNING

Take especial care with batteries, which contain highly corrosive sulphuric acid which is poisonous, will burn skin and clothing, and will cause permanent damage including blindness if splashed into the eyes. If acid accidentally comes into contact

with skin, eyes or clothes, ﬂ ush it

away with copious amounts of fresh water and seek medical aid.

1.8 PRECAUTIONS WITH ELECTRICAL SYSTEMS

• Ensure that the battery is of sufﬁ cient

capacity to start the engine down to its minimum operating temperature, taking into account any drag that may be imposed on the engine by the type of trans mission that is attached to it.

• Ensure that the battery and all engine wiring cables are of sufﬁ cient

size to carry the currents required.

• Check that the engine-mounted alternator is of sufﬁ cient output to cope

with the total electrical load required by

the machine to which it is ﬁ tted.

Wiring Cables

Ensure that the engine wiring cables are:

• Bound together in a loom and

adequately supported.

• Routed to avoid any hot surfaces,

particularly the exhaust system.

• Not in contact with any rough

surfaces or sharp corners so as to avoid

any possibility of chaﬁ ng taking place.

Alternator

The following points must be strictly

observed when an alternator is ﬁ tted,

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.

• Nev er disc onnect the b atter y

unless the engine has stopped and all switches are in the off position.

• Always ensure that cables are ﬁ tted

to their correct terminals.

CAUTION

A short circuit or reversal of polarity will ruin diodes and transistors.

• Never 'flash' any connection to check the current ﬂ ow.

• Ne v e r e x p e r i m e n t w i t h a n y

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.

1.9 WASTE DISPOSAL PRECAUTIONS

• Extr e me ca re mu st be taken

to ensure that waste oil, fuel, filter elements, coolant concentrate, battery electrolyte, solvents or other toxic wastes are disposed of in accordance with l ocal regulati ons to prevent contamination.

WARNING

To avoid contamination and personal injury, never dispose of toxic or other waste except in accordance

with ofﬁ cial regulations.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

1.10 PRECAUTIONS BEFORE STARTING

WARNING

Starting any diesel engine can be d anger ous in t he hands of inexpe r i enced pe o ple. Eng i ne operators must be instructed in the co rrect procedures bef ore attempting to start any engine.

• Ensure that the engine is free to

turn without obstruction.

• Check that the lubricating oil level is correct. The oil sump must be ﬁ lled

to the ‘full’ mark on the dipstick; do not

overﬁ ll.

• Check that the radiator is ﬁ lled to

within 13-25 mm (0.5-1.0 in) below the

neck of the radiator ﬁ ller.

• Check that the fuel sup ply is

adequate and the system is primed.

• Ensure that the battery is connected,

fully charged and serviceable.

• Where possible, disengage the

driven equipment while starting.

1.11 LIFTING PRECAUTIONS

Engine lifting eyes are ﬁ tted to Alpha

and New Alpha engines. The following points must be considered before attempting to lift the engine.

• Ensure any lifting equipment to be

used has the correct capacity to lift the engine.

• Ensure that the lifting equipment

is designed to give a vertical lift from directly above the engine lifting eye.

• Check that the engine lifting eyes

are not damaged and that they are secure.

• The engine lifting eyes are suitable

for lifting the engine and accessory

assemblies originally ﬁ tted by Lister

Petter.

WARNING

Engine lifting eyes must not be used to lift the complete plant.

WARNING

DO NOT WORK UNDER ANY PLANT THAT IS ONLY HELD BY OVERHEAD LIFTING EQUIPMENT.

1.12 PRECAUTIONS BEFORE MAINTENANCE

• Understand the service procedures

before commencing any work.

• Ensure all starting devices are

removed or isolated before beginning any work on engine or plant.

• Ensure the work area is clean,

dry, well ventilated and has adequate lighting.

• Ensure that all persons using

equipment or processes in connection with the maintenance of plant and mach inery have received adequate and suitable training.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

Table 2 gives technical data for all the engines in the Lister Petter Alpha (LPW, LPWX) and New Alpha (LPWS) range.

2.1 COMBUSTION AIR

Engine performance is affected by ambient temperature, which is taken to mean the temperature of the air entering the engine. The temperature of the combustion air is measured at the air inlet manifold, or the air cleaner, and the temperature of the cooling air is measured at the radiator fan inlet. The higher of these two temperatures is taken as being ambient temperature as far as engine ratings are concerned. Ever y effort should be taken to ensure that the air cleaner draws in combustion air at a consistent ambient

2. TECHNICAL DATA

temperature. Lister Petter LPW, LPWX, LPWT, LPWS and LPWST engines are able to run satisfactorily at ambient temperatures up to the standard engine reference condition of 25°C (77°F) without derating. If the combustion air tempe ratu re rises above this temperature, the rated power must be reduced in accordance with the relevant standard: LPW/LPWX/LPWT ISO 3046 LPWS ISO 14396 Generating Sets ISO 8528 The maximum permitted ambient temperature is 52°C (125°F).

2.2 THE COOLING SYSTEM

Cooling is by a radiator with water circulation being assisted by an engine mounted, centrifugal, belt driven water pump using a single belt.

TECHNICAL DATA

LPW series model LPW(X)2, LPW(X)3, LPW(X)4 LPW(S)T4 LPWS2, LPWS3, LPWS4

Rotation Anti clockwise (when looking on the ﬂ ywheel)

Type of injection Direct Indirect

Firing order:

2 cylinders 1 - 2 n/a 1 - 2

3 cylinders 1 - 2 - 3 n/a 1 - 2 - 3

4 cylinders 1 - 3 - 4 - 2 1 - 3 - 4 - 2 1 - 3 - 4 - 2

Electrical system 12V negative earth

Starter battery charging 12V engine mounted alternator

Oil pressure

at idle 1.0 bar (14.5 lbf in

)

3000

r/min

2.0 bar

(29.0 lbf in2)

2.5 bar

(36.3 lbf in2)

2.0 bar

(29.0 lbf in2)

Oil sump capacity Refer to table 5.6.3a: Sump Capacity (page 19).

Coolant capacity Refer to table 5.5: Engine Block Coolant Capacity (page 18).

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

The following information is of a general nature and should be read in conjunction with the manufacturers' instructions for any other equipment you are using.

WARNING

Do not attempt to start or operate a diesel engine unless you have been properly trained. Read the safety information in section 1 and the information below on controls and the starting procedures.

CAUTION

DO NOT US E ET H E R B AS E D COLD START AIDS UNDER ANY CIRCUMSTANCES.

WARNING

D O N O T B R E ATH E X H A U S T GASES. THEY CONTAIN CARBON MONO X I D E , A COLOU R L E S S, ODOUR L E S S G AS T H AT CAN CAUSE UNCONSCIOUSNESS AND DEATH.

CAUTION

On LPWT4 engines, ensure that the turbocharger housing is full of oil. Failure to do so can result in serious damage to the bearing. Run on 'no load' after starting for 30 seconds, to ensure an adequate oil supply to the turbocharger, and for 30 seconds before stopping to allow the heat from the bearing to dissipate.

3.1 GENERAL INFORMATION

Start/Stop Control

The basic engine has a plastic knob fitted to the control. Other variants for automatic or remote operation are available.

3. STARTING AND STOPPING

Engines not ﬁ tted with a fuel control

sole noid have a spring clip to hold the engine control in the stop position.

WARNING

Use suitable hand protection when stopping the engine, as the stop control may be hot after prolonged running.

Oil Pressure Switch

If an oil pressure switch bypass button

is ﬁ tted it must be depressed during

engine cranking, and until the engine attains full speed.

Heater and Glow Plugs

LPW, LPWX: a 345 W heater plug (A)

may be ﬁ tted to the inlet manifold.

LPWT4: a 696 W heater plug (A) is

ﬁ tted in the inlet manifold. LPWS: a 12v glow plug (B) is ﬁ tted in

each cylinder and a 696 W heater plug

(A) is also ﬁ tted in the inlet manifold as

standard.

3.1 Heater and glow plugs - A. Manifold heater plug; B. Cylinder glow plug.

3.2 KEY START

Before starting your engine read the cautions, warnings and the general information above.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

3.2.1 Start control

Starting LPW(X)2, LPW (X) 3 and LPW (X) 4

1. With reference to Figure 3.2.1, move the engine control lever (A) clockwise until it is against the stop screw (B).

2. On variable speed engines move the speed control to the fast position.

3. Turn the key clockwise to the START posi tion. Immediately the engine starts the key must be turned anti clockwise to the RUN position.

4. On variable speed engines reduce the engine speed as necessary.

3.2.2 Key start

Starting LPWS2, LPWS3, LPWS4

1. With reference to ﬁ gure 3.2.1, move

the engine control lever (A) clockwise until it is against the stop screw (B).

2. On variable speed engines move the speed control to the fast position.

3. For ambient starting temperatures above -10°C (14°F) turn the key

clockwise and hold it in the PREHEAT position for 5 to 10 seconds before turning it to the START position.

For ambient starting temperatures

below -10°C (14°F) turn the key clockwise to the PREHEAT position for 15 to 20 seconds before turning the key to the START position.

Immediately the engine starts the key

must be turned anti clockwise to the RUN position.

4. On variable speed engines reduce the engine speed as necessary.

Starting LPWT4

1. With reference to ﬁ gure 3.2.1, move

the engine control lever (A) clockwise until it is against the stop screw (B).

2. On variable speed engines move the speed control to the fast position.

3. For ambient starting temperatures above -10°C (14°F) turn the key clockwise and hold it in the preheat position for 10 to 15 seconds before turning it to the start position.

For ambient starting temperatures

below -10°C (14°F) turn the key clockwise to the preheat position for 15 to 20 seconds before turning the key to the start position.

Immediately the engine starts the key

must be turned anti clockwise and held in the preheat position until the engine has attained full speed.

4. When the engine has attained full speed turn the key anti clockwise to the run position.

5. On variable speed engines reduce the engine speed as necessary.

3.3 FAILURE TO START

Should the engine fail to start within 30 seconds, release the key and, after

allowing sufﬁ cient time for all moving

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

parts to stop, attempt to restart.

3.4 STOPPING (ALL ENGINES)

CAUTION

It is recommended that LPWT4 engines run on 'no load' for 30 seconds before stopping to allow the heat from the turbocharger bearing to dissipate.

1. If possible, remove the load from the engine.

2. If a variable speed control is ﬁ tted

reduce the engine speed.

3. On engines ﬁ tted with a fuel control

solenoid turn the key to the OFF position.

On engines not fitted with a fuel

control solenoid move the engine control lever anti clockwise into the

STOP position (ﬁ gure 3.4) and turn the key to the OFF position.

CAUTION

Turning the key to the off position alone will not stop the engine unless

a fuel control solenoid is ﬁ tted.

3.4 Stop control

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

4.1 FUEL SPECIFICATION

The engine must be used only with diesel fuel oil that conforms to one of the following:

• BS 2869:1988 Class A2;

• BS EN590:1995 Class A1;

• USA Speciﬁ cation ASTM D-975-77

Grades 1-D and 2-D;

• BSMA 100 Class M1 for marine use.

The fuel must be a distillate and not a residual oil or blend. Vaporising oils are not suitable as fuels for Lister Petter engines.

4.1.1 LPWS Bio

LPWS Bio is a specially developed engine range that will run on B100 (100% biofuel) as well as on those fuels

speciﬁ ed above.

CAUTION

Although the engines may operate o n f u e l s o u t s i d e t h e a b o v e

speciﬁ cations, such operation may

result in excessive wear and damage.

CAUTION

It is of the utmost importance to keep fuel free from water and other contaminants. The fuel injection equipment is manufactured to very accurate limits, and the smallest particle of d irt will destroy its

efﬁ ciency.

4.2 OIL SPECIFICATION

To assist running-in, all engines are

despatched with an initial ﬁ ll lubricating

oil which must be changed, with the

ﬁ lter, after the ﬁ rst 100 hours.

All subsequent oil changes must be as

speciﬁ ed in 5. Routine Maintenance.

• The temperatures cited in Figure

4.3 are the ambient temperatures at

the time when the engine is started (see 2.2 Combustion Air). If monograde oils are used and running ambient

temperatures are signiﬁ cantly higher

than starting temperatures, a higher viscosity oil should be selected, subject to satisfactory starting performance. Multi grade oils may be us ed to overcome the problem.

• Wher e ambient te mperat ures

are variable and it is not practical to continually change oils accordingly, a suitable multigrade oil is recommended to ensure adequate starting performance at the lowest temperature likely to be encountered.

• The engines must be run on heavy-

duty lubricating oils. Straight mineral oils are not suitable, neither are oils of

less detergency than speciﬁ ed.

• API CF-4, API CG-4, API CH or API

CI oils must be used in all engines.

• For engines in long-running

installations Lister Petter should be consulted.

Oil Viscosity

Figure 4.3 shows the recommended oil viscosity ranges for various °C ambient temperatures from cold start to maximum running. Non - s y nth e t ic o ils a t v e ry l ow temperatures will suffer from wax crystallisation, so synthetic oils are recommended for these conditions. SAE 5W-20 oils are recommended on the basis that they are fully synthetic and are technically suitable for use up to 25°C (77°F). (Monograde SAE 5W is not normally available as a synthetic oil therefore does not appear in the chart). SAE 30 and 10W-30 oils may be used at up to 52°C (126°F), but oil consumption may be affected. 10W-40, 15W-40 and

4. ENGINE FLUIDS

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

4.2 Recommended oil viscosity grades for different temperature ranges.

Note A: intermittent running; Note B: synthetic oils only. NB. The formula for conversion

from degrees Fahrenheit to degrees Centigrade is°F = (1.8 x °C) + 32.

20W-40 multi grades are recommended for continuous full-load operation at this temperature. (Monograde SAE 40 oils are not recommended.) In order to maintain the cold-starting characteristics of any recommended grade it is essential that oil changes are made within the Lister Petter recommendations (see 5. Routine Maintenance). An oi l change is recommende d immediately if the engine fails to reach its normal cold start cranking speed owing to excessive oil viscosity.

CAUTION

Dilution of the lubricating oil with fuel will adversely affect cold starting and will increase oil consumption.

4.3 COOLANT * MIXTURE

CONCENTRATION

To determine the amount of coolant

concentrate to be added, ﬁ rst calculate

the total coolant capacity by adding together the engine and radiator volumes (see 5.5.4 Coolant Capacity).

4.3.1

For engines with aluminium core radiator: Do not use tap water, the minerals and ions typi c a l l y f o u n d in tap water can be corrosive to internal e n g i n e c o m p o n e n t s i n c l u d i n g radiators, and can cause a more rapid depletion of the anti-corrosion additives found in most antifreeze. A 50% conc entrati o n of cool a nt additives by volume must be maintained under all operating conditions. If a component fails due to an incorrect coolant concentration being used it will not be covered by the LP warranty. When topping up coolant please ensure that the “top up” is of the correct concentrate mix and not just water. The spe cification of the cool ant concentrate should comply with one of the following: BS6580 : 1985; MIL-A-11755D; MIL-A-46153/B.

* Coolant de ned as the combination of water, corrosion inhibitor and antifreeze

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

• Do you know and understand the

engine and all the related systems?

• Do you have sufﬁ cient electrical

and mechanical knowledge and skills to understand the symptoms?

• Do you have suitable electrical

diagnostic equipment available?

• Do you have, or have access to, the

necessary Lister Petter spare parts?

5.2 IMPORTANT INSTRUCTIONS

• Remove the battery before carrying

out any maintenance work on an engine.

• Dis c o nn e c t t he ba t t er y an d

alternator before commencing any electric welding when a pole strap is directly or indirectly connected to the engine.

• Fuel pumps and injectors can only

be checked and set off the engine using suitable specialist test equipment.

5.3 MAINTENANCE SCHEDULE

The table on page 17 sets out the frequency with which maintenance and servicing tasks should be performed. This is t h e minimum fr e q u e n cy required to keep your engine running at peak performance with trouble-free operation. The instructions are based on average operating conditions. Air cleaners,

lubricating oil and fuel ﬁ lters will require

more frequent attention if conditions are very dusty. De carbonising may be required more often if the engine has been running on light loads for long periods.

5. ROUTINE MAINTENANCE

This section is designed primarily for use by trained technicians but it does contain sufficient information, illustrations and detail to allow the operator to perform basic maintenance work.

WARNING

Rout ine mainten ance must be

performed by qualiﬁ ed personnel

who ar e c o n versa n t w i t h the hazards of oil, fuel, electricity and machinery.

This work can be carried out only if the necessary hand and service tools are available. When the user has

insufﬁ cient tools, experience or ability

to carry out adjustments, maintenance and repairs this work should not be attempted. Where accurate measurements or torque values are required they can only be made using calibrated instruments.

CAUTION

Under no circumstances should makeshift tools or equipment be used, as their use may adversely affect safe working procedures and engine operation.

T h e s e r e c o m m e n d a t i o n s a n d instructions cover several engine models, therefore they are of a general nature. The engine may include optional

equipment not speciﬁ cally covered in

this book.

5.1 BEFORE STARTING

Before starti n g any dismant l i ng procedure read 1. Safety Information and Pre cau tions. Consider t h e following:

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

1. See also Table 1 above. 2. Inspect more frequently if fuel is contaminated. Inspect regularly

on engines in low duty cycle applications, for example, stand-by generating sets.

How to Service your Engine

Instructions are given in the remaining sections of this chapter.

After Servicing

• It is essential to ensure that nuts

and bolts are tightened to the torques

speciﬁ ed in the Workshop Manual.

• When re-assembling an engine

lubricate all moving parts with engine oil.

• Renew nuts and bolts that have

been taken from high-stress locations. In particular nuts and/or bolts from the connecting rods should be renewed.

CAUTION

Long periods of light or ‘no load’ running early in the engine’s life may lead to cylinder bore glazing and high oil consumption.

MAINTENANCE SCHEDULE

At all times

Continuously monitor engine performance.

Observe the correct oil and ﬁ lter change periods as speciﬁ ed below.

1. Oil and Filter Change Periods (hours)

Ambient

temperature

LPWS(T) LPWT LPW(X)

Every

Above 35 C (95 F) 125 hrs 125 hrs 250 hrs

Up to 35 C (95 F) 250 hrs 250 hrs 500 hrs

Every Day

Check the level and condition of lubricating oil. Check the coolant level. Check the level and supply of fuel. Examine the cooling fan for damage. Clean the air cleaner if the engine is operating

under very dusty conditions.

After the ﬁ rst 100 hours

Marine propulsion engines: check idling speed and reset if necessary.

Change the initial ﬁ ll lubricating oil

Renew the oil ﬁ lter.

Every 125 hours

Do all the above, and the following: Clean the air cleaner if the engine is operating

under moderately dusty conditions. Check for fuel, coolant and oil leaks. Check the serviceability of the battery.

Every 250 hours

Do all the above, and the following: Check the condition and tension of the radiator

drive belt.

Check the radiator ﬁ ns for contamination or

blockage. Clean the fuel injector nozzles if exhaust is dirty.

Renew the fuel ﬁ lter element if the fuel is not

perfectly clean.

Every 500 hours

Do all the above, and the following:

Renew the fuel ﬁ lter element.

Renew the air cleaner element. Check the air induction systems for leaks, damage

and restrictions. Change the lubricating oil

Renew the oil ﬁ lter

LPWT4: Clean the crankcase breather canister and hoses.

Every 1000 hours

Do all the above, and the following: Check all external nuts, bolts and unions for

tightness.

Ensure that all guards are ﬁ rmly attached and are

not damaged. Replace the fuel-lift pump diaphragm.

Every 2000 hours

Do all the above, and the following: Drain and clean the engine-mounted fuel tank, if

ﬁ tted.

Check the engine and speed controls for free movement.

Clean and check, and if necessary replace, the fuel injector nozzles.

Check the radiator ﬁ ns and radiator fan blades for

damage.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

MAINTENANCE SCHEDULE

Replace the radiator fan drive belt, irrespective of its condition.

Check the lubricating oil pressure. Renew the air cleaner element.

Every year

Drain, ﬂ ush and reﬁ ll the cooling system, adding

new coolant concentrate to a 50% concentration.

If your engine is ﬁ tted with an aluminium radiator you are advised to Drain, ﬂ ush and reﬁ ll the cooling

system with de-ionized or distilled water, adding new coolant concentrate to a 50% concentration. See 4.3.1.

Drain and replace the lubricating oil and ﬁ lter,

irrespective of their condition, if the engine has run for less than 250 hours in the preceding twelve months.

On marine engines, change the air cleaner element, if it was not changed at the prescribed intervals.

Every two years

Replace the coolant hoses, irrespective of their condition.

When necessary

Undertake a decake/major overhaul.

5.4 DRIVE BELT

The tension of the drive belt (see ﬁ gure

5.4) must be checked:

1. After the ﬁ rst 50 hours;

2. Every 250 hours;

3. After an overhaul when the belt is

reﬁ tted or replaced.

4. The drive belt must be replaced every 2000 hours, irrespective of its condition.

When a new belt is correctly ﬁ tted and

tensioned, a force (F) of 31.0 -33.5 N

(7.0-7.5 lbf) is required to deﬂ ect it a

distance (d) of 3.5mm (0.14in). O n s u b s e q u e n t ch e c k i n g a n d adjustment a force (F) of 22.0-24.0N

(5.0-5.4lbf) is required to deﬂ ect it a

distance (d) of 3.5mm (0.14 in).

5.4 Checking drive belt tension.

F denotes force and d denotes distance.

5.5 COOLING SYSTEM

Draining the Cooling System

WARNING

The cooling system is pressurised and extreme care must be taken when removing the radiator cap if the engine is hot.

1. Place a suitable container under the radiator bottom hose if the coolant is to be retained.

2. Slacken the clips of the hose and slide the hose off.

3. Remove the radiator ﬁ ller cap.

4. Allow sufﬁ cient time for the system

to drain.

Flushing the Cooling System

1. With the bottom hose removed,

ﬂ ush the radiator through the ﬁ ller

with clean fresh water, preferably using a hose pipe, until clean water emerges.

2. With the top and bottom hoses removed from the engine, flush the engine through the top hose with clean fresh water, preferably using a hose pipe, until clean water emerges.

3. Replace the hoses.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

For these reasons it is advisable to ascertain the radiator capacity which must then be added to that given in the table above under Engine Block before determining the amount of coolant concentrate to be added to maintain a 50% concentration. The capacity of hoses on remote radiator applications must also be taken into consideration.

5.6 LUBRICATING OIL

Check the lubricating oil daily using the dipstick, and top up when necessary with oil of the corre c t ty p e and specification (see section 4.2 Oil Speci cation). Table 5.6.3 gives the capacity between the dipstick marks of all engines in the LPW range.

Table 5.6.1.

CAPACITY BETWEEN DIPSTICK

MARKS

LPW2 LPWX2 LPWS2

LPW3 LPWX3 LPWS3

LPW4 LPWX4 LPWT4

LPWS(T)4

All builds except 28, 51, 52, 57, 58, 59

litres 0.90 0.95 1.20

pints 1.58 1.67 2.11

US gallons 0.24 0.25 0.32

Builds 28, 51, 52, 57, 58, 59

litres 1.50 1.75 2.20

pints 2.64 3.08 3,87

US gallons 0.39 0.46 0.58

Change the lubricating oil and ﬁ lter for the ﬁ rst time at 100 hours and then as speciﬁ ed in 5.3. Maintenance Schedule

(Table 1).

Filling the Cooling System

CAUTION

Under some circumstances an air lock can occur when filling the system, causing a false level indication.

1. Ensure the hoses have been replaced.

2. Reﬁ ll the system with clean fresh

water and coolant concentrate to a 50% concentration while bleeding air from the system at a suitable point. If your engine is fitted with an aluminium radiator you are advised to D r a in, f l ush a nd r e f ill t he cooling system with de-ionized or distilled water, adding new coolant concentrate to a 50% concentration.

The radiator should be ﬁ lled to within

13.0-25.0mm (0.5-1.0 in) below the

neck of the radiator ﬁ ller.

3. Run the engine for a short time and check the coolant level.

Coolant Capacity: Engine Block

Table 5.5.

ENGINE BLOCK COOLANT

CAPACITY

LPW2 LPWX2 LPWS2

LPW3 LPWX3 LPWS3

LPW4 LPWX4 LPWT4

LPWS(T)4

litres 2.1 2.5 3.0

pints 3.7 4.4 5.3

US gallons 0.55 0.66 0.79

Coolant Capacity: Radiator

Ther e are a number of radia t or options available for LPW, LPWX, LPWT and LPWS engines, including some which may not have been ori ginally fitted by Lister Pe tter.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

5.6.1. The oil  ller (A) and dipstick handle

1. Ensure the new oil meets the correct

speciﬁ cation and viscosity, as given

in 4.2 Oil Speci cation.

2. Fill the sump through the oil ﬁ ller (A)

to the upper mark on the dipstick.

3. Start the engine and run it for a few minutes to circulate the oil.

4. Stop the engine and allow time for the oil to drain down. Check the level on the dipstick.

5. Add more oil if necessary.

CAUTION

Do not overﬁ ll with oil. If a cylinderhead oil ﬁ ller is ﬁ tted the oil must only be poured into the ﬁ ller at a

rate which enables it to drain into the crankcase. If the oil is poured in too

quickly it can ﬂ ood the crankcase

breather holes and escape into the inlet manifold and cylinders.

Changing the Oil Filter

The full ﬂ ow ﬁ lter is a spin-on cartridge

type located on the crankcase door.

Only approved ﬁ lters should be used,

as these have high te mperature

resistant joints, adequate ﬁ lter paper

characteristics and a rigid case. Other filters may have the same external dimensions and thread as the genuine one but may fail in service. Before ch a n g i ng the fil t e r read

1.5 Precautions with Filte rs a nd

Elements.

CAUTION

Continuous operation under heavy loads in ambient temperatures above 35°C (95°F) causes the oil to deteriorate more quickly.

Draining the Oil Sump

Before draining the oil read 1 .5 Precautions with Filters and Elements

and 1.6 Precautions with Oil Seals. The oil sump drain plugs are located

on the oil ﬁ lter side and the gear end of

the crankcase. It is better if the engine has been run immediately before draining, as the warm oil will drain more quickly.

1. Remove the oil ﬁ ller cap.

2. Remove the drain plug and allow the oil to run into a suitable retainer.

3. Clean the drain plug threads and coat them with Hylomar PL32/M, Loctite 572 or Hylogrip 760.

4. Replace the plug and tighten it.

Reﬁ lling the Oil Sump

Table 5.6.3 gives the sump capacity

(excluding the ﬁ lter) of all engines in

the LPW range.

Table 5.6.3

SUMP CAPACITY

(Figures exclude the ﬁ lter)

LPW2 LPWX2 LPWS2

LPW3 LPWX3 LPWS3

LPW4 LPWX4 LPWT4

LPWS(T)4

All builds except 28, 51, 52, 57, 58, 59

litres 3.00 3.75 5.50

pints 5.28 6.60 9.68

US gallons 0.79 0.99 1.45

Builds 28, 51, 52, 57, 58, 59

litres 5.85 8.25 11.5

pints 10.29 14.52 20.23

US gallons 1.55 2.18 3.03

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

1. Use a band-type gripping tool to

remove the ﬁ lter from the engine.

2. Lightly grease or oil the face of the

rubber joint on the new ﬁ lter.

3. Screw the ne w filte r onto the crankcase filter adaptor, or filter mounting bracket facing, until the rubber joint just makes contact with the crankcase facing of mounting bracket.

4. Screw the ﬁ lter on a further quarter

to half a turn.

5. Start the engine and run it for a few minutes to circulate the oil.

6. Stop the engine and allow time for the oil to drain down and check the level on the dipstick.

7. Add more oil if necessary.

5.7 FUEL SYSTEM

Priming the Fuel System

1. Ensure there is sufﬁ cient fuel.

2. Figure 5.7.1 shows the two types of

ﬁ lter. Release the bleed screws (A) on the ﬁ lter and re-tighten when no

further air bubbles are expelled.

3. On variable speed engines move the speed control to the fast position.

4. Move the engine stop/run control from the stop to the run position

(ﬁ gure 3.3.2, page 13).

5. Operate the fuel-lift pump by hand.

5.7.1 Priming the fuel  lter: the bleed

screws are denoted by A.

Changing the Agglomerator

Before starting, read 1.5 Precautions with Filters and Elements and study

ﬁ gure 5.7.2.

1. Before removing the agglomerator cartridge (A) from the agglomerator

head (B) you should ﬁ rst drain the

water from the agglomer ator by unscrewing the drain tap (C).

2. Using a suitable strap wrench, unscrew the cartridge (A) from the head (B).

5.7.2. The agglomerator: cartridge (A); head (B); drain tap (C).

3. Screw a new cartridge onto the head and hand tighten it.

Changing the Fuel Filter

The element should be renewed every 500 hours, or more frequently if for any reason the fuel is known to be dirty. Before ch a n g i ng the filt e r read

1.5 Precaution s with Filte rs a nd

Elements.

1. Isolate the fuel supply or drain the tank.

2. Unscrew the centre bolt (A) of the

ﬁ lter assembly.

3. Discard the old element (B) and ﬁ t a

replacement.

4. Fill the fuel tank and prime the system (see 5.7.1 Priming the Fuel System).

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

5. Run the engine and check to see that

no fuel is leaking from the ﬁ lter.

5.7.3 Changing the fuel  lter. The centre bolt

is denoted by A and the old element by B

5.8 AIR CLEANER

Ever y effort should be taken to ensure that the air cleaner draws in combustion air at the prevailing ambient temperature. Any increase in combu s t ion air temperature above the standard engine reference condition of 25°C (77°F) will incur an engine derate factor.

Light Duty Air Cleaner

The snout is normally fitted lying horizontally and pointing towards the gear end, although the cleaner itself can be rotated through 360°.

1. Release the three cover clips (A).

2. Lift off the cover (B).

3. Lift out the element (C).

4. Fit a new element.

5. Replace the cover and clips.

5.8.1 The light duty air cleaner

Cyclonic Air Cleaner

A cyclonic air cleaner can be remote

or engine-mounted over the ﬂ ywheel

housing. In either case it is connected to the engine by a moulded rubber hose secured by jubilee clips.

1. Regularly remove the dust cap (A) and empty out all the dust.

2. Gain access to the paper element by undoing the two over-centre clips (B).

3. Remove the element.

4. Clean the element by directing a lowpressure compressed-air nozzle up and down the pleats from inside the element.

5. Inspect the element for damage by placing a suitable light source inside it. If the element is found to have any holes it must be replaced.

5.8.2 The cyclonic air cleaner

5.9 BATTERY

Check the battery as follows.

1. We a r p r o t e c t i v e g l o v e s a n d goggles.

2. Clean the top of the ﬁ ller-plug area.

3. Remove the ﬁ ller plugs and check

that the electrolyte level is 6.0-9.0 mm (0.25-0.37 in) above the tops of the separators.

4. If necessary, top up with distilled water. In cold weather distilled water should only be added immediately before running the engine.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

5. Replace and tighten the ﬁ ller plugs.

6. Check that the terminal connections are tight; petroleum jelly will help to protect them from corrosion.

CAUTION

BATTERIES CONTAIN SULPHURIC A C I D W H I C H C A N C A U S E SEVERE BURNS AND PRODUCE EX P L OS I VE G A S ES . I F A C I D IS SPLASHED ON THE SKIN, EYES OR CLOTHES FLUSH WITH COPIOUS AMOUNTS OF FRESH WATER AND SEEK IMMEDIATE MEDICAL AID.

5.10 LONG TERM ENGINE

STORAGE

If the engine is not required for a period of a few weeks it should be run on full load for approximately 45 minutes once a month If the engine will not be required for some months, prepare it for storage as follows.

CAUTION

As a direct result of combustion the lubricating oil may contain harmful acids and therefore it should not be left in the sump if it is known that the engine will not be used for extended periods.

1. Replace the fuel in the tank with a small supply of suitable inhibition

ﬂ uid.

2. Drain the lubricating oil from the

sump and reﬁ ll with new oil.

3. Run the engine for a period to circulate the oil through the system

and to ensure the inhibition ﬂ uid is

passed through the fuel pumps and injectors.

4. Stop the engine, drain the cooling system and drain the lubricating oil from the sump.

The crankshaft should not be turned

until the engine is again required for service.

The inhibition ﬂ uid should be left in

the fuel system.

5. Seal all openings on the engine with tape.

6. Remove the batteries and store them fully charged after coating the terminals with petroleum jelly.

7. Grease all external bright metal parts and the speed control linkage.

8. Tie labels on to the engine, clearly stating what steps have been taken to inhibit the engine during storage.

Returning the Engine to Service

Refer to the appropriate sections for the relevant detailed instructions necessary to complete this work.

1. Remove the tie-on labels and all the protective coverings from openings and apertures.

2. Check the drive belt for deterioration and correct tension.

Check to ensure that the drive-

belt pulley grooves are free from corrosion.

3. Fill the fuel tank.

4. Reﬁ ll the cooling system, adding new

coolant to a 40% concentration.

5. Reﬁ ll the oil sump with new oil of the correct speciﬁ cation and viscosity.

6. Remove the batteries from store and recharge them if necessary. Reconnect them to the engine.

Coat the terminals with petroleum jelly.

7. Start the engine and check for coolant, fuel and oil leaks before applying load.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

6. TROUBLESHOOTING

When an engine does not operate as

expected it can be difﬁ cult to diagnose

the cause. The table in this chapter suggests a number of possible causes of various problems, together with recommended solutions. The operator should check carefully which of these applies in a particular case. Many of the suggested solutions can be carried out by the operator, guided by section 5. Routine Maintenance. Where indicated1 you should seek assistance from an experienced engineer (who must refer to the Workshop Manual). The list is of a general nature as it covers the basic engine; your particular application may be different. Before starting any maintenance

procedure please read 1. Safety Information and Precautions, taking especial note of 1.8.

6.1 METHOD OF FAULT

DIAGNOSIS

1. Diagnose the problem by checking and eliminating the easiest causes

ﬁ rst. In the case of electrical problems always check the battery ﬁ rst.

2. Double check your observations.

3. Carry out the recommended solution, or request an engineer to do this.

A comprehensive list of problems and the methods of correction is given in the Workshop Manual. If you are in any doubt, contact your Lister Petter distributor.

TROUBLESHOOTING

Problem Cause Solution

Difﬁ culty

starting or

failure to start

Incorrect starting procedure. Refer to section 3.

Unsuitable lubricating oil or fuel. Refer to section 4.

No fuel in the tank or the ﬁ lter is choked.

Reﬁ ll the tank and prime the fuel system or

replace the ﬁ lter.

Air in the fuel system. Prime the fuel system.

Water or dirt in the fuel system. Drain, ﬂ ush, reﬁ ll and prime the fuel system.

Faulty injector or pump.

Replace the injector or pump or have it

serviced.

Discharged battery or poor battery

connections.

Recharge or replace the battery. Check the

terminals are tight.

Fuel control solenoid not energised.

Check the shutdown devices of the

electrical system.

Starter motor

does not

operate

Loose or corroded connections. Clean and tighten the connections.

Worn out battery. Replace the battery.

Faulty starter panel or connections.

Adjust the connections and/or replace the

panel.

Battery will not

charge

Loose or corroded connections. Clean and tighten the connections.

Worn-out battery. Replace the battery.

Loose alternator drive belt. Replace or re-tension the drive belt.

1. Requires an experienced engineer.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

TROUBLESHOOTING

Problem Cause Solution

Engine speed

unstable

Poor quality fuel. Drain, ﬂ ush, reﬁ ll and prime the fuel system.

Fuel system restriction. Replace fuel ﬁ lter.

Restriction in induction system. Replace air cleaner element.

Fault in fuel lift pump. Replace diaphragm and/or pump.

Overheating

Radiator fan belt too slack. Adjust belt tension.

Overload. Reduce the load.

Lubricating oil level too low. Reﬁ ll the sump.

Recirculation of exhaust gases or cooling air. Redesign exhaust and ventilation system.

Radiator cooling ﬁ ns blocked. Clean the ﬁ ns of all obstruction.

Low level of coolant. Check for leaks and reﬁ ll.

Cooling system obstructed. Drain, ﬂ ush and reﬁ ll the system.

Engine stops

Lack of fuel. Check the system.

Reﬁ ll the tank.

Air in the fuel system. Prime the fuel ﬁ lter.

Water in the fuel system. Drain, ﬂ ush, reﬁ ll and prime the fuel system.

Choked fuel ﬁ lter. Replace the ﬁ lter.

Choked air ﬁ lter. Dismantle and clean the cap and element.

Overload. Reduce the load.

Overheating. See Overheating section.

Loss of compression. Check the piston rings and the valves.

Loss of electrical supply to the fuel pump solenoid. Check the electrical feed.

Automatic shutdown, if protective devices are

ﬁ tted.

Investigate the cause and rectify.

Lack, or loss,

of power

Loss of compression. Check the piston rings and the valves.

Choked air ﬁ lter. Dismantle and clean the cap and element.

Poor quality fuel. Drain, ﬂ ush, reﬁ ll and prime the fuel system.

Choked exhaust system. Dismantle and clean.

Overload. Reduce the load.

Choked fuel ﬁ lter. Replace the ﬁ lter.

Worn engine. Give the engine a major overhaul.

Undercharging

Excessive electrical load from added

accessories.

Remove accessories or ﬁ t higher output

alternator.

Poor electrical connections to alternator or

battery.

Inspect, clean and rectify the cause.

Faulty battery. Test and recharge or replace.

Faulty alternator. Test and if necessary replace.

Overcharging Faulty alternator. Test and if necessary replace.

Battery

requires

excessive

amounts of

water

Battery case leaking. Clean surrounding area and replace the battery.

Defective battery. Test or replace the battery.

Battery charging rate is too high.

Check the alternator output and battery

charging system.

1. Requires an experienced engineer.

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

7. MAINTENANCE RECORD

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

Your Lister Pe t t e r engine must be properly maintained using the timings and procedures described i n t h i s m a n u a l . You m u s t b e familiar with the routine tasks set out in 5. Engine Servicing, and their correct frequency as described in

5.3 Maintenance Schedule. Details

of the maintenance work carried out

on the engine during the ﬁ rst 5000

hours, except the daily checks, must be recorded in the spaces allocated in this section: pages 29-33 for routine maintenance and pages 34-36 for records of non-routine maintenance.

7.1 ROUTINE MAINTENANCE

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

7.2 NON-ROUTINE MAINTENANCE

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

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

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

On receipt of your engine please fill in the section on page 38. This information will be required in the event of a claim under your two-year warranty, according to the conditions set out below.

8.1 STANDARD WARRANTY COVER

The standard warranty includes twoyear/5000-hour cover for all nonserviceable

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 8.3 Condi tions of Warran ty an d the limitations set out in 8.4 Limitations of Warranty.

8.2 EXTENDED WARRANTY COVER

In orde r to ext end the warrant y period beyond the initial two-year period you must register the engine with a Lister Petter dealer within 28 days of receipt. A list of dealers is available at www.lister-petter.co.uk. The extended warranty gives fiveyear/5000-hour cover, beginning on the date of delivery to the original retail purchaser, and is transferable. It includes the following:

Years 1 and 2: all non-serviceable

components, parts and labour. Year 3: core engine2, parts an d labour. Year 4: core engine, parts and labour. Year 5: core engine, parts only.

8.3 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 7. Maintenance Record. Servicing must be by approved dealers or competent engineers. The conditions of warranty are:

• The maintenance record must be

completed.

• Oils and other ﬂ uids must be to the speciﬁ cations/grades given in 4.

Engine Fluids or as instructed in the Workshop Manual.

• Only genuine Lister Petter service

parts must be used.

• When Li ster P etter par ts are

purchased from a dealer, this must be noted, with the dealer's stamp, in

7. 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

8. WARRANTY

Notes:

1. Serviceable items (unless defective) include, but are not limited to: air  lters, fuel  lters, oil  lters, 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 speci c legal rights; the purchaser may also have other

rights, which vary by country or state.

Continued

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

engineer, intended to be used on the warrantable Lister Petter engine.

• Evidence will be required of engine

hours run and should be entered in

7. 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 ﬁ tted, twelve hours per calendar day

will be used as a basis for the hours-run calculation.

• T h e in s t a l l a t i o n s h o u l d b e

in accordance with data supplied by the Lister P etter Applications Department.

• Long term light load and cold engine

running will invalidate the warranty.

8.4 LIMITATIONS OF WARRANTY

• The sel l e r d oe s no t ac c e p t

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

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

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

............................................................................................................................

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

Date Registered with Lister Petter: ........................................................................

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

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

or lubricants; lack of, or incorrect, maintenance; incorrect repair; improper storage; incorrect starting, stopping or operating procedures; the use of nonapproved parts; fair wear and tear; and serviceable items (see note 1).

8.5 PURCHASE AND REGISTRATION DETAILS OF YOUR ENGINE

Please ﬁ ll in the section below with your

purchase and registration details. This information will be required in the case of a claim under warranty.

8.6 REPAIRS UNDER WARRANTY

• Lister Petter must be contacted

and authorisation given before any warrantable work is commenced.

8.7 CONTACTING LISTER PETTER

Lister Petter Limited, Dursley GL11 4HS, England Telephone: +44 (0)1453 546732 Website: www.lister-petter.co.uk

LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK

9. INDEX

Agglomerator ................................. 24

Air cleaner - cyclonic ..................... 25

Air cleaner - light duty .................... 25

Battery ........................................... 25

Cooling system ......................... 13,21

Cooling System - ﬁ lling .................. 22

Cooling System - ﬂ ushing .............. 21

Drive belt tension ........................... 21

Fuel ﬁ lter element .......................... 24

Fuel system - priming .................... 24

Glow plug....................................... 14

Maintenance record ....................... 29

Oil ﬁ lter .......................................... 23

Oil pressure switch ........................ 14

Oil speciﬁ cation ............................. 17

Oil Sump - ﬁ lling ............................ 23

Other Publications ........................... 2

Priming the fuel system ................. 24

Publications ..................................... 2

Routine maintenance..................... 19

Safety precautions

Waste disposal ......................... 11

Safety symbols ................................ 8

Start/stop control ........................... 14

Stopping ........................................ 16

Storage .......................................... 26

Troubleshooting ............................. 27

Warranty deﬁ nitions ....................... 37

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

OPERATORS' HANDBOOK,

P027-08270, EDITION 4, APRIL 2014

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State

of California to cause cancer, birth defects, and other reproductive harm.

LISTER PETTER LIMITED

Long Street, Dursley, Gloucestershire, GL11 4HS, England

TEL: +44 (0)1453 544141; FAX: +44 (0)1453 546732

E-mail: sales@lister-petter.co.uk

www.lister-petter.co.uk

UAE

LISTER PETTER FZE

Dubai Silicon Oasis Headquarters,

PO Box 341077, Dubai, UAE,

TEL: +971 4 372 4331; FAX: +971 4 372 4318

E-mail: sales@listerpettergroup.com;

www.lister-petter.co.uk

Lister Petter LPW2, LPW3, LPW4, LPWT4, LPWX2 Operator's Handbook Manual

Specifications and Main Features

Frequently Asked Questions

User Manual