LISTER PETTER ALPHA Series LPA LPW LPWT LPWS LPWG Workshop Manual

LPA, LPW, LPWT, LPWS and LPWG Alpha Series Workshop Manual P027-08240

Alpha Series Workshop Manual

Alpha Series Workshop Manual Edition10: May 2003 Manual Contents page Introduction ........................................................................... 4 Section 01. General Information ........................................... 5 Section 02. Engine Servicing and Adjustments ................... 13 Section 03. Engine Fluids ................................................... 75 Section 04. The LPWG Gas and Electrical Systems .......... 79 Section 05. Operating Instructions ...................................... 85 Section 06. Marine Gearboxes ............................................ 91 Section 07. Routine Maintenance ....................................... 95 Section 08. Troubleshooting .............................................. 105 Section 09. Wiring Diagrams - industrial engines .............. 109 Section 10. Wiring Diagrams - marine engines ................. 119 Section 11. Wiring Diagrams - LPWG engines ................. 129 Section 12. Engine Build Details ....................................... 133 Section 13. Technical Data ................................................ 135 Section 14. Dismantle and Rebuild ................................... 143 Section 15. Conversion Factors ........................................ 145 Section 16. Index .............................................................. 149

Alpha Series Workshop Manual Introduction The purpose of this manual is to give information, operating, maintenance and repair procedures for the 'Alpha' series of industrial, marine and gas fuelled engines. The manual is designed primarily for use by qualified technicians with electrical and mechanical experience. This work can only be carried out if the necessary hand and service tools are available. When the user has insufficient tools, experience or ability to carry out adjustments, maintenance and repairs then this work should not be attempted. Where accurate measurements, or torque values, are required they can only be made using calibrated instruments. Under no circumstances should makeshift tools or equipment be used, as their use may adversely affect safe working procedures and engine operation. The specification details given apply to a range of engines and not to any one particular engine. In cases of difficulty the user should consult the local Lister Petter Distributor or Dealer for further advice and technical assistance. 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, Distributor or 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 organisation cannot be relied upon for correct material, dimensions or finish. This Company cannot therefore, be responsible for any damage arising from the use of such parts and the guarantee will be invalidated. When purchasing parts or giving instructions for repairs users should, in their own interests, always specify Genuine Lister Petter Parts and quote the Description of the Part and the Engine Serial Number. Associated Publications LPA, LPW, LPWT, LPWS Operators Handbook English ........................................... P027-08182 German .................................... P027-08182/ger Italian ......................................... P027-08182/ita French ....................................... P027-08182/fre Spanish ................................... P027-08182/spa Portuguese ..................................... P027-08196 Russian/English .............................. P027-09126 LPWG Operators Handbook ............... P027-08197 Alpha Marine Operators Handbook ..... P027-08181 LPA Master Parts Manual .................... P027-08040 LPW/LPWS Master Parts Manual ....... P027-08041 LPWG Master Parts Manual ................ P027-08044 Technical Handbook ............................ P027-08247 Various technical/sales leaflets are available; please contact your Lister Petter Distributor or Dealer for details. Training Comprehensive training in the correct operation, service and overhaul procedures of engines is available at the Lister Petter International Product Training Centre. Please contact Lister Petter for details. If Problems Occur If problems occur with your engine, or any of the Lister Petter approved accessories fitted to it, your local Lister Petter Distributor should be consulted. There are Lister Petter Distributors in most countries of the world and details for these can be obtained from any one of the companies listed on the back cover. Using this Workshop Manual Each section title is given at the top of the relevant pages and a full cross reference 'Index' appears at the back of the manual. It is recommended the individual steps contained in the various maintenance or repair operations are followed in the sequence in which they appear. At times it may be necessary to refer to other parts of the section, or to a different section, for more specific or detailed information. Caution and Warning Symbols When an engine is operating or being overhauled there are a number of associated practices which may lead to personal injury or product damage. The symbols are shown and described on the next page. WARNING Unauthorised adjustments to the emission compliant fuel injection pump may invalidate warranty claims. In the USA, unauthorised adjustment of emission critical components is prohibited by Federal Law, incurring civil penalty. Introduction

Alpha Series Workshop Manual Section 01 General Information - safety 01.1 SAFETY PRECAUTIONS AND SAFE WORKING PRACTICES At all times follow the recommended precautions and safe operating and working practices. The following are of a general nature and more specific information appears where it is relevant. Caution and Warning Symbols CAUTION This caution symbol draws attention to special instructions or procedures which, if not correctly followed, may result in damage to, or destruction of, equipment. WARNING This warning symbol draws attention to special instructions or procedures which, if not strictly observed, may result in personal injury. WARNING A WARNING SYMBOL WITH THIS TYPE OF TEXT DRAWS ATTENTION TO SPECIAL INSTRUCTIONS OR PROCEDURES WHICH, IF NOT STRICTLY OBSERVED, MAY RESULT IN SEVERE PERSONAL INJURY, OR LOSS OF LIFE. Follow All Safety Instructions a. Carefully read all safety messages in this manual and the safety and informative symbols on your engine and plant. b. Starting any diesel engine can be dangerous in the hands of inexperienced people. Engine operators must be instructed in the correct procedures before attempting to start any engine. c. Do not make any unauthorised modifications as these may affect the safe operation of the engine and put the operator at risk. d. Ensure all starting devices are removed, or isolated, before commencing any work on the engine or plant. Emergency Considerations a. Be prepared with suitable equipment, and knowledge, in case a fire starts. b. Know where to make calls to the emergency services from. c. Ensure a third party knows where you are working and when you leave the working area. Handling Fluids Safely a. When working with fuel or batteries do not smoke or work near to heaters or other fire hazards. b. Store flammable liquids away from fire hazards. c. Do not expose pressurised containers to heat and do not incinerate or puncture them. d. Handle fuel with care and always stop the engine before refuelling. Do not overfill the fuel tank. e. Thoroughly clean any lubricating or fuel oil from the skin as soon as possible. f. Rectify all fuel, coolant and oil leaks as soon as practicable and clean any spills when they occur. g. Remove any build-up of grease, oil or debris. h. Batteries contain sulphuric acid - if the acid has been splashed on the skin, eyes or clothes flush it away with copious amounts of fresh water and seek medical aid. Personal Safety a. Tie long hair close to your head. b. Do not wear a necktie, scarf, loose clothing or necklace when working close to a running engine. c. It is advisable to remove rings and other jewellery to prevent possible entanglement in moving parts. These items could also cause an electric short circuit if any part of the electrical system is being worked on. d. Ensure any lifting equipment to be used has the correct capacity to lift the engine. e. Lifting equipment must be designed to give two vertical lifts from directly above the engine lifting eyes. f. The engine lifting eyes fitted to the engine are suitable for lifting the engine and accessory assemblies originally fitted by Lister Petter. They must not be used to lift the complete plant. g. Do not work under any plant that is only held by overhead lifting equipment. Protective Clothing and Equipment a. Wear close fitting clothing and personal protective clothing and safety equipment appropriate to the work being done. b. Wear suitable ear protection to protect against objectionable or uncomfortable loud noise. Prolonged exposure to loud noise can cause impairment, or loss of hearing. c. The use of music or radio headphones could cause a loss of concentration. Section 01. General Information

Alpha Series Workshop Manual Handling Chemical Products Safely a. Direct exposure to hazardous chemicals can cause serious injury. b. Potentially hazardous chemicals include such items as lubricants, fuel, coolant concentrate, battery acid, paint and adhesives. c. Manufacturers Safety Data Sheets will provide specific details of the physical and health hazards, safety and emergency procedures and any necessary personal protection equipment required while working with hazardous materials. Rotating Machinery a. Entanglement with any rotating equipment can cause serious injury or death. b. If unprotected skin comes into contact with rotating equipment severe burns can result. Safe Maintenance Considerations a. Understand the service procedures before commencing any work. b. Ensure the work area is clean, dry, well ventilated and has adequate lighting. c. Isolate the engine starting system before commencing any work on the plant. d. All persons using equipment or processes in connection with the maintenance of plant and machinery must have received adequate and suitable training. High Pressure Fluids a. Never allow any part of the body to come into contact with high pressure hydraulic oil, compressed air or fuel oil, for example when testing fuel injection equipment. b. Both digested and injested fluids can lead to serious injury, possibly with fatal results in a very short period of time. Electrical System Considerations a. Ensure that the battery is of sufficient 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 transmission that is attached to it. b. Ensure the battery and all engine wiring cables are of sufficient size to carry the currents required. c. 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. d. Ensure engine wiring cables are: Bound together in a loom and adequately supported. Routed to avoid any hot surfaces, particularly the exhaust system. Not in contact with any rough surfaces or sharp corners so as to avoid any possibility of chaffing taking place Alternator Precautions a. Never remove any electrical cable while the battery is connected in the circuit. b. Only disconnect the battery with the engine stopped and all switches in the OFF position. c. Ensure cables are fitted to their correct terminals. A short circuit or reversal of polarity will ruin diodes and transistors. Never connect a battery into the system without checking that the voltage and polarity are correct. d. Never flash any connection to check the current flow or experiment with any adjustments or repairs to the system. e. The battery and alternator must be disconnected before commencing any electric welding when a pole strap is directly or indirectly connected to the engine. Starter Battery Precautions WARNING Sulphuric acid in battery electrolyte is poisonous, is strong enough to burn skin, eat holes in clothing and cause blindness if splashed into the eyes. a. Do not smoke near the batteries and keep sparks and flames away from them. b. Batteries contain sulphuric acid - if the acid has been splashed on the skin, eyes or clothes flush it away with copious amounts of fresh water and seek immediate medical aid. c. Keep the top of the battery well ventilated during charging. Switch off the battery charger before connecting or disconnecting the charger leads. d. Disconnect the battery negative (earth) lead first and reconnect last. e. Never 'flash' connections to check current flow. f. A damaged or unserviceable battery must never be used. g. Do not attempt to charge a frozen battery; it may explode; warm the battery to 16°C (60°F). Waste Contamination a. Extreme care must 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 local regulations to prevent contamination. b. Drains and water courses must not be used to dispose of contaminated, or waste fluids. Oil Seals Containing Viton Some engines may be fitted with seals or 'O' rings manufactured from 'Viton' or a similar material. When exposed to abnormally high temperatures, in excess of 400°C (752°F), an extremely corrosive acid is produced which cannot be removed from the skin. If signs of decomposition are evident, or if in doubt, always wear disposable heavy duty gloves. Section 01 General Information - safety

Alpha Series Workshop Manual Section 01 General Information - safety, safety symbols Fuel System Precautions a. When priming or checking the fuel injection pump timing, care must be taken to wipe spilled fuel from the outside of the engine. b. Always fit a new joint when a union has been disturbed. c. Special care must be taken to see that there is no leakage from the joints of the fuel pipe connection to the pump. d. When tightening or loosening the fuel injection pump delivery connections, use two spanners to prevent the un-sealing of the fuel pump delivery valve holders. e. When refitting the fuel pipe from the pump to 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. f. It is most important that all fuel joints are tight and leak proof. g. Always fill the fuel tank through a fine strainer, preferably at the end of the engine work period. If any sediment is stirred up during the process this has time to settle before the engine is used again, this will minimise the risk of condensation contaminating the fuel. If cans are used, avoid tipping out the last few drops. h. Funnels are very difficult to keep clean in dusty conditions. Wash them before and after use and wrap them up when not required, or fill the tank direct from a small mouthed screw capped fuel can. i. The fuel injection equipment is manufactured to very accurate limits and the smallest particle of dirt will destroy its efficiency. Fuel free from water and contaminants is of the utmost importance. Precautions for Oil, Filters and Elements a. Used liquid filters and elements contain some of the filtered liquid and should be handled and disposed of with care. b. After handling new or used elements the users hands should be thoroughly washed, particularly before eating. c. Fuel and new or used lubricating oil may cause skin irritation. Contact with used lubricating oil can cause cancer, birth defects or other reproductive harm. d. 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 gasses if they are burnt. e. Extreme care must be taken to ensure that waste oil, filter elements, solvents or other toxic wastes are disposed of in accordance with local regulations to prevent contamination. f. 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. 01.2 SAFETY SYMBOLS This section identifies the ISO 8999 symbols currently used by Lister Petter

Alpha Series Workshop Manual LPA3 Axial Fan Alternator Sump Drain Plug Fuel Pump Cylinder Head Cover LPWS4 Marine Sail/Work Boat Air Cleaner Exhaust Outlet Heat Exchanger Anti-vibration Mounting Inlet Manifold Exhaust Manifold Fuel Filter Oil Filter Oil Filler LPW2 Engine Control Radiator Fan Flywheel Housing Lifting Eye Oil Filler Oil Dipstick Fuel Control Solenoid Oil Filter Fuel Lift Pump Sump Pump Newage PRM Gearbox Fuel Filter LPWS4 Marine Canal Star Make-up Tank Filler Fuel Lift Pump LPWT4 Lifting Eye Turbocharger Fuel Filter Radiator Fan Oil Cooler Adaptor Oil Filter Water Pump 01.3 ENGINE FEATURES Section 01 General Information - engine features

Alpha Series Workshop Manual Radiator Filler Cap Alternator Air Cleaner Starter Motor Ignition Coils Main Gas Solenoid Valve and Regulator Electronic Governor and Carburettor LPWG4 European Version Radiator Fan Oil Filter Oil Filler Main Gas Solenoid Valve and Regulator Electronic Governor and Carburettor LPWG4 U.S. Version 01.3.1 ENGINE FEATURES - LPWG Section 01 General Information - engine features

Alpha Series Workshop Manual Section 01 General Information - engine identification 01.4 ENGINE IDENTIFICATION 01.4.1 Nomenclature LPA2 and 3 - two and three cylinder, direct injection, naturally aspirated axial fan cooled diesel engines. LPW2, 3 and 4 - two, three and four cylinder, direct injection, naturally aspirated water cooled diesel engines. LPWT4 - four cylinder, direct injection, turbocharged water cooled diesel engine. LPWG2, 3 and 4 - two, three and four cylinder, gas fuelled, naturally aspirated water cooled diesel engines. LPWS2, 3 and 4 - two, three and four cylinder, indirect injection, naturally aspirated water cooled diesel engines. 01.4.2 Build Information The engines within each range have been assembled to predetermined configurations and where the build number is preceded by a '9' this indicates that the engine is either of a non-standard configuration, or contains non-standard parts or accessories. When new parts are required for such a build it is suggested that reference be made to Lister Petter to determine the exact engine specification and which parts are non-standard. Where the engine serial number contains a 'G', for example GLPW3, this denotes the engine was built into a generating set by Lister Petter. A full list of builds is given in "Section 13 - The Engine Builds". 01.4.3 Marine Builds Marine engines are designated Builds 40, 41, 42, 43, 44, 45, 46, 47, 48 and 49. In general 'Alpha' marine propulsion engines are designed for the following applications. LPA - leisure and commercial craft. LPW - workboats and commercial craft. LPWT - workboats and commercial craft. LPWS - canal boats. 01.4.3 Engine Serial Number The engine serial number is stamped on a plate attached to the engine. It is necessary to identify the type and build of each engine to enable the correct maintenance procedures, as described later in this publication, to be carried out. An example number is shown below. 03 00123 LPW3 A 01 03 ............ Year of manufacture code (03 = 2003) 00123 ...... Consecutive number of engine LPW3 ...... Model (T = turbocharger, S = indirect injection) G = gas fuelled) A .............. Anticlockwise rotation 01 ............ Build of engine

LISTER PETTER ALPHA Series LPA LPW LPWT LPWS LPWG Workshop Manual

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