Lister Petter ALPHA Series Operator's Handbook Manual
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Lister Petter ALPHA Series Operator's Handbook Manual

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LPW4
G Build Engine
LPW/LPWS/LPWX ENGINE
OPEratOrS' HaNdbOOk
OVERVIEW
The G Build engine is specifically designed as a Power
generating engine suitable for use in unregulated
emissions territories. It is durable, reliable and easy
to maintain with oil & filter changes up to 500 hours,
dependant on operational conditions. It is designed
for continuous operation in ambient temperatures up
to 52° (122°F) and a cold start capability down to -32°
(-25.6°F).
Note:
This engine does not comply with Harmonised International Regulated
Emissions Limits.
* Optional items standard on most builds.
LPW4 G Build Engine
1500 | 1800 | 3000 | 3600 r/min
15.0 - 29.5 kW | 20.1 - 39.5 bhp
BASIC ENGINE CHARACTERISTICS
▪ diesel fuelled and approved for operation on biodiesel,
that conforms with ASTM D6751 and EN14214,
concentrations of up to 20%
▪ direct fuel injection
▪ 4 cylinders
▪ liquid cooled
▪ naturally aspirated
ORIGINAL INSTRUCTIONS
DESIGN FEATURES AND EQUIPMENT
▪ inlet and exhaust manifolds*
▪ fuel lift pump
▪ mechanical governing
▪ self-vent fuel system with individual
▪ fuel Injection pumps
▪ fuel lter/agglomerator
▪ thermostatically controlled cooling system with belt
driven coolant pump
▪ radiator with pusher fan and belt guard*
▪ gear driven positive displacement type
▪ lubricating oil pump
▪ spin on full flow lubricating oil filter
▪ high inertia flywheel to SAE J620: 7.5" *
▪ SAE 5 flywheel housing *
▪ 12V Starter motor *
▪ 12V battery charge alternator *
▪ oil pressure and coolant temperature switches *
▪ fuel control solenoid (energised to run)*
▪ skid base packing
▪ operators hand book (English)*
OPTIONAL ITEMS
A range of options are available that allows you to select
a specification that matches your requirements; Please
consult you Lister Petter Power Systems distributor.
ALPHA SERIES
xed speeds
1
P027-08270

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  • Page 1 This engine does not comply with Harmonised International Regulated Emissions Limits. OPTIONAL ITEMS A range of options are available that allows you to select a specification that matches your requirements; Please consult you Lister Petter Power Systems distributor. * Optional items standard on most builds. P027-08270...
  • Page 2 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.

  • Page 3: Table Of Contents

    CoNteNts 1. INTRODUCTION................... 7 1.1 Using the Handbook 1.2 Engine Identification 1.3 Engine Models 1.4 Running In 2. SAFETY INFORMATION................9 2.1 General Safety Information 2.1.1 Emergency Precautions 2.1.2 General Precautions 2.1.3 Emissions 2.2 Personal Safety 2.3 Safety Symbols 2.4 Precautions with Chemicals 2.4.1 Fuel and High Pressure Fluids 2.5 Fuel System Precautions...
  • Page 4 5. ENGINE FLUIDS..................22 5.1 Fuel 5.1.1 Fuel Specification 5.1.2 LPWS Bio 5.2 Lubricating Oil 5.2.1 Oil Specification 5.2.2 Oil Viscosity 5.2.2.1 Oil Viscosity Table 5.2.3 Oil Capacities 5.2.3.1 Capacity between Dipstick Marks 5.2.3.2 Sump Capacity 5.2.4 Engine Operation 5.3 Coolant 5.3.1 Coolant Specification 5.3.2...
  • Page 5 7.3 Troubleshooting Table 8. MAINTENANCE RECORD................41 9. WARRANTY....................45 9.1 General 9.2 Standard Warranty Cover 9.3 Conditions of Warranty 9.4 Limitations of Warranty 9.5 Purchase and Registrations Details of Engine 9.6 Repairs under Warranty 9.7 Contacting Lister Petter Power Systems...
  • Page 6 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK Glow Plugs Inlet Manifold Exhaust Manifold Radiator Fan (may have 6 blades) Fuel Filter Flywheel Housing Filter LPWS2 Sump Drain Plug Exhaust Manifold Inlet Manifold Alternator 2.1 Features of the LPW...

  • Page 7: Introduction

    Petter distributor or dealer. 1.2 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 identifies the type and build of the engine (see table below) to enable the correct maintenance procedures to be carried out.

  • Page 8: Engine Models

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 1.3 eNGINe ModeLs 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...

  • Page 9: Safety Information

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 2. sAfety INfoRMAtIoN Read the information in this section carefully and follow all the advice given. Pay special 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.

  • Page 10: General Precautions

    NON-ROAD INDUSTRIAL AND MARINE ENGINES. THEY MAY ONLY BE USED FOR EXEMPT APPLICATIONS E.G. STATIONARY ENGINES AND WITHIN THE FLEXIBILITY CLAUSES DEFINED IN THE EPA AND EUROPEAN REGULATIONS. IF IN DOUBT, PLEASE CONTACT LISTER PETTER POWER SYSTEMS LIMITED. WARNING CALIFORNIA PROPOSITION 65 WARNING...

  • Page 11: Safety Symbols

    This figure identifies the ISO8999 symbols currently used by Lister Petter Power Systems. 1. Safety Symbols This fi gure identifi es the ISO 8999 symbols currently used by Lister Petter...

  • Page 12: Fuel And High Pressure Fluids

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 2.4 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 emergency procedures and any necessary personal protection equipment required while working with hazardous materials.

  • Page 13: Fuel System Precautions

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 2.5 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. • When priming or checking the fuel injection pump timing, care must be taken to wipe any spilled fuel from the outside of the engine.

  • Page 14: Precautions With Oil Seals

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook WARNING Take careful precautions with filters 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.

  • Page 15: Precautions With Electrical Systems

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 2.9 PReCAutIoNs WIth eLeCtRICAL systeMs • 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 trans mission that is attached to it.

  • Page 16: Precautions Before Starting Engine

    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 fitted by Lister Petter Power Systems. 2.13 PReCAutIoNs befoRe MAINteNANCe • Understand the service procedures before commencing any work.

  • Page 17: Technical Data

    Every effort should be taken to ensure that the air cleaner draws in combustion air at a consistent ambient temperature. Lister Petter Power Systems 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...

  • Page 18: Operating Instructions

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 4. oPeRAtING INstRuCtIoNs 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.

  • Page 19: Keystart

    WARNING e using. Use suitable hand protection when WARNING stopping the engine, as the stop control may be hot after prolonged LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook t attempt to start or operate a running. engine unless you have been rly trained.

  • Page 20: Failure To Start

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 3. Turn the key clockwise to the stARt posi tion. Immediately the engine starts the key must be released and it will return to the RuN position due to internal spring. 4. On variable speed engines reduce the engine speed as necessary. starting LPWs engines 1.

  • Page 21: Stopping Of Engine

    LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 4.4 stoPPING of eNGINe CAutIoN It is recommended that LPWT4 and LPWST4 engines run on ‘No Load’ for 30 seconds before stopping to allow the heat from the turbocharger bearing to dissipate. 1.
  • Page 22 BSMA 100 Class M1 for marine use. The fuel must be a distillate and not a residual oil or blend. Vapourising oils are not suitable as fuels for Lister Petter Power Systems engines. 5.1.2 LPWs bio LPWS Bio is a specially developed engine range that will run on B100 (100% biofuel) as well as on those fuels specified above.
  • Page 23 150°C (302°F) under severe tropical conditions, and 120°C (248°F) under normal conditions. • For engines running in long-running installations Lister Petter Power Systems should be consulted. 5.2.2 oil Viscosity Figure 5.2.2.1 shows the recommended oil viscosity ranges for various °C ambient temperatures from cold start to maximum running.
  • Page 24 (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 6. Routine Maintenance). An oil change is recommended immediately if the engine fails to reach its normal LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK cold start cranking speed owing to excessive oil viscosity.
  • Page 25 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 5.2.3 oil Capacities CAPACITy BeTWeeN DIPSTICk SUMP CAPACITy MARkS (Figures exclude the filter) LPW4 LPW2 LPW3 LPW4 LPWX4 LPW2 LPW3 LPWX2 LPWX3 LPWX4 LPWT4 LPWX2 LPWX3 LPWS2 LPWS3 LPWT4 LPWS(T)4 LPWS2 LPWS3 LPWS(T)4 All builds except 28, 51, 52, 57, 58, 59 All builds except 28, 51, 52, 57, 58, 59...
  • Page 26 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook The specification of the coolant concentrate should comply with one of the following: BS6580: 1985 MIL-A-11755D MIL-A-46153/B 5.3.3 Water Quality The water to be mixed with the additive must be de-ionized or distilled water having the following characteristics: •...
  • Page 27 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.
  • Page 28 • Do you have suitable electrical diagnostic equipment available? • Do you have, or have access to, the necessary Lister Petter Power Systems spare parts? 6.3 IMPoRtANt INstRuCtIoNs • Remove the battery before carrying out any maintenance work on an engine.
  • Page 29 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 6.4 MAINteNANCe sCheduLe The following table sets out the frequency with which maintenance and servicing tasks should be performed. This is the minimum frequency required to keep your engine running at peak performance with trouble-free operation. The instructions are based on average operating conditions.
  • Page 30 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook OPeRATION Change the lubricating oil. LPW(X) engines operating • above 35°C ambient temperature and LPWT and LPWS(T) engines operating below 35°C ambient temperature. Renew the oil filter. LPW(X) engines operating above • 35°C ambient temperatuireLPWT &...
  • Page 31 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 6.5 LubRICAtING oIL Check the lubricating oil daily using the dipstick, and top up when necessary with oil of the correct type and specification (see section 5.2 Oil Lubricating Oil). See Table 5.2.3.1 for the capacity between the dipstick marks of all engines in the LPW range.
  • Page 32 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook CAutIoN Do not overfill with oil. If a cylinder head oil filler is fitted the oil must only be poured into the filler at a rate which enables it to drain into the crankcase. If the oil is poured in too quickly it can flood the crankcase breather holes and escape into the inlet manifold and cylinders.
  • Page 33 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook through the top hose with clean fresh water, preferably using a hose pipe, until clean water emerges. 3. Replace the hoses. 6.6.3 filling the Cooling system CAutIoN Under some circumstances an air lock can occur when filling the system, causing a false level indication.
  • Page 34 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 2. Using a suitable strap wrench, unscrew the cartridge (A) from the head (B). 6.7.2.1 The agglomerator: cartridge (A); head (B); drain tap (C). 3. Screw a new cartridge onto the head and hand tighten it. 6.7.3 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.
  • Page 35 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook On subsequent checking and adjustment a force (F) of 22.0-24.0N (5.0-5.4lbf) is LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK required to deflect it a distance (d) of 3.5mm (0.14 in). INTENANCE SCHEDULE he radiator fan drive belt, irrespective of e lubricating oil pressure.
  • Page 36 2. Gain access to the paper element by undoing the two over-centre clips (B). 3. Remove the element. LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 4. Clean the element by directing a low- Changing the fuel fi lter. The centre bolt pressure compressed-air nozzle up oted by A and the old element by B 2.
  • Page 37 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 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.
  • Page 38 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 Power Systems distributor.
  • Page 39 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook TROUBLeShOOTING Problem Cause Solution Loose or corroded connections. Clean and tighten the connections. Battery will not Worn-out battery. Replace the battery. charge Loose alternator drive belt. Replace or re-tension the drive belt. Poor quality fuel.
  • Page 40 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook TROUBLeShOOTING Problem Cause Solution Overcharging Faulty alternator. Test and if necessary replace. Battery Battery case leaking. Clean surrounding area and replace the battery. requires Defective battery. Test or replace the battery. excessive Check the alternator output and battery amounts of Battery charging rate is too high.
  • Page 41 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 8. MAINteNANCe ReCoRd Your Lister Petter Power Systems engine must be properly maintained using the timings and procedures described in this manual. You must be familiar with the routine tasks set out in 6. Routine Servicing, and their correct frequency as described in 6.4 Maintenance Schedule.
  • Page 42 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook Hours run Work done by Details of service Distributor / Dealer Stamp Date...
  • Page 43 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook 8.2 NoN-RoutINe MAINteNANCe Hours run Work done by Details of service Distributor / Dealer Stamp Date...
  • Page 44 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook Hours run Work done by Details of service Distributor/Dealer Stamp Date...
  • Page 45 • 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.
  • Page 46 Please fill in the section below with your purchase details. This information will be required in the case of a claim under warranty. 9.6 RePAIRs uNdeR WARRANty • Lister Petter Power Systems must be contacted and authorisation given before any warrantable work is commenced. 9.7 CoNtACtING LIsteR PetteR PoWeR systeMs...
  • Page 47 LPW / LPWs / LPWX eNGINe oPeRAtoRs' hANdbook...
  • Page 48 LPW / LPWS / LPWX eNGINe OPeRATORS' hANDBOOk, P027-08270, eDITION 7, JUNe 2019 © LISTER PETTER POWER SYSTEMS Head Office LISTER PETTER POWER SYSTEMS LIMITED Unit 14 Estuary Court, Broadmeadow Industrial Estate Teignmouth, TQ14 9FA T: +44 (0) 1285 702211...

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