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The information given is subject to the Company’s publication are given with Lister Petter Power current Conditions of Tender and Sale, is for the Systems' best intentions and are believed to be assistance of users and is based upon results correct at the time of going to press.
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'Alpha' series of industrial, marine and gas specify Genuine Lister Petter Parts and quote the fuelled engines. Description of the Part and the Engine Serial The manual is designed primarily for use by Number.
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fitted by Lister Petter Power d. Ensure all starting devices are removed, or Systems. They must not be used to lift the isolated, before commencing any work on the complete plant.
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ALPHA series engines worksHoP mAnuAL b. Wear suitable ear protection to protect against Bound together in a loom and adequately objectionable or uncomfortable loud noise. supported. Prolonged exposure to loud noise can cause Routed to avoid any hot surfaces, particularly the impairment, or loss of hearing.
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Funnels are very difficult to keep clean in dusty that the engine will not be used for extended conditions. periods. 1.2 SAFETY SYMBOLS This section identifies the ISO 8999 symbols currently used by Lister Petter Power Systems...
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ALPHA series engines worksHoP mAnuAL 1.3 engine feAtures LPw2 inlet manifold exhaust manifold radiator fan fuel filter flywheel Housing engine 'stop' Control oil filler oil filter LPwt4 Lifting eye turbocharger water Pump/thermostat housing radiator fuel filter fuel Lift Pump oil Cooler...
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GLPW3, this denotes the engine was built 1.4.1 Nomenclature into a generating set by Lister Petter Power Systems. LPW2, 3 and 4 - two, three and four cylinder, direct A full list of builds is given in "7. Engine Build injection, naturally aspirated water cooled diesel Details".
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Arctic or Alkaline batteries must be 1.5.5 Disconnecting a Slave Battery used. 1. Start the engine. Lister Petter Power Systems recommend that a 2. Disconnect the slave battery negative (-) jumper battery shouldprovide a minimum cranking period lead first.
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105A 160A 300A 1.5.7 Recommended Battery Type Lister Petter Power Systems recommend that a battery shouldprovide a minimum cranking period Heavy Duty Batteries to BS3911:982 or IEC95-1 of 60 seconds from a 70% charged 12 volt battery, are recommended for all applications.
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ALPHA series engines worksHoP mAnuAL 2. engine serviCing And Adjustments 2.1 PreLiminAry instruCtions 2.2 tHe Air CLeAner Plastic air cleaners have been available since wArning March 2000 and these complement the existing Maintenance must be performed by qualified sheet metal types.
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ALPHA series engines worksHoP mAnuAL seconds before stopping to allow the heat from the bearing to dissipate. 2.5.1 removing the turbocharger 1. Disconnect and remove the turbocharger oil feed pipe (A) and oil return pipe (B). 2. Remove the air cleaner, exhaust silencer and associated parts.
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ALPHA series engines worksHoP mAnuAL 2.7.1 removing the starter motor through a fitting on the crankcase door. The remaining vapours are then routed from the 1. Isolate the battery. canister to the air inlet. This results in the blow- 2. Disconnect the electrical wiring loom from the by vapours being re-burned in the combustion starter.
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ALPHA series engines worksHoP mAnuAL If an alternator is not required, a jockey pulley is fitted in its place. The alternator is belt driven at the gear cover end by a V-ribbed belt and the alternator to engine speed ratio and output is constant for all engines.
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ALPHA series engines worksHoP mAnuAL 2.9.1 tensioning the drive Belt 2.10.1 removing the fuel tank When a new belt is correctly fitted and tensioned 1. Drain the fuel tank into a clean receptacle. a force (F) of 31.0-33.5N (7.0-7.5lbf) is required to 2.
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ALPHA series engines worksHoP mAnuAL Figure 2.11.1 Industrial Fuel Lift Pumps - Pienne/Corona pump Figure 2.12.1 Fuel Filter 2.11.1 replacing the fuel Lift Pump 5. Fill the fuel tank and prime the system. The fuel lift pump is operated by a push rod from 6.
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ALPHA series engines worksHoP mAnuAL 2.13.1 removing a fuel Pump This will ensure it is correctly located over the end of stud (B) which is fitted inside the crankcase. To retain the governor setting leave one fuel pump in position.
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ALPHA series engines worksHoP mAnuAL 7. Torque the nut to 34.0Nm (25.0lbf ft). from the top face of the crankcase, to the top of 8. Replace the fuel pipes. the fuel pump tappet cap. 9. To ensure the control lever is positively stopped by 6.
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ALPHA series engines worksHoP mAnuAL 2.15 fueL PumP timing vALues Piston Build Speed Setting Engine ºBTDC Displacement from TDC (mm) 01,02,03,04,12,13,14,16,40,42,46,4 Variable - up to 3000r/min 20º 3.097 8,49,51,52,70,75,86,102 LPWS3, 4 01, 02,03,13,42,46,48,49, Variable - up to 3000r/min LPWS2 22º...
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ALPHA series engines worksHoP mAnuAL 2.16 tHe fueL injeCtor LPws & LPwst4 engines fuel injector Part numbers for Alpha LPWS ENGINES - (PRE NOV 1998) engines Engine Type Build Number Part Number LPW/LPWT4 - (Industrial Engines) 751-19700 INDUSTRIAL LPW/LPWT4 - (Marine Engines)
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ALPHA series engines worksHoP mAnuAL It is important to maintain the fuel injection All sprays on LPW injectors should have the same equipment, injection pipes, and unions between the appearance, and the same length of penetration in fuel supply filter and the injector in an absolutely the air.
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ALPHA series engines worksHoP mAnuAL point grease to one side of a new injector sealing crankshaft and bearings. washer and place it over the injector nozzle, The connecting rod big end bearings are pressure greased side first. fed through internal drilling in the crankshaft from the supply to the main bearings.
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ALPHA series engines worksHoP mAnuAL 2.19 tHe oiL diPstiCk 2.21.2 Refilling the oil sump Before refilling the oil sump ensure the new oil Extreme care must be taken to ensure the correct meets the specification and viscosity as given in dipstick is returned to the engine.
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Refer to "5.2 Oil and Filter Change Periods" for revised oil change periods. for revised oil change periods. Only filters approved by Lister Petter Power Systems should be used as these have the correct by-pass valve pressure to match the oil pump relief valve, high temperature joints, adequate filter paper characteristics and a rigid case.
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ALPHA series engines worksHoP mAnuAL onto the crankcase. 6. On LPW(S)T4 engines remove the breather Builds 07, 81 and 84 are not fitted with an oil flexible pipe from the cylinder head cover. cooler. 7. Remove the lifting eye. 8. Remove the cylinder head covers and gaskets.
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ALPHA series engines worksHoP mAnuAL note: The lower torque figure is used on earlier engines and the higher figure for later 'High Boss' cylinder barrels. on earlier barrels the bosses and threads are below the top fin. on the 'High Boss' arrangement the bosses and threads (A) are at the top of the barrel.
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ALPHA series engines worksHoP mAnuAL 34.0Nm (25.0lbf ft) and wait for the lubricating oil to ‘bleed down’: Up to 90 seconds on a new tappet. Up to 45 minutes on a used tappet. CAution During the waiting period the crankshaft must not be turned.
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ALPHA series engines worksHoP mAnuAL amount of high melting point grease place the to the figures given in "2.27.3 The Valve Seats". two pieces of wire (A) onto the piston crown (B) Care must be taken to ensure that all valve at either side of the gudgeon pin axis and 90°...
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ALPHA series engines worksHoP mAnuAL 2.27.3 the valve seats Valve seat inserts are only fitted to LPWT4 and LPWST4 and LPWS Bio engines. The valve seats must be precision ground so that the valves are sunk below the combustion surface of the head as shown.
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ALPHA series engines worksHoP mAnuAL 2. Select the necessary cutting tool (B) and assemble it to the handle (C). 3. Place the cutter over the mandrel and adjust the three individual blades, using the Allen Key, if necessary. 4. Rotate the tool in a clockwise direction until the valve seat or recess finish is satisfactory.
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ALPHA series engines worksHoP mAnuAL 2.30 tHe geAr end Cover CAution The LPW4 and LPW(S)T4 crankcase doors are The light alloy, standard and hydraulic pump build, not interchangeable. end cover is located on two dowels and secured to the crankcase on seven bolts.
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The lip seals used must be the approved type as A - Early Type Fixing; B - Late Type Fixin supplied by Lister Petter Power Systems; ordinary rubber seals may quickly harden in use, rapidly wear the shaft, or not even seal on fitting and therefore must not be used.
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ALPHA series engines worksHoP mAnuAL 6. Unhook the small spring (D) from the lower end of the governor lever assembly retaining pin (E). 7. Remove the pins from the top and bottom of the governor lever assembly taking care to retain any end float shims that are fitted.
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ALPHA series engines worksHoP mAnuAL Figure 2.31.4 Thrust Plate Spring Figure 2.31.6 Checking Camshaft End float 6. Fit the speeder spring (A) to the governor 4. Zero the gauge. lever assembly (B) and the speed control lever 5. Move the camshaft as far as it will go towards assembly (C) with the fixed spring tail onto the the gear end.
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ALPHA series engines worksHoP mAnuAL 2. Screw on the depth plate (C); see the above controlled expansion piston assemblies have been illustration. fitted. Either type of piston, with the correct rings, 3. Fit the slide hammer onto the guide threads.
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ALPHA series engines worksHoP mAnuAL 2.33.4 inspecting and servicing the Piston 2. Place the connecting rod into the piston and Insert the gudgeon pin and circlips into the 1. Thoroughly clean the cylinder barrel and check piston. Special care must be taken to ensure the for scoring and wear.
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ALPHA series engines worksHoP mAnuAL CAution 2. Replace the bearing and torque the bolts to 35.0Nm (26.0lbf ft). Do not attempt to drill out the plugs or increase the oil jet hole diameter. CAution Care must be taken to ensure the crankshaft is not turned when the ‘Plastigauge’...
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ALPHA series engines worksHoP mAnuAL 2.37.1 removing the flywheel Housing 1. Remove the flywheel. 2. Remove the four housing retaining bolts. 3. Lift off the housing. 2.37.2 fitting the flywheel Housing 1. Replace the bolts finger tight. 2. Align the previously scribed marks.
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Copper lead and aluminium tin main bearing The lip seals used must be the approved type as shells must not be mixed in an engine. supplied by Lister Petter Power Systems; ordinary rubber seals may quickly harden in use, rapidly CAUTION...
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ALPHA series engines worksHoP mAnuAL The balance weights are an integral part of the shaft and the centre bearing housing is in two halves secured by two capscrews. End thrust is taken on steel backed copper faced split thrust washers fitted at the gear end of the crankcase and in the flywheel end main bearing housing.
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ALPHA series engines worksHoP mAnuAL half as matched pairs. 9. Remove the thrust washers from the gear end of the crankcase and the flywheel end main bearing housing. 2.41.2 inspecting the Crankshaft a. Inspect the main bearings for scoring or wear.
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ALPHA series engines worksHoP mAnuAL Figure 2.42.1 Checking Crankshaft End float Figure 2.43.1 Main Bearing Tool 2. Push the crankshaft firmly towards the gear end 3. Fit the bolt and dolly into the bearing from the oil of the engine and zero the indicator.
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ALPHA series engines worksHoP mAnuAL 2.44 tHe oiL strAiner And PumP 6. Fit the assembly into the housing from the oil seal side (crankcase outside face at the gear Access to the pump is only possible after removing end) with the spigot in line with the pencil line on the end cover.
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40% concentration. Aluminium radiators require 50% mix of water and coolant. Lister Petter Power Systems engines are often built with aluminium core radiators rather than copper nowadays. In order to protect and ensure the longevity of all water system components, the water used is critical.
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ALPHA series engines worksHoP mAnuAL 2.47 tHe tHermostAt to be retained. Some heat exchangers may be fitted with a drain plug. A common thermostat is not fitted therefore 2. Slacken a bottom hose clip and slide the hose off. reference should be made to the Master Parts 3.Remove the radiator, heat exchanger or...
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15.0lb/in cap is used on all radiators originally fitted 'Figure 2.47.1'. by Lister Petter Power Systems. If there is any doubt 4. Replace the engine temperature switch, if fitted. as to which is fitted Lister Petter Power Systems 5. Replace the radiator top hose.
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3. Remove the radiator filler cap. mounted away from the engine and some may not 4. Allow sufficient time for the radiator to drain. have been originally fitted by Lister Petter Power 5. Slacken the clip at the radiator end of the top Systems.
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ALPHA series engines worksHoP mAnuAL 2.50 tHe wAter CirCuLAting PumP If an early type pump is being replaced with the later type it will be necessary to change the water pipes and the original thermostat; refer to the Master Parts Manual.
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ALPHA series engines worksHoP mAnuAL 2.51 tHe governor 4. Fit the lower governor assembly retaining pin and shim onto the governor lever assembly. The method of governing is common for all other On Builds 71, 72 and LPW Builds 74, 173 and engines.
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ALPHA series engines worksHoP mAnuAL LPwst4 2.51.3 governor sleeve and washer Combinations All except 407, 408, 457, 458, 751-12823 751-10288 751-13130 Part Number Thrust Collar 751-12823 Build Thrust Governor Steel 407, 408, 457, 458, Thrust Washer 751-15950 Collar Sleeve Washer...
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ALPHA series engines worksHoP mAnuAL 2.52.2 governor weights and springs - LPw2,3 Part Number of Number of Part Number of Spring Colour Engine Build Weight Weights Speeder Spring Code LPW2 1, 2, 51, 52, 602, 846, 848 751-11091 751-15720 Green/White...
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ALPHA series engines worksHoP mAnuAL 2.52.5 governor weights and springs - LPws2 and 3 Part Number of Number of Part Number of Spring Colour Engine Build Weight Weights Speeder Spring Code LPWS2 402, 442, 446, 448 751-11091 751-15300 None LPWS3...
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ALPHA series engines worksHoP mAnuAL CAution On some engines a tamperproof setscrew nut is fitted to prevent changes being made to the engine stop/run control settings. In these cases adjustment is not possible. CAution The settings given below are the initial settings.
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ALPHA series engines worksHoP mAnuAL 2.56 Adjusting tHe engine sPeed The speed adjustments must only be made after the governor has been correctly set. The locations of the two adjusting setscrews are given in "2.56.2 Speed Adjustment Setscrews". CAution On some engines a tamperproof setscrew nut is fitted to prevent changes being made to the engine stop/run control settings.
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ALPHA series engines worksHoP mAnuAL Figure 2.56.2 Speed Adjustment Setscrews; MA - Tamperproof screw A - Variable Speed; B - Fixed Speed 3000/3600rpm; C - Fixed Speed 1500rpm; D - Fixed Speed 1800rpm; E - Dual Speed 2.57 CrAnkCAse vACuum In engines in good condition the vacuum increases slightly with engine speed, but not proportionally.
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In cases of difficulty, it is suggested contact be made with 3.1.3 Oil Viscosity a reputable oil supplier or any Lister Petter Power Systems Distributor. Past and Current US API Grade Oils API Service Category CD:...
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3.2 engine fLuids - fueL 3.3.1 Concentrate Specification 3.2.1 the Fuel Specification Lister Petter engines are often built with aluminium The engine must only be used with diesel fuel oil core radiators rather than copper nowadays. In which conforms to one of the following: order to protect and ensure the longevity of all water a.
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ALPHA series engines worksHoP mAnuAL 3.3.2 Concentration CAution A 40% concentration must be maintained under all The cooling system is pressurised, extreme care operating conditions. must be taken when removing the radiator cap To determine the amount of coolant concentrate if the engine is hot.
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ALPHA series engines worksHoP mAnuAL 4. oPerAting instruCtions 4.1 industriAL engine Heater and glow Plugs To provide additional heating of the combustion air oPerAting instruCtions during starting a 345W heater plug may be fitted The following information is of a general nature and to the inlet manifold on and LPW engines.
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ALPHA series engines worksHoP mAnuAL key start 3. For ambient starting temperatures above -10°C (14°F) turn the key clockwise and hold it in the ‘Heat’ position for 10 to 15 seconds before turning it to the ‘Start’ position. 4. For ambient starting temperatures below -10°C (14°F) turn the key clockwise to the ‘Preheat’...
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ALPHA series engines worksHoP mAnuAL it to the ‘Start’ position. 4. 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. 5. Immediately the engine starts the key must be turned anti clockwise and held in the 'Preheat’...
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SIGNS OF DECOMPOSITION ARE EVIDENT, equipment not specifically covered in this book OR IF IN DOUBT, ALWAYS WEAR DISPOSABLE in which case any Lister Petter Power Systems HEAVY DUTY GLOVES. Distributor or Dealer can be consulted. •...
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ALPHA series engines worksHoP mAnuAL 5.3 routine mAintenAnCe - 5.1.3 interim maintenance These checks are to be carried out daily and are in sCHeduLe Hours addition to those given in "5.3 Routine Maintenance Both schedules are based on average operating - schedule hours".
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ALPHA series engines worksHoP mAnuAL Clean and check, or replace, the fuel injector nozzles. Every Year - LPW and LPWS Check the radiator fins and radiator fan blades for damage. Drain, flush and refill the cooling system adding new coolant concentrate to a 40% concentration.
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ALPHA series engines worksHoP mAnuAL 5.4 seALing ComPounds Component Compound to Use Applying the Compound Assemble the joint dry and with all surfaces dry and Cylinder head cover clean. Coat the outside of the plug or the bore. Do not allow the...
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ALPHA series engines worksHoP mAnuAL 5.5 sPAnner torQues 5.5.1 stator motor terminal torques The tolerance for all torque settings is ±10%, except those marked with a * when it is +5% -0%. For practical purposes the figures have been rounded.
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ALPHA series engines worksHoP mAnuAL notes to Both tables: 5.7 dimensions of weAring 1 - Left hand thread PArts 2 - early engines The following information is given as a guide to 3 - Builds 28, 51, 52, 57, 58, 59...
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ALPHA series engines worksHoP mAnuAL 5.7.4 dimensions of wearing Parts Initial Dimension, Initial Clearance, Maximum Clearance, All Engines Cylinder bore 86.000 - 86.025 0.039 - 0.134 0.40 Piston diameter - bottom of skirt across thrust face 85.891 - 85.901 Controlled expansion Pistons Piston ring gaps 0.25 - 0.50...
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ALPHA series engines worksHoP mAnuAL Initial Dimension, Initial Clearance, Maximum Clearance, All Engines Connecting rod big end bore 53.525 - 53.545 Bearing shell thickness 1.740 - 1.750 0.025 - 0.080 0.12 Crankpin diameter 49.985 - 50.000 Flywheel end main bearing housing bore 74.040 - 74.065...
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ALPHA series engines worksHoP mAnuAL 5.8 Long term storAge 5.8.2 returning the engine to service Refer to the appropriate sections for the relevant 5.8.1 Preparing the engine for storage detailed instructions as necessary to complete this The following routine should be carried out when work.
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Do you have sufficient electrical and mechanical knowledge skills understand symptoms? c. Do you have suitable electrical diagnostic equipment available? d. Do you have, or access to, the necessary Lister Petter spare parts before you commence dismantling.
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Check the electrical supply. Poor battery connections. Clean, replace and coat with petroleum jelly. Faulty fuel pump. Contact a Lister Petter Power Systems distributor. Excessive Carbon Deposits Choked air filter. Dismantle and clean the cap and element. Choked exhaust system.
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ALPHA series engines worksHoP mAnuAL Problem Method of Correction Lack or loss of Power Loss of compression. Check the piston rings and the valves. Choked air filter. Dismantle and clean the cap and element. Choked exhaust system. Dismantle and clean.
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7. ENGINE BUILD DETAILS 7.1 GENERAL INFORMATION When new parts are required for such a build it is suggested that reference be made to Lister Petter Where the build number is preceded by a 9 this Power Systems to determine the exact engine indicates that the engine is either of a non-standard specification and which parts are non-standard.
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ALPHA series engines worksHoP mAnuAL LPWS Build and details 4 T4 4 T4 Variable speed 850-3000r/min 110% load. Class B1 • • • Variable speed 850-3000r/min 100% load. Class B1. Deep sump • • • Constant speed 1800r/min. Deep sump. US EPA •...
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ALPHA series engines worksHoP mAnuAL LPWS Build and details 4 T4 4 T4 Fixed speed 3000r/min, A1 governing, 110% load, std crankcase, e/cover for water • • • • pump drive - Marine Auxiliary Variable speed 850-3000r/min, 110% load, std crankcase, e/cover for water pump •...
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1.4:1 1.4:1 1.4:1 Maximum continuous crankshaft end thrust Dry engine weight - approximate and based on Build 01. Refer to Lister Petter Power Systems for actual figures mm H Maximum permissible intake restriction at full load in H 10.0 10.0 10.0...
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23.6 23.6 Radiator fan ratio Maximum continuous crankshaft end thrust Dry engine weight - approximate and based on Build 01. Refer to Lister Petter Power Systems for actual figures mm H Maximum permissible intake restriction at full load 10.0 10.0 10.0...
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ALPHA series engines worksHoP mAnuAL 9. dismAntLe And reBuiLd 9.1 dismAntLing An engine 19. Remove the oil filter. 20. Remove the dipstick and crankcase door. wArning 21. Remove the oil pressure relief valve and the oil Maintenance must be performed by qualified strainer.
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ALPHA series engines worksHoP mAnuAL both ways so that no oil is left in the combustion 19. Set the governor. chamber or inside the piston. 20. Replace the fuel pumps. Replace all joints and gaskets. 21. Replace the gear end cover.
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ALPHA series engines worksHoP mAnuAL 10. Conversion fACtors 10.1 formuLAe Piston speed metres/second = stroke (mm) x r/min BmeP 30000 Bar = kW x 60000 x 20000 Cylinders x r/min x bore area (mm ) x stroke (mm) feet/minute =...
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ALPHA series engines worksHoP mAnuAL rate of flow - volume cubic metre per litre per second cubic foot per UK gallon per second - m /sec l/sec second - ft /sec second - gal/sec /sec 1000.0 35.3147 219.969 1 l/sec 0.0010...
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ALPHA series engines worksHoP mAnuAL The kilogram is known as the kilopond (kp) in Germany. 1 kgf m = 1 kp m 1 pdl = 1 lb ft/s² 1 N = 1 kg m/s² energy - table 1 kilowatt hour...
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