Alpha Series Workshop Manual - Engine.od.ua

Section 01General Information- safetyHandling Chemical Products SafelyAlternator Precautionsa. Direct exposure to hazardous chemicals cancause serious injury.b. Potentially hazardous chemicals include suchitems as lubricants, fuel, coolant concentrate,battery acid, paint and adhesives.c. Manufacturers Safety Data Sheets will providespecific details of the physical and health hazards,safety and emergency procedures and anynecessary personal protection equipment requiredwhile working with hazardous materials.a. Never remove any electrical cable while the batteryis connected in the circuit.b. Only disconnect the battery with the enginestopped 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 diodesand transistors. Never connect a battery into thesystem without checking that the voltage andpolarity are correct.d. Never flash any connection to check the currentflow or experiment with any adjustments or repairsto the system.e. The battery and alternator must be disconnectedbefore commencing any electric welding when a polestrap is directly or indirectly connected to the engine.Rotating Machinerya. Entanglement with any rotating equipment cancause serious injury or death.b. If unprotected skin comes into contact with rotatingequipment severe burns can result.Starter Battery PrecautionsSafe Maintenance Considerationsa. Understand the service procedures beforecommencing any work.b. Ensure the work area is clean, dry, well ventilatedand has adequate lighting.c. Isolate the engine starting system beforecommencing any work on the plant.d. All persons using equipment or processes inconnection with the maintenance of plant andmachinery must have received adequate andsuitable training.High Pressure Fluidsa. Never allow any part of the body to come intocontact with high pressure hydraulic oil,compressed air or fuel oil, for example whentesting fuel injection equipment.b. Both digested and injested fluids can lead toserious injury, possibly with fatal results in a veryshort period of time.WARNINGSulphuric acid in battery electrolyte is poisonous, is strongenough to burn skin, eat holes in clothing and causeblindness if splashed into the eyes.a. Do not smoke near the batteries and keep sparksand flames away from them.b. Batteries contain sulphuric acid - if the acid hasbeen splashed on the skin, eyes or clothes flushit away with copious amounts of fresh water andseek immediate medical aid.c. Keep the top of the battery well ventilated duringcharging. Switch off the battery charger beforeconnecting or disconnecting the charger leads.d. Disconnect the battery negative (earth) lead firstand reconnect last.e. Never 'flash' connections to check current flow.f. A damaged or unserviceable battery must neverbe used.g. Do not attempt to charge a frozen battery; it mayexplode; warm the battery to 16 C (60 F).Electrical System Considerationsa. Ensure that the battery is of sufficient capacity tostart the engine down to its minimum operatingtemperature taking into account any drag that maybe imposed on the engine by the type oftransmission that is attached to it.b. Ensure the battery and all engine wiring cablesare of sufficient size to carry the currents required.c. Check that the engine mounted alternator is ofsufficient output to cope with the total electricalload required by the machine to which it is fitted.d. Ensure engine wiring cables are:Bound together in a loom and adequatelysupported.Routed to avoid any hot surfaces, particularly theexhaust system.Not in contact with any rough surfaces or sharpcorners so as to avoid any possibility of chaffingtaking placepage 6Waste Contaminationa. Extreme care must be taken to ensure that wasteoil, fuel, filter elements, coolant concentrate,battery electrolyte, solvents or other toxic wastesare disposed of in accordance with localregulations to prevent contamination.b. Drains and water courses must not be used todispose of contaminated, or waste fluids.Oil Seals Containing VitonSome engines may be fitted with seals or 'O' ringsmanufactured from 'Viton' or a similar material.When exposed to abnormally high temperatures,in excess of 400 C (752 F), an extremely corrosiveacid is produced which cannot be removed from theskin.If signs of decomposition are evident, or if in doubt,always wear disposable heavy duty gloves.Alpha Series Workshop Manual

Section 01General Information- safety, safety symbolsFuel System PrecautionsPrecautions for Oil, Filters and Elementsa. When priming or checking the fuel injection pumptiming, care must be taken to wipe spilled fuel fromthe outside of the engine.b. Always fit a new joint when a union has beendisturbed.c. Special care must be taken to see that there is noleakage from the joints of the fuel pipe connectionto the pump.d. When tightening or loosening the fuel injectionpump delivery connections, use two spanners toprevent the un-sealing of the fuel pump deliveryvalve holders.e. When refitting the fuel pipe from the pump toinjector, the connection to the injector must betightened before the connection to the fuel pump.This procedure will ensure that there is no leakagefrom these joints.f. It is most important that all fuel joints are tight andleak 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 processthis has time to settle before the engine is usedagain, this will minimise the risk of condensationcontaminating the fuel.If cans are used, avoid tipping out the last fewdrops.h. Funnels are very difficult to keep clean in dustyconditions.Wash them before and after use and wrap themup when not required, or fill the tank direct from asmall mouthed screw capped fuel can.i. The fuel injection equipment is manufactured tovery accurate limits and the smallest particle ofdirt will destroy its efficiency.Fuel free from water and contaminants is of theutmost importance.a. Used liquid filters and elements contain some ofthe filtered liquid and should be handled anddisposed of with care.b. After handling new or used elements the usershands should be thoroughly washed, particularlybefore eating.c. Fuel and new or used lubricating oil may causeskin irritation.Contact with used lubricating oil can cause cancer,birth defects or other reproductive harm.d. The materials used in the manufacture andtreatment of some filters and elements may causeirritation or discomfort if they come into contactwith the eyes or mouth and they may give off toxicgasses if they are burnt.e. Extreme care must be taken to ensure that wasteoil, filter elements, solvents or other toxic wastesare disposed of in accordance with localregulations to prevent contamination.f. As a direct result of combustion the lubricating oilmay contain harmful acids and therefore it shouldnot be left in the sump if it is known that the enginewill not be used for extended periods.01.2 SAFETY SYMBOLSThis section identifies the ISO 8999 symbols currently used by Lister PetterAlpha Series Workshop Manualpage 7

Section 01General Information- engine features01.3 ENGINE FEATURESLPWS4 Marine Sail/Work BoatCylinder HeadCoverAir CleanerAxial FanFuelPumpExhaustOutletHeatExchangerSumpDrain PlugAlternatorLPA3Anti-vibrationMountingLifting EyeWater PumpTurbochargerRadiatorFanFuel FilterFuel Lift PumpLPWT4Oil CoolerAdaptorOil FilterLPWS4 Marine Canal StarLifting EyeInletManifoldOil FillerMake-upTank FillerOil lterFuel erOil FillerOil FilterFuel Lift PumpLPW2Sump PumpNewage PRM Gearboxpage 8Alpha Series Workshop Manual

Section 01General Information- engine features01.3.1 ENGINE FEATURES - LPWGElectronic Governorand CarburettorRadiator FanMain Gas SolenoidValve and RegulatorOil FillerLPWG4 U.S. VersionOil FilterRadiator Filler CapElectronic Governor andCarburettorIgnition CoilsAir CleanerMain Gas SolenoidValve and RegulatorAlternatorStarter MotorLPWG4 European VersionAlpha Series Workshop Manualpage 9

Section 01General Information- engine identification01.4 ENGINE IDENTIFICATION01.4.1 NomenclatureLPA2 and 3 - two and three cylinder, directinjection, naturally aspirated axial fan cooled dieselengines.LPW2, 3 and 4 - two, three and four cylinder, directinjection, naturally aspirated water cooled dieselengines.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 dieselengines.LPWS2, 3 and 4 - two, three and four cylinder,indirect injection, naturally aspirated water cooleddiesel engines.01.4.3 Engine Serial NumberThe engine serial number is stamped on a plateattached to the engine.It is necessary to identify the type and build of eachengine to enable the correct maintenance procedures,as described later in this publication, to be carriedout.An example number is shown below.03 00123 LPW3 A 0103 . Year of manufacture code (03 2003)00123 . Consecutive number of engineLPW3 . Model(T turbocharger, S indirect injection)G gas fuelled)A . Anticlockwise rotation01 . Build of engine01.4.2 Build InformationThe engines within each range have beenassembled to predetermined configurations andwhere the build number is preceded by a '9' thisindicates that the engine is either of a non-standardconfiguration, or contains non-standard parts oraccessories.When new parts are required for such a build it issuggested that reference be made to Lister Petter todetermine the exact engine specification and whichparts are non-standard.Where the engine serial number contains a 'G',for example GLPW3, this denotes the engine wasbuilt into a generating set by Lister Petter.A full list of builds is given in "Section 13 - TheEngine Builds".01.4.3 Marine BuildsMarine engines are designated Builds 40, 41, 42,43, 44, 45, 46, 47, 48 and 49.In general 'Alpha' marine propulsion engines aredesigned for the following applications.LPA leisure and commercial craft.LPW - workboats and commercial craft.LPWT - workboats and commercial craft.LPWS - canal boats.page 10Alpha Series Workshop Manual

Section 01General Information- batteries01.5 BATTERY DETAILSWARNINGBattery posts, terminals and related accessories containlead and lead compounds, chemicals known to the Stateof California to cause cancer and reproductive harm. Washhands after handling.01.5.4 Connecting BatteriesIt is most important to ensure that the starterbattery, or batteries, are properly connected and allconnections are tight.WARNINGSulphuric acid in battery electrolyte is poisonous, is strongenough to burn skin, eat holes in clothing and causeblindness if splashed into the eyes.01.5.1 Battery PolarityThe electrical system for all engines is 12 or 24 voltnegative earth.01.5.2 Recommended Battery TypeHeavy Duty Batteries to BS3911:982 or IEC95-1are recommended for all engine applications.For temperatures below -18 C (0 F), highdischarge, low resistance Arctic or Alkaline batteriesmust be used.Lister Petter recommend that a battery shouldprovide a minimum cranking period of 60 secondsfrom a 70% charged 12 volt battery, with a minimumvoltage at the end of the cranking period of 8.4 volts(16.8 volts on a 24 volt system).01.5.3 Preparing a Battery for UseThe following procedure should be used to preparea battery with factory sealed charge.1. Where necessary remove the flash seal in eachvent plug hole.2. Fill with battery grade sulphuric acid of specificgravity 1.260 (1.200 for tropical climates - seeNote). The temperature of this acid should not beabove 30 C (90 F) before filling. The correct levelis 6mm (0.25in) above the separator guards.3. Stand the filled battery for one hour and adjustthe acid to the correct level by adding more acidwhere necessary.4. Charge the battery at 6-12 amps for a minimumperiod of 4 hours.5. At the end of this charge period the specific gravityof the acid in any cell should not be less than 1.260(1.200 for tropical climates).If the specific gravity readings are uneven or thespecific gravity low, continue charging until twoconsecutive half hourly readings of specific gravityand charge voltage are approximately the same.Discontinue charging and allow the battery to coolif the temperature rises above 40 C (110 F).Note:Tropical climates apply to those countries or areas wherethe average temperature of any month of the year exceeds27 C (80 F).Alpha Series Workshop ManualFigure 1.5.1 Battery ConnectionsA - 12 volt system using four 6 volt batteriesconnected in series-parallel.B - 12 volt system using two 6 volt batteries connected inseries.01.5.5 Connecting a Slave BatteryA slave, or booster battery can be connected inparallel with the existing battery to aid starting in coldweather conditions.WARNINGHeavy duty jumper leads must always be used and noattempt must be made to use any others.WARNINGDo not allow the jumper lead free ends to directly, orindirectly touch the engine at any time.1. Connect one end of the jumper lead to the positive( ) post of the slave battery.2. Connect the other end of the jumper lead to thepositive ( ) post of the battery connected to thestarter motor.3. Connect one end of the jumper lead to the negative(-) post of the slave battery.4. Make the final connection of the negative (-) cableto a good earth on the engine frame and awayfrom all the batteries.01.5.6 Disconnecting a Slave Battery1. Start the engine.2. Disconnect the slave battery negative (-) jumperlead first.3. Disconnect the remaining jumper leads.01.5.7 Servicing a BatteryIn freezing weather conditions, run the engine forat least 30 minutes to ensure thorough mixing afteradding distilled water to the battery.The battery electrolyte level should be checkedevery 500 hours and distilled water added, ifnecessary, to bring the level to the bottom of eachfiller neck.Keep the battery clean by wiping it with a dampcloth. If the terminals or battery posts are corrodedwash them with a solution of 1 part baking soda to 4parts of water.To help reduce corrosion, coat the batteryterminals or posts with petroleum jelly and bakingsoda.page 11

Section 01General Information- batteries, cold start performanceThe recommendations made assume that theengine is filled with the recommended type and gradeof lubricating oil and is not required to start againsthigh inertia loads such as concrete mixers, tar boilers,hydraulic pumps, screw pumps and similar. In theseapplications, wherever possible, means should beprovided to overcome such loads by the inclusion ofclutches and unloading valves, etc.01.5.8 Cold Cranking Battery RequirementThe cold cranking battery requirement table belowis to BS3911 and IEC95-1.The table below defines the recommendedminimum cold cranking performance required fromlead acid batteries, when tested at an ambienttemperature of -18 C (0 F).Ambient Temperature Range C ( F)LPA2LPA3LPW2, LPWS2LPW3, LPWS3LPW4, bove 27 (80 )26 to 1 (79 to 34 )0 to -8 (32 to -18 )-9 to -18 (16 to 0 60A315A355A245A350A215A600A285A670A300A01.5.9 Recommended Battery TypeHeavy Duty Batteries to BS3911:982 or IEC95-1are recommended for all applications.For temperatures below -18 C (0 F), highdischarge, low resistance Arctic or Alkaline batteriesmust be used.Lister-Petter recommend that a battery shouldprovide a minimum cranking period of 60 secondsfrom a 70% charged 12 volt battery, with a minimumvoltage at the end of the cranking period of 8.4 volts(16.8 volts on a 24 volt system).01.5.10 Cold Starting PerformanceThe figures given in the table below are for bareengines only.30 to 5 (86 to 41 )LPA, LPW, LPWSLPWT4A-DAmbient Temperature Range C ( F)4 to -15 -16 to -25 -26 to -32(39 to 5 )(3 to -13 )(-15 to -26 )B-D-FC-D-IC - D - I- GB-D-F-IBelow -32 (-26 )C - D - I- G- H1.15.7.1 Table CodeA. 15W/40 Lubricating oil in the sump.B. 10W/30 Lubricating oil in the sump.C. 5W/20 Lubricating oil in the sump.D. 12 volt starting.E. Air inlet manifold heater energised while cranking.F. High discharge, low resistance artic type or alkaline batteries.G. Heating of the engine and batteries in a housing or engine room.H. Air inlet manifold heater energised for pre-heat and while cranking.page 12Alpha Series Workshop Manual

Section 02Engine Servicing and Adjustments- preliminary instructionsSection 02. Engine Servicing and Adjustments02.1 PRELIMINARY INSTRUCTIONSWARNINGMaintenance must be performed by qualified persons whoare conversant with the hazards of fuels, electricity andmachinery.Before commencing any work on the engine read the"Safety Precautions and Safe Working Practices" at thefront of this manual.Dismantling and RebuildingWhen the engine is being dismantled all itemsmust be identified and retained in their respectivecylinder orientation and all related components mustbe treated similarly.The instructions given deal with individualcomponents and it may be necessary to removeothers before the relevant instructions can be carriedout.a. Disconnect or isolate any non-electric startingsystems.b. Disconnect and remove the battery.c. Drain the diesel fuel and lubricating oil.d. Drain the coolant.e. Disconnect all services.f. Remove any accessories or components that maybe susceptible to damage when the engine isturned out of its normal plane.Because of the various engine configurations, andinstallations in which the engine can be fitted, it is notpossible to give detailed instruction for each one.Tightening torques are included in the text asnecessary and in table format in "07.5 SpannerTorques". Sealing compounds and mating faceinstructions are given in "Section 07.4".When assembling the engine, use the same typeof lubricating oil as used in the engine to spray allmoving parts during assembly. All bearings andbushes must be well lubricated during assembly.Renew all joints, gaskets, connecting rod nuts andbolts and the cylinder head bolts.WARNINGDo not attempt to remove the fuel injection pumps withoutreferring to the relevant instructions.WARNINGThese engines are fitted with hydraulic tappets thereforeit is important to follow the procedures given.Alpha Series Workshop Manualpage 13

Section 02Engine Servicing and Adjustments- air cleaner02.2 THE AIR CLEANER02.2.2 The Cyclonic Air CleanerPlastic air cleaners have been available sinceMarch 2000 and these complement the existing sheetmetal types.Care must be taken to ensure that the air cleanerdraws air in at a temperature not exceeding:a. 12 C (54 F) above outside ambient in temperateclimates.b. 6 C (43 F) above outside ambient in tropicalclimates.A cyclonic air cleaner can be remote or enginemounted over the flywheel housing, both areconnected to the engine by a moulded rubber hosesecured by jubilee clips.Regularly remove the dust cap (A) and empty allthe dust.02.2.1 The Light Duty Air CleanerThe industrial type has a replaceable paperelement, and the marine type a serviceable foamelement.The snout is normally fitted lying horizontal andpointing towards the gear end although the cleaneritself 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. Industrial Engines:a. Fit a new paper element.Figure 2.2.2 Cyclonic Type Air Cleaner1. Access to the paper element (B) is gained byundoing the wing nut in the centre of the mainbody of the filter.2. Remove the element.3. The element can be cleaned by directing a lowpressure compressed air nozzle up and down thepleats from inside the element.4. Inspect the element for damage by placing asuitable light source inside it. If the element isfound to have any holes it must be replaced.5. Replace the element and dust cap.02.2.3 Intake RestrictionThe maximum intake restriction figures at full loadare 254mm WG (10.0in WG).Figure 2.2.1 Light Duty Air CleanerMarine Engines:b. Wash the foam element in petrol or fuel oil.c. Soak the element in clean engine lubricating oil

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