Lister Petter alpha Series Service manual

LPW/LPWS/LPWX ENGINE
OPEratOrS' HaNdbOOk
ORIGINAL INSTRUCTIONS
15.0 - 29.5 kW | 20.1 - 39.5 bhp
ALPHA SERIES
LPW4
G Build Engine
xed speeds
1500 | 1800 | 3000 | 3600 r/min
LPW4 G Build Engine
1
* Optional items standard on most builds.
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.
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
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.
P027-08270

2
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 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, the Distributor nor the 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 Power Systems organisation cannot
be relied upon for correct material, dimensions or nish. The Company cannot therefore
be held responsible for any damage arising from the use of such parts, and the guarantee
will be invalidated.
P027-08270 Copyright © Lister Petter Power Systems
WARNING
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNING
MENTIONED IN THIS MANUAL.
WARNING
IMPROPER OPERATION OR MAINTENANCE PROCEDURES COULD
RESULT IN SERIOUS ACCIDENT OR DAMAGE TO THE EQUIUPMENT
CAUSING INJURY OR DEATH.
WARNING
NON-COMPLIANCE WITH THESE INSTRUCTIONS MAY INVALIDATE THE
WARRANTY.
WARNING
MAKE CERTAIN THAT THE ENGINE CANNOT BE STRTED IN ANY WAY
BEFORE UNDETAKING ANY MAINTENANCE, PARTICULARLY IN THE CASE
OF AUTOMATICALLY STARTING GENERATING SETS.

3
CONTENTS
1. INTRODUCTION........................................................................................... 7
1.1 Using the Handbook
1.2 Engine Identication
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
2.6 Precautions with Filters and Elements
2.7 Precautions with Oil Seals
2.8 Precautions with Batteries
2.9 Precautions with Electrical Systems
2.10 Waste Disposal
2.11 Precautions before Starting Engine
2.12 Lifting Precautions
2.13 Precautions before Maintenance
3. TECHNICAL DATA...................................................................................... 17
3.1 Technical Data Table
3.2 Combustion Air
3.3 The Cooling System
4. OPERATING INSTRUCTIONS....................................................................18
4,1 General Information
4.2 Keystart
4.3 Failure to Start
4.4 Stopping of Engine

4
5. ENGINE FLUIDS......................................................................................... 22
5.1 Fuel
5.1.1 Fuel Specication
5.1.2 LPWS Bio
5.2 Lubricating Oil
5.2.1 Oil Specication
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 Specication
5.3.2 Engine Cooling System
5.3.3 Water Quality
5.3.4 Additives to Water
5.3.5 Coolant Capacity
5.3.6 Maintenance of Coolant
6. ROUTINE MAINTENANCE......................................................................... 28
6.1 General
6.2 Before Starting Maintenance
6.3 Important Instructions
6.4 Maintenance Schedule
6.5 Lubricating Oil
6.5.1 Draining the Oil Sump
6.5.2 Relling the Oil Sump
6.5.3 Changing the Oil Filter
6.6 Cooling System
6.6.1 Draining the Cooling System
6.6.2 Flushing the Cooling System
6.6.3 Filling the Cooling System
6.7 Fuel System
6.7.1 Priming the Fuel System
6.7.2 Changing the Agglomerator
6.7.3 Changing the Fuel Filter
6.8 Radiator Fan Drive Belt
6.9 Air Cleaner
6.9.1 Light Duty Air Cleaner
6.9.2 Cyclonic Air Cleaner

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
6.10 Battery
6.11 Long Term Storage
6.11.1 Returning the Engine to Service
7. TROUBLESHOOTING................................................................................ 38
7.1 General
7.2 Method of Fault Diagnosis
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

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
2.1 Features of the LPW
series diesel engines
Oil Filter
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

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
1. INTRODUCTION
This handbook explains the operation and routine maintenance of Lister Petter
water cooled diesel engines in the Alpha (LPW,LPWS and LPWX) 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.
1.1 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
instructions given. This is for your safety and to ensure the correct maintenance
of your engine. For specific aspects of operation and maintenance, use the table
of contents (page 3, 4 and 5) to find the section you need. Where instructions
are numbered in sequence, they must be followed in that order. This applies in
particular to maintenance and repair procedures (sections 6 and 7).
In cases of difficulty, or to obtain spare parts, please consult your local Lister
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. 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 6 show features of the different engine models. When
following the instructions in this handbook you will need to be familiar with the
parts labelled.

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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 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
LPWS3 Three cylinders, water cooled, naturally aspirated, indirect injection
LPWS4 Four cylinders, water cooled, naturally aspirated, indirect injection
LPWST4 Four cylinders, water cooled, naturally aspirated, indirect injection
1.4 RUNNING-IN
To assist running-in all engines are dispatched with an initial fill 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.

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
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.
WARNING
This warning draws attention to special information or procedures which must
be strictly observed. Failure to do so may result in personal injury.
WARNING
THIS WARNING DRAWS ATTENTION TO SPECIAL INFORMATION OR
PROCEDURES WHICH MUST BE STRICTLY OBSERVED. FAILURE TO DO
SO MAY RESULT IN SERIOUS INJURY OR DEATH.
2.1 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 safety instructions accurately.
Carefully read and follow all safety information and instructions in this manual.
Observe the safety and informative symbols on your engine and equipment.
2.1.1 Emergency Precautions
• Be prepared with suitable equipment and knowledge in case a fire 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.
2. SAFETY INFORMATION

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
2.1.2 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 fitted by
the purchaser. Keep all safety guards in position.
• Do not make any unauthorised modifications as these may affect the safe
operation of the engine and put the operator at risk.
2.1.3 Emissions
WARNING
MODEL YEAR 2019 ENGINES ONWARDS DO NOT COMPLY WITH U.S.
FEDERAL OR EUROPEAN EXHAUST EMISSIONS REGULATIONS FOR
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
DIESEL ENGINE EXHAUST AND SOME OF ITS CONSTITUENTS ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS, AND OTHER REPRODUCTIVE HARM.
2.2 PERSONAL SAFETY
• Wear personal protective clothing and safety equipment appropriate to the
work being done.
• Keep clear of moving parts at all times.
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.

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
2.3 SAFETY SYMBOLS
This figure identifies the ISO8999 symbols currently used by Lister Petter Power
Systems.
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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
1. Safety Symbols This fi gure identifi es the ISO 8999 symbols currently used by Lister Petter
WARNING
KEEP THE BODY AND CLOTHING
CLEAR OF MOVING OR HOT PARTS
AT ALLTIMES. 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 emergency procedures and
• Tie long hair back securely.
• Wear close-fitting 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 fitted.

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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.
• Handle uids 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 fluid 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.
2.4.1 Fuel and High Pressure Fluids
• Store fuel and other ammable liquids away from fire hazards.
• Always stop the engine before refuelling.
• Do not overfill the fuel tank.
• When working with fuel do not smoke or work near to heaters or other fire
hazards.
• High pressure uids are extremely hazardous. Never allow any part of the body
to come into contact with high-pressure fuel oil, compressed air or hydraulic
oil, for example when testing fuel injection equipment.
WARNING
Do not expose pressurised containers to heat, and do not incinerate or puncture
them.
WARNING
NEVER TOUCH OR INGEST HIGH PRESSURE FLUIDS SUCHAS HYDRAULIC
OIL, COMPRESSED AIR OR FUEL OIL. THIS COULD LEAD TO SERIOUS
INJURY OR DEATH.

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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.
• Always fit 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 refitting 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 fill the fuel tank through a fine strainer. It is best to do this at the end
of the engine work period so 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 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 can.
• The fuel injection equipment is manufactured to very accurate limits and the
smallest particle of dirt will destroy its efficiency.
WARNING
Keep the fuel free from water and contaminants.
2.6 PRECAUTIONS WITH FILTERS AND ELEMENTS
• Used filters and elements contain some of the filtered 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.

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
WARNING
Take careful precautions with 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.
2.7 PRECAUTIONS WITH OIL SEALS
Some engines may be fitted 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 OIL SEAL CONTAINING VITON (OR SIMILAR MATERIAL)
DEGENERATES, IT PRODUCES AN EXTREMELY CORROSIVE ACID
THAT CANNOT BE REMOVED FROM THE SKIN. IF YOU SEE SIGNS OF
DECOMPOSITION, OR ARE IN DOUBT, WEAR DISPOSABLE HEAVY DUTY
GLOVES.
• If in any doubt about an oil seal, always wear disposable heavy duty gloves.
2.8 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 ames away from them.
Do not work near to heaters or other fire hazards.
• Switch off the battery charger before connecting or disconnecting the charger
leads. Disconnect the battery negative (earth) lead first and reconnect last.
• Keep the top of the battery well ventilated during charging.
• Never '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).
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, ush it away with copious amounts of fresh
water and seek medical aid.

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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 transmission that is attached to it.
• Ensure that the battery and all engine wiring cables are of sufficient size to
carry the currents required.
• 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.
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 chafing taking place.
Alternator
The following points must be strictly observed when an alternator is fitted, 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.
• Never disconnect the battery unless the engine has stopped and all switches
are in the off position.
• Always ensure that cables are fitted to their correct terminals.
CAUTION
A short circuit or reversal of polarity will destroy diodes and transistors.
• Never 'ash' any connection to check the current ow.
• Never experiment with any 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.
2.10 WASTE DISPOSAL PRECAUTIONS
• 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.

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
WARNING
To avoid contamination and personal injury, never dispose of toxic or other
waste except in accordance with ofcial regulations.
2.11 PRECAUTIONS BEFORE STARTING
WARNING
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.
• Ensure that the engine is free to turn without obstruction.
• Check that the lubricating oil level is correct. The oil sump must be filled to the
‘full’ mark on the dipstick; do not overfill.
• The radiator must be filled to within 13-25 mm (0.5-1.0 in) below the neck of
the radiator filler with the correct coolant mixture. See section 5.3.
• Check that the fuel supply 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.
2.12 LIFTING PRECAUTIONS
Engine lifting eyes are fitted 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 fitted by Lister Petter Power Systems.
2.13 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 machinery have received adequate and suitable
training.

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
3.2 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.
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
derating. If the combustion air temperature 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).
3.3 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.
3. TECHNICAL DATA
3.1 TECHNICAL DATA TABLE
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 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 in2)
3000
r/min1
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 5.2.3.2: Sump Capacity (page 25).
Coolant capacity Refer to table 5.3.5: Engine Block Coolant Capacity (page 26).
Note: Oil Pressure at 3000 r/min is with the oil at 110°C (230°F).

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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 2 and the information below on
controls and the starting procedures.
CAUTION
DO NOT USE ETHER BASED COLD START AIDS UNDER ANY
CIRCUMSTANCES.
WARNING
DO NOT BREATHE EXHAUST GASSES. THEY CONTAIN CARBON
MONOXIDE, A COLOURLESS, ODOURLESS GAS THAT CAN CAUSE
UNCONSCIOUSNESS AND DEATH.
WARNING
ENSURE ALL ENGINE FLUIDS ARE CHARGED / FILLED TO CORRECT
LEVELS IN ACCORDANCE WITH SECTION 5, BEFORE OPERATION.
CAUTION
On LPWT4/LPWST4 engines, ensure that the turbocharger housing is full of
oil. Failure to do so can result in serious damage to the bearings. 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.
4.1 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.
Engines not fitted with a fuel control solenoid have a spring clip to hold the engine
control in the stop position.
4. OPERATING INSTRUCTIONS

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
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 fitted 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 fitted to the inlet manifold.
LPWT4: a 696 W heater plug (A) is fitted in the inlet manifold.
LPWS: a 12v glow plug (B) is fitted in each cylinder and a 696 W heater plug (A)
is also fitted in the inlet manifold as standard.
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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 USE ETHER BASED
COLD START AIDS UNDER ANY
CIRCUMSTANCES.
WARNING
DO NOT BREATH EXHAUST
GASES. THEY CONTAIN CARBON
MONOXIDE, A COLOURLESS,
ODOURLESS GAS THAT 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
solenoid 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.
4.1 Heater and glow plugs - A. Manifold heater plug; B. Cylinder glow plug.
4.2 KEY START
Before starting your engine read the cautions, warnings and the general information
above.
4.2.1 Start control 4.2.2 Key start
Starting LPW(X) Engines
1.With reference to Figure 4.2.1 and 4.2.2, 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.

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LPW / LPWS / LPWX ENGINE OPERATORS' HANDBOOK
3.Turn the key clockwise to the START position. 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.With reference to Figure 4.2.1 and 4.2.2, 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 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 LPWT Engines
1.With reference to Figure 4.2.1 and 4.2.2, 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 pposition 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 engine has attained full speed.
4.When the engine has attained full speed release the key and it will return to the
RUN position due to internal spring.
5.On variable speed engines reduce the engine speed as necessary.
4.3 FAILURE TO START
Should the engine fail to start within 30 seconds, release the key and, after allowing
sufficient time for all moving parts to stop, attempt to restart.