Lister Petter GW3 Service manual
GW3, GWT3, GW4, GWT4, GWT6-1A
GWT6-2A, GWTA6 ENGINEs
OpErATOrs' HANdbOOk
ORIGINAL INSTRUCTIONS
P027-08199
GAMMA SERIES
2
Associated Publications
Master Parts Manual P027-08557
Workshop Manual P027-08220
Technical Handbook P027-08315
Statement of Indemnity
The information, specications, 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.
P027-08199 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
INTRODUCTION ............................................................................................... 6
Engine Identication 6
Engine lifting 7
Care of your engine 7
Service literature 7
Training 7
1. SAFETY INFORMATION AND PRECAUTIONS ............................................ 8
1.1 Personal Safety 9
1.2 General Precautions 9
1.3 Care with Lubricating Oil 11
1.4 Precautions with Diesel Fuel 11
1.5 Precautions with Coolant 11
1.6 Precautions with Batteries 12
Battery Charge Alternator 12
1.7 Care with Electrical Systems 13
Wiring Cables 13
1.8 Lifting Precautions 13
1.9 Care with Filters and Elements 14
1.10 Waste Disposal 14
2. ENGINE PARTS AND TECHNICAL DATA ................................................... 15
2.1 Front and Left Side 15
2.2 Rear and Right Side 15
3. OPERATING INSTRUCTIONS .....................................................................17
3.1 Starting the Engine 17
3.1.1 Starting a Warm Engine 17
3.1.2 Starting a Cold Engine without Starting Aids 17
3.1.3 Starting a Cold Engine with Starting Aids 18
3.2 Stopping the Engine 18
3.3 Adjustment of Engine Speed 18
4
3.4 Running-In 19
3.5 Altitude 19
4. ENGINE FLUIDS ..........................................................................................20
4.1 Fuel Specication 20
4.1.1 Low Temperature Fuels 20
4.2 Lubricating Oil Specication 21
4.3 Coolant Specication 22
5. ROUTINE MAINTENANCE .......................................................................... 23
5.1 Maintenance Schedule 23
5.2 Draining the Cooling System 24
5.3 Checking the Drive Belts 25
5.3.1 Adjusting the Belt Tension 25
5.4 Cleaning the Fuel Lift Pump 26
5.5 Checking the Fuel Pre-Filter 27
5.6 Renewing the Fuel Filter Element 27
5.6.1 Renewing a Separate Type Fuel Filter Element 27
5.6.2 Renewing a Canister Type Fuel Filter Element 28
5.6.3 Renewing a Quick Release
Canister Type Fuel Filter Element 28
5.7 Renewing a Fuel Injector 30
5.8 Eliminating Air from the Fuel System 31
5.8.1 Standard Method 31
5.8.2 Method Using In-Line PB Type Injection Pump 33
5.9 Changing the Lubricating Oil 34
5.10 Replacing the Oil Filter Canister 34
5.11 Cleaning the Breather system 35
5.12 Servicing the Air Cleaner 36
5.12.1 Air Filter 37
5.12.2 Restriction Indicator 38
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
5.13 Checking Valve Clearances 38
5.13.1 Three Cylinder Engines 38
5.13.2 Four Cylinder Engines 39
5.13.3 Six Cylinder Engines 40
5.13.4 Valve Positions 40
6. FAULT DIAGNOSIS ..................................................................................... 41
6.1 Problems and Possible Causes 41
6.2 Code List of Possible Causes 42
7. ENGINE STORAGE ..................................................................................... 43
7.1 Preparing the Engine for Storage 43
7.2 Returning the Engine to Service 43
8. MAINTENANCE RECORD .......................................................................... 44
8.1 Routine Maintenance 44
8.2 Non-Routine Maintenance 48
9. WARRANTY ................................................................................................. 52
9.1 Standard Warranty Cover 52
9.2 Conditions of Warranty 52
9.3 Limitations of Warranty 53
9.4 Repairs under Warranty 53
9.4.1 Contact Details 53
APPENDIX: FUEL PUMPS AND GOVERNORS ..............................................54
PB Pump 54
Adjustment and Use of the PB Pump 55
Adjustment of Static Fuel Supply 55
RSV Governor - PB Pump 56
Rotary Type Fuel Pumps 57
Electronic Governor 58
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
INTRODUCTION
Your Gamma engine should be correctly operated and serviced in accordance
with this handbook.
To obtain the best performance and the longest life from your engine you must
ensure that maintenance operations are carried out at the intervals indicated in
5. Routine Maintenance
lubricating oil regularly in order to ensure that the engine components remain clean.
If the engine operates in a very dusty environment or other adverse conditions
some of the maintenance intervals will be shorter. Ensure that all adjustments and
repairs are done by properly trained personnel. Your Lister Petter Power Systems
distributor can assist in this matter and will also supply the genuine Lister Petter
Power Systems parts needed for your engine.
to the section below.
ENGINE IDENTIFICATION
In this handbook the different engine types are indicated by code letters.
The meanings of these codes are as indicated below:
GAMMA MODELS
Model Number Cylinders Aspiration
GW3 3 Natural
GWT3 3 Turbocharged
GW4 4 Natural
GWT4 4 Turbocharged
GWT6-1A 6 Turbocharged
GWT6-2A 6 Turbocharged
GWTA6 6 Turbocharged
and Intercooled
The engine number is stamped on a label fastened to the left side (1) or rear (2)
Example of the engine numbers are:
09300158GW40015 or 09300021GWT62A18RP
09 ..................................... Year code (09 = 2009)
3 ....................................... Factory code
00158 ............................... Unique engine number
GW ................................... Engine model (GWT)
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
4 ....................................... Number of cylinders
00 ..................................... Reserved for 6 cylinder turbocharged variant 1A or 2A
15 ..................................... Engine speed 1500 r/min or
18 ..................................... Engine speed 1800 r/min or
22 ..................................... Engine speed 2200 r/min
RP .................................... Rotary fuel injection pump
This should be quoted when requesting parts, service or information from your
Lister Petter Power Systems distributor.
ENGINE LIFTING
In different applications of the engine the maximum dry weight (without coolant
or lubricating oil) will vary. The maximum recommended weight of the engines
for lifting is as follows:
3-cyIinder engines: 420 kg (925 Ib)
4-cyIinder engines: 500 kg (1100 Ib)
6-cylinder engines: 600 kg (1320 Ib)
Before lifting the engine, read 1.8 Lifting Precautions.
CARE OF YOUR ENGINE
Your engine must receive the correct routine maintenance as described in section 5.
If faults do occur they can usually be diagnosed and corrected using the information
in section 6.
In case of queries about your engine or its installation contact your Lister Petter
Power Systems distributor. Your distributor can undertake repairs and will ensure
SERVICE LITERATURE
Workshop manuals and other service publications are available from your Lister
Petter Power Systems distributor.
TRAINING
Local training for the correct operation, service and overhaul of engines is available
at certain Lister Petter Power Systems distributors. If special training is necessary,
your distributor can advise you how to obtain it.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
Carefully read and follow all safety messages in this manual (some items only
symbols on your equipment. You must also refer to the local regulations in the
country of use.
Ensure that you are familiar with the safety symbols used by Lister Petter Power
Systems (Figure 1).
Take especial care when handling potentially hazardous chemicals. These include
lubricants, fuel, coolant concentrate, battery acid (see sect ion 1.4 Precautions
with Batteries), paint and adhesives.
health hazards, safety and emergency procedures and any necessary personal
protection equipment required while working with hazardous materials.
CAUTION
Follow all safety instructions accurately.
1. SAFETY INFORMATION
AND PRECAUTIONS
8
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
ATALL TIMES. 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
1. This gure identies the ISO 8999 symbols
currently used by Lister Petter Power Systems.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
1.1 PERSONAL SAFETY
emergency procedures.
necessary.
leave the working area.
work being done.
WARNING
Be aware that the fan cannot be seen clearly while the engine is running.
WARNING
KEEP CLEAR OF ALL ROTATING PARTS. DO NOT WEAR A NECKTIE, A
SCARF, LOOSE CLOTHING OR A NECKLACE WHEN WORKING CLOSE TO
A RUNNING ENGINE. ENTANGLEMENT WITH ROTATING PARTS COULD
CAUSE SERIOUS INJURY OR DEATH.
to avoid causing a short circuit.
WARNING
Prolonged exposure to loud noise can cause impairment or loss of hearing.
1.2 GENERAL PRECAUTIONS
Engine operators must be instructed in the correct procedures before attempting
to start any engine.
WARNING
It is dangerous to permit an inexperienced person to start any diesel engine.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
designed.
WARNING
LACK OF VENTILATION CAN RESULT IN THE BUILD-UP OF TOXIC, AND
POTENTIALLY FATAL, EMISSIONS.
is in operation.
operator's position.
position before the engine is started.
safe operation and put the operator at risk.
equipment.
oil, or adjust it in any way.
WARNING
NEVER ALLOW ANY PART OF THE BODY TO COME INTO CONTACT WITH
HIGH PRESSURE FUEL OIL, COMPRESSED AIR OR HYDRAULIC OIL.
CONTACT WITH, OR INGESTION OF, THESE SUBSTANCES CAN CAUSE
SERIOUS INJURY OR DEATH.
spillages immediately.
soil your hands.
WARNING
Diesel fuel and lubricating oil can damage the skin.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
WARNING
Do not expose pressurised containers to heat. Do not incinerate or puncture
them.
1.3 CARE WITH LUBRICATING OIL
that is contaminated with oil into your pockets.
strictly in accordance with local regulations. Preferably take to a recycling site.
1.4 PRECAUTIONS WITH DIESEL FUEL
WARNING
Material that has been contaminated by diesel must be kept away from all
sources of ignition and safely disposed of.
immediately.
WARNING
HIGH PRESSURE FUEL CAN CAUSE SERIOUS INJURY OR DEATH.
1.5 PRECAUTIONS WITH COOLANT
while the coolant is under pressure, because dangerous hot coolant can be
discharged.
closed cooling circuit.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
1.6 PRECAUTIONS WITH BATTERIES
Batteries contain hazardous sulphuric acid.
Great care therefore needs to be taken when using them.
WARNING
BATTERY ACID IS HIGHLY CORROSIVE AND POISONOUS, AND WILL BURN
SKIN AND CLOTHING. IT WILL CAUSE PERMANENT DAMAGE, INCLUDING
BLINDNESS, IF SPLASHED INTO THE EYES.
with copious amounts of water and seek medical aid.
WARNING
The electrolyte gases are highly ammable.
system.
battery to 16°C (60°F).
reconnected last.
Battery Charge Alternator
serious damage can be done.
polarity are correct.
off position.
CAUTION
A short circuit or reversal of polarity will ruin diodes and transistors.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
welding when a pole strap is directly or indirectly connected to engine.
1.7 CARE WITH ELECTRICAL SYSTEMS
operating temperature, taking into account any drag that may be imposed on
the engine by the type of transmission that is attached to it.
carry the currents required.
Wiring Cables
Ensure that wiring cables are:
1.8 LIFTING PRECAUTIONS
The engine lifting eyes are suitable for lifting only the engine and accessory
used to attempt to lift an entire generating set.
1.8 Lifting a Gamma series engine using overhead lifting eyes.
WARNING
Do not attempt to lift the complete plant using the engine lifting eyes.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
Preparations required before lifting an engine:
secure.
Note:
The torque setting for the lifting eyes is 44 Nm (33 ft Ib or 4.5 kgf m).
lifting appliance shown in Figure 1.8 is recommended for use when lifting
vertically and should be connected directly to the lifting eyes.
lifting equipment and the cover.
WARNING
DO NOT WORK UNDER ANY PLANT THAT IS HELD ONLY BY OVERHEAD
LIFTING EQUIPMENT.
1.9 CARE WITH FILTERS AND ELEMENTS
certain seals) can become extremely dangerous if burned. Never allow burnt
material to come into contact with the skin or eyes.
WARNING
The materials used in the manufacture and treatment of some lters and
elements may cause irritation or discomfort. If they come into contact with the
eyes or mouth, and they may give off toxic gases if they are burnt.
handled and disposed of with care.
1.10 WASTE DISPOSAL
regulations to prevent contamination.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
Lister Petter Power Systems engines are built for many applications. The views
2. ENGINE PARTS AND TECHNICAL DATA
2.1 FRONT AND LEFT SIDE
1. Filler cap for lubricating oil
3. Lubricating oil cooler
4. Fuel injection pump
5. Lubricating oil dipstick
8. Crankshaft pulley
10. Water pump
11. Fan
12.Water outlet
13. Front lift bracket
14. Injector
2.2 REAR AND RIGHT SIDE
15. Turbocharger
16. Exhaust manifold
17. Radiator
18. Alternator
19. Bracket
20. Lubricating oil sump
21. Starter motor
22. Flywheel housing
23. Flywheel
25. Rear lift bracket
26. Induction manifold
2.1 Engine type GWT6: front and left side
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
2.2 Engine type GWT4: rear and right side
TECHNICAL DATA
General Engine Data
Engine cycle 4-stroke
Cylinder arrangement Inline
Direction of rotation Anti clockwise viewed from
ywheel end
Induction System
GW3, GW4 Naturally aspirated
GWT3, GWT4, GWT6 Turbocharged
GWTA6 Turbocharged and Intercooled
Combustion System Bore (nominal) 100 mm (3.94 in.)
Stroke 127 mm (5 in.)
Compression Ratio GW3, GW4 16.5:1
GWT3, GWT4, GWT6, GWTA6 17.5:1
Cubic Capacity
3-cylinder engines 2.99 litres (183 in3)
4-cylinder engines 3.99 litres (243 in3)
6-cylinder engines 5.99 litres (365 in3)
Firing Order
3-cylinder 1 - 2 - 3
4-cylinder 1 - 3 - 4 - 2
6-cylinder 1 - 5 - 3 - 6 - 2 - 4
Valve Clearance Inlet 0.20 mm (0.008 in.)
Exhaust 0.45 mm (0.018 in.)
Lubricating Oil Pressure
(min. when at max. speed and
normal engine temperature)
Engine without piston cooling jets 207 kN/m2
Engine with piston cooling jets 280 kN/m2
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
3.1 STARTING THE ENGINE
Several factors affect engine start, for example:
of operation.
Lister Petter Power Systems engines can be equipped with various cold starting
systems. For the Gamma engine range these systems are:
Fuel Start Aid:
of diesel fuel in the induction manifold in order to heat the induction air.
3. OPERATING INSTRUCTIONS
3.1.1 Starting key positions:
R=run; H=heat; S=start
3.1.2 Starting key positions:
R=run; S=start
3.1.1 Starting a Warm Engine
1. If the engine is equipped with a manual stop control, ensure that it is in the run
position (R).
2. Adjust the engine speed control to the quarter open position.
3. Turn the key to the start position (HS/S) to engage the starter motor (Figures
3.1.1 and 3 .1.2).
4. Allow the start key to return to position R as soon as the engine starts. Always
ensure that the engine and starter motor are stationary before the starter motor
is engaged again.
3.1.2 Starting a Cold Engine without Starting Aids
1. lf the engine is equipped with a manual stop control, ensure that it is in the run
position (R).
2. Adjust the engine speed control to the maximum speed position.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
3. Turn the start key to the start position (S) to engage the starter motor (Figure
3.1.2). Allow the key to return to position R when the engine starts. Adjust the
speed control to get an even idle speed.
4. lf the engine does not start in 30 seconds, allow the start key to return to the
Rposition for another 30 seconds. Then engage the starter motor again for a
maximum period of 30 seconds.
3.1.3 Starting a Cold Engine with Starting Aids
1. If the engine is equipped with a manual stop control, ensure that it is in the
run position.
2. Turn the start key to position Hand leave there for 15 seconds (Figure 3.1.1).
3. Adjust the engine speed control to the maximum speed position.
4. Turn the start key to position HS to engage the starter motor (Figure 3.1.1).
Allow the start key to return to position Ras soon as the engine starts. Adjust
the speed control to get an even idle speed.
5. lf the engine does not start in 15 seconds, turn the start key to the Hposition
and hold it there for 10 seconds then engage the starting motor again.
CAUTION
A short circuit or reversal of polarity will ruin diodes and transistors.
3.2 STOPPING THE ENGINE
0or operate
the manual stop control. If a manual stop control is used, ensure that the control
returns to the run position after the engine has stopped. Also, ensure that the
engine start key is turned to the 0position.
CAUTION
It is recommended that a turbocharged engine is run at approximately 1000
r/min at a reduced load for 2-3 minutes before it is shut down. This allows the
turbocharger to cool.
3.3 ADJUSTMENT OF ENGINE SPEED
The idle or maximum speed setting must not be changed by the engine operator
as this may damage the engine or transmission.
The warranty of the engine is invalidated if the seals on the fuel injection pump
are broken during the warranty period by a person who is not approved by Lister
Petter Power Systems.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
3.4 RUNNING-IN
A gradual running-in of a new engine is not necessary.
CAUTION
Prolonged operation at ght load during the early life of the engine can cause
lubricating oil to enter the exhaust system.
Maximum load can be applied to a new engine as soon as the engine is put into
service and the coolant temperature has reached a minimum of 60°C (140°F).
is put into service.
CAUTION
Do not operate the engine at high speeds without load.
CAUTION
Do not overload the engine.
3.5 ALTITUDE
If the naturally aspirated engine is to run at an altitude above 600 m (2000 ft)
the fuel delivery can be changed to reduce fuel consumption and smoke. Lister
Petter Power Systems can give the percentage of fuel reduction necessary if
details of engine application and ambient conditions are provided. Information for
turbocharged engines can be obtained from Lister Petter Power Systems. Changes
to the settings of the fuel injection pump must be made by a Lister Petter Power
Systems distributor or by an approved distributor for the fuel injection pump.
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GAMMA SERIES ENGINES OPERATORS' HANDBOOK
4.1 FUEL SPECIFICATION
To get the correct power and performance from your engine, use good quality fuel.
indicated below.
4. ENGINE FLUIDS
FUEL SPECIFICATION
Factor Specication
Cetane Number 50 minimum
Viscosity 2.0 / 4.5 centistoke at 40°C
Density 0.835-0.855 kg/litre
Sulphur 0.2% of mass maximum
Distillation 85% at 350°C
Cetane Number
This indicates ignition performance. A fuel with a low cetane number can cause
starting problems and affect combustion.
Viscosity
the given limits.
Density
A low-density fuel reduces engine power. A high density fuel increases engine
power and exhaust emissions
Sulphur
A high sulphur content (not normally found in Europe, North America or
Australasia) can cause engine wear. Where only high sulphur fuels are
available, it is necessary to use highly alkaline lubricating oil or to renew the
lubricating oil more frequently (see sections 5.1 and 5.9).
Distillation
This is an indication of the mixture of different hydrocarbons in the fuel. A high
ratio of lightweight hydrocarbons can affect the combustion characteristics.
4.1.1 Low Temperature Fuels
Special winter fuels may be available for engine operation at temperatures below
0°C. These fuels have a lower viscosity and also limit the wax format ion in the
This manual suits for next models
6
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