Lister Petter alpha Series Service manual
Long Running LLR genset
opeRatoRs' Handbook
suppLement
P027-08373
ORIGINAL INSTRUCTIONS
ALPHA SERIES
2
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
tech nical 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
P027-08373
Copyright © Lister Petter Power Systems
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.
3
CONTENTS
Long Running LLR Genset ..........................................................5
1. Introduction ..............................................................................6
2. Tank Preparation .....................................................................7
3. Tank Installation .......................................................................9
4. Engine Adaption ....................................................................10
5. Auxiliary Filter ........................................................................13
6. Expansion Tank .....................................................................15
7. Lubricating Oil Tank Drain Pipe .............................................16
8. Commissioning ......................................................................17
9. Checklist For OEM Long Run Generator Set Constructors .. 18
10. Routine Maintenance...........................................................20
11. Parts List ..............................................................................21
4
5
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
LONG RUNNING LLR GENSET
1. Drawing of the long-running LLR generating set with oil reservoir in the base
AUXILIARY FILTER
6
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
1. INTRODUCTION
This publication is a supplement to the
Alpha LLR generating set operators'
handbook, publication P027-08108.
long-running Alpha generating set.
generating set in having an oil reservoir
in the base. It has been designed to
longer periods without servicing.
line in the base) and the lubricating oil
PRINCIPLE OF OPERATION
that the standard mechanical lube oil
oil tank and the second is pumping it
around the engine.
The standard engine oil pickup is
removed and replaced with a pipe
crankcase door. From this there is then
connect between the door and the 55-
litre base mounted lube oil tank. The oil
is drawn up this pipe into the oil pump
and then circulated around the engine
engine then drips down into the engine
external lube tank via a large return
pipe in the crankcase door.
between the engine crankcase and the
the external lube oil tank.
To ensure that the oil is maintained in
good operational condition throughout
Lister
Petter Power Systems HD auxiliary
lter.
coolant expelled during the extended
returned to the radiator when the
engine cools.
close as practicable to the genset. The
7
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
2. TANK PREPARATION
Figure 2 represents the lubricating
oil tank. Prepare the tank according
(the letters and headings allude to the
BREATHER RETURN (A)
1.Fit copper washer 013-22350 to
coned pipe union 366-01100.
A. Fitting the washer on the pipe union of
the breather return.
BYPASS RETURN (B)
4.Fit copper washer 013-22350 to
union 103-00106.
B. Applying thread sealant to the union of
the bypass return.
2. LPW2 – Lube Tank 803-03092
LPW3 – Lube Tank 803-03070
LPW4/T4 – Lube Tank 803-03077
A: Breather return;
B: Bypass return;
C: Lube supply to engine;
D: Oil level;
E: Lube tank ll;
F: Oil return;
G: Inspection Cover.
8
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
LUBE SUPPLY TO ENGINE (C)
7.Fit copper washer 013-21778
01189/089.
OIL LEVEL (D)
into the lubricating oil tank – ensure
11. Ensure that the dipstick seals down
on the “O” ring.
LUBE TANK FILL (E)
OIL RETURN (F)
C. Fitting the copper washer to the suction
pipe assembly 804-01189/089
(detail bottom).
9
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
3. TANK INSTALLATION
1.Fit the prepared lubricating oil tank
generating set. Figure 3 shows the
engine and alternator.
3. The lubricating oil tank in place in the base of the generating set prior to the tting of
the engine and alternator.
A: Fuel feed adaptor
B: Leak-off adaptor
A B
The engine and alternator can now
10
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
4. ENGINE ADAPTION
instructions.
Where instructions are given to tighten
stated otherwise).
RETURN HOSE ADAPTOR
Figure 4.1.
1.Fit the return hose adaptor 751-47330
(A) with the bonded seal 751-47340.
nut 751-47310 along with the seal
751-47340 and the copper washer
BREATHER RETURN ELBOW
AND PIPE
Figure 4.2.
751-47350.
nut 803-02991 (E) onto union (D)
and tighten.
BREATHER PIPE FITMENT
Figures 4.3 and 4.4.
7.Fit a clip 027-05878 (F) onto hose 027-
04651 (G).
BC
4.2. Engine adaption
B. Elbow 751-47360
C. Union connection 751-47350
4.3. Engine adaption
C. Union connection 751-47350
D.Clip 027-05878
E. Hose 027-04651
C D E
4.1. Engine adaption
A. Return hose adaptor 751-47330
B. Internal suction pipe 751-47300
AB
11
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
8.Push hose onto coned pipe 803-
02991 (E) and tighten clip.
9.Feed hose (G) around engine (F/W/E)
and down to lubricating oil tank.
10.Fit a coned pipe 803-02991 (H) onto
union 108-00106 (I) and tighten.
11.Fit a clip 027-05878 (D) on to hose
(E).
12.Push hose onto coned pipe (F) and
tighten.
RETURN PIPE FITMENT
Figure 4.5.
13.Fit a clip 027-04231 (G) over one
(H).
14.Push return elbow over hose adaptor
751-47330 (I) and tighten clip.
15.Fit another clip 027-04231 (G) over
(H).
16.Push return elbow over lube return
stub pipe (J) in tank and tighten
clip.
tighten.
SUCTION PIPE FITMENT
Figures 4.6 and 4.7.
18.Fit suction hose 803-03071 (L) onto
19.Fit suction hose (L) onto lubricating
oil tank suction pipe 804-01189/089
(N).
hose (L).
DE
F
4.4. Engine adaption.
D.Clip 027-05878
E. Hose 027-04651
F. Coned pipe union 366-01100
4.5. Engine adaption.
G. Clip 027-04231
H. Return elbow 803-03041
I. Hose adaptor 751-47330
J. Lube return stub pipe
K. Oil lter 328-11500
P. Oil lter 328-21600
Q. Oil feed adaptor 803-03035
R. Suction hose 803-03048
I
J
G
K
H
G
12
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
4.7. Engine adaption.
L. Suction hose 803-03071
N. Suction pipe 804-01189/089
N
L
4.6. Engine adaption.
L. Suction hose 803-03071
M. Oil feed adaptor 803-03035
M
L
13
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
5. AUXILIARY FILTER
AUXILIARY FILTER
PREPARATION
Figures 5.1, 5.2 and 5.3.
cubicle support.
Figure
5.1).
(C).
4.Fit unions 803-03001 (D) into the
hose 027-04650 (E) and secure
using hose clips 751-15210.
A
A
5.1. Marks (A) on cubicle support.
B
C
5.2. Fitting bypass bracket (B) to cubicle
support using four bolts (C).
D
E
5.3. Auxiliary lter tted with lengths of
synthetic rubber hose (E) by means of
unions (D).
14
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
Auxiliary Filter Fitment
Figures 5.7, 5.8 and 5.9.
with pre-drilled bracket holes and
7.Fit union 366-07038 (F) into
distribution block and coned pipe
803-02993 to union.
is attached to point C. Ensure clip is
tightened at distribution block.
9.Lubricating oil returned to the tank
the coned pipe 803-03001 in the
external lubricating oil tank. Ensure
clip is tightened at lubricating oil tank
connection.
5.7. Auxiliary lter.
A. Auxiliary lter 803-02985
A1. Filter element 803-02986
B. Bolts 272-00707
C. Entry point of lubricating oil to lter
D. Exit point of lubricating oil from lter
A (A1)
B
C
D
5.9. Re-entry point of lubricating oil into
tank.
G: Re-entry point
G
5.8. Exit point of lubricating oil from tank.
E. Exit point
F. Union 366-07038
E
F
15
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
6. EXPANSION TANK
6.1 Fitting of the expansion tank.
A. Radiator cap 757-31010
B. Nylon pipe 757-30970
C. Bottle 757-30950
D. Bracket 757-30960
A
B
C
D
E
16
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
Figures 7.1 and 7.2.
1.Fit copper washer 013-021778 to
union 201-47720.
lubricating oil drain hole (A).
7. LUBRICATING OIL TANK DRAIN PIPE
7.1. Lubricating oil tank drain hole.
A
B
7 LPW2 627 New Long Run Build
LPW3 627 New Long Run Build
onto union and tighten.
4.Ensure coned plug 803-10098 is
oil.
17
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
NOTE
The units are supplied tested and
with 20L of oil in the tank.
be delivered with no oil in the tank
, as
or CD 15W40. For the running in
here.
under all operating conditions.
the level marked.
4.Connect the unit to a suitable load
bank to ensure that the unit can
is primed prior to starting the engine,
8. COMMISSIONING
be started.
6.Once the engine has obtained
essential to ensure that the engine
is run in prior to commissioning. It
running.
not need replacing at this time.)
NOTES
Running hours (2000) are based on
the following parameters:
operational condition.
well ventilated.
0.5% of the fuel consumption.
of clean combustion air (In dusty
operating conditions additional air
does not drop below 40% of its rated
load.
IMPORTANT NOTE
18
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
These guidelines are intended to
outline the various engineering aspects
that incorporates a Lister Petter Power
engine. The guide lines are generic and
Engineering Department. This will be
SUCTION HEAD
This must be less than 350mm. All
external pipes linking the tank to the
engine oil pump must be smooth bore
incorporated pipe must be smooth
radiuses no acute bends are permitted.
OIL TANK CAPACITY
2000hours.When calculating the tank
should be used ie Fuel consumption
BY PASS OIL FILTER
must be controlled. To achieve this a
return.
should be located in an area that is
IMPORTANT
Should you consider creating your
own long running system we would
recommend that the Lister Petter
is incorporated within your system.
Deviation from this and retention
of LP Warranty would incur a test
period and detailed oil analysis
CRANKCASE BREATHING
SYSTEM
The engine has a closed circuit
leaks. It is essential that this concept is
to ensure that the main oil tank operates
via a balance pipe linked to the engine
9. CHECKLIST FOR OEM LONG RUN
GENERATOR SET CONSTRUCTORS
19
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
H2
engine to the tank are to be airtight
and the hose routed back to the tank,
OIL TANK
connection points are to be welded
and the whole construction cleaned
The tank must incorporate oil drain
points and have an inspection cover to
permit a high pressure cleaning lance
to be used. The tank will incorporate
a suction strainer, dipstick and sealed
PROTECTION DEVICES
1. Oil pressure
The engine oil pressure switch will
Normal oil pressure will be 1.5 bar
and care must be taken to ensure
up.
2. Expansion tank
tank. The radiator must be connected
bottle. The bottle must be vented
to atmosphere and have suitable
relative to the radiator is important
APPLICATION SIGN OFF
Engineering Department.
(bars)
normal ambient (secs)
Tank internal construction details
Engineering Department. This
chargeable.
20
ALPHA LONG RUN GENSETS OPHBK SUPPLEMENT
10. ROUTINE MAINTENANCE
BASED ON 2000 HRS RUNNING PERIOD
2000 - 4000 - 6000 - 8000 -10000* Hours
Drain oil tank and engine sump.
Check lubricating oil pressure.
condition).
*Overhaul if necessary
Renew water pump
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