Lister Petter alpha Series - Repair Manual

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LPW, LPWS & TURBO

ENGINES

WORKSHOP MANUAL

ALPHA SERIES

P027-08240

Main Page

Other manuals for Lister Petter alpha Series

Operator's Handbook48 pages

Installation Guide105 pages

Questions and Answers

D
Deborah LesterAug 3, 2025
Why is my Lister Petter alpha Engine difficult to start?
- B
  bjohnsonAug 3, 2025
  If your Lister Petter Engine is difficult to start or fails to start, several factors could be the cause. It might be due to no fuel in the tank or a choked filter, in which case you should refill the tank, prime the fuel system, or replace the filter. Air or water/dirt in the fuel system can also be culprits; drain, flush, refill, and prime the fuel system. Other potential causes include a faulty injector or pump (replace or service them), a discharged battery or poor connections (recharge/replace the battery and tighten terminals), or a fuel control solenoid not energised (check the electrical system's shutdown devices).
V
Valerie AtkinsonAug 16, 2025
How to fix a starter motor that does not operate on a Lister Petter alpha?
- B
  bhernandezAug 16, 2025
  If the starter motor on your Lister Petter Engine isn't working, start by checking for loose or corroded connections and clean and tighten them. A worn-out battery can also prevent the starter motor from operating, so replace the battery if necessary. Lastly, inspect the starter panel and its connections; adjust the connections or replace the panel if it's faulty.

Summary

General Information

Safety Precautions and Safe Working Practices

Recommended safety procedures and practices for engine operation and maintenance.

Battery Details

Engine Servicing and Adjustments

The Air Cleaner

The Cyclonic Air Cleaner

The Manifolds and Silencer

The Cold Start Aid

Turbocharger

Covers the turbocharger system, including removal and refitting procedures.

Crankcase Breather

Starter Motor

Procedures for removing, replacing, and torquing starter motor components.

Alternator

Information on alternator types, removal, and replacement procedures.

Drive Belt

Fuel Tank

Fuel Lift Pump

Details on the fuel lift pump operation, inspection, and part numbers.

Replacing the Fuel Lift Pump

Step-by-step instructions for replacing the fuel lift pump assembly.

Filter and Agglomerator

Fuel Injection Pump

Covers the fuel injection pump system, including removal and fitting.

Removing a Fuel Pump

Procedure for safely removing individual fuel pumps from the engine.

Refitting a Fuel Pump

Steps for correctly refitting a fuel pump, including governor adjustment.

Fuel Pump Timing

Procedures for timing the fuel pump using piston displacement or gauge methods.

Fuel Pump Timing Values

Table of specific timing values for various engine builds and speeds.

Fuel Injector

Details on fuel injector part numbers for different engine types and builds.

Fuel Injector Settings

Cleaning and Servicing the Injector

Replacing an Injector

Step-by-step guide for removing and replacing fuel injectors.

Oil System

Lubricating Oil Pressure

Oil and Filter Changes

Recommendations for changing engine oil and filters based on operating hours and temperature.

Draining the Oil Sump

Refilling the Oil Sump

The Oil Filter

Details on oil filter types, identification, and part numbers.

Changing the Oil Filter

Procedure for correctly removing and fitting the oil filter.

Oil Cooler

Cylinder Head

Overview of the cylinder head assembly, including covers and valve rockers.

Refitting a Cylinder Head

Detailed steps for correctly refitting the cylinder head assembly.

Hydraulic Tappets

Cylinder Head Clearance

Procedure for checking cylinder head clearance using lead wire.

Checking the Clearance

Detailed method for measuring cylinder head clearance.

The Valves

Removing a Valve

Refitting a Valve

The Valve Seats

Valve Seat and Recess Cutting

The Valve Guides

Removing a Valve Guide

Refitting a Valve Guide

Crankcase Door

Removing the Crankcase Door

Replacing the Crankcase Door

Gear End Cover

Removing the End Cover

Fitting a New End Cover Oil Seal

Fitting the End Cover

Camshaft

Overview of the camshaft system, including removal and installation.

Removing the Camshaft

Detailed procedure for removing the camshaft from the engine.

Inspection of the Camshaft

Replacing the Camshaft

Steps for correctly refitting the camshaft, including timing marks.

Camshaft Bush

Removing the Bush

Fitting a New Bush

Piston

Overview of the piston assembly, including rings and construction.

Piston Rings

Piston Assemblies

Removing a Piston

Procedure for removing a piston and connecting rod assembly.

Inspecting and Servicing the Piston

Fitting a Piston

Procedure for correctly fitting a piston and connecting rod assembly.

Connecting Rod

Details on the connecting rod, its assembly, and bearing shells.

Checking Bearing Clearance

Method for checking connecting rod bearing clearance using Plastigauge.

Flywheel

Removing the Flywheel

Refitting the Flywheel

Flywheel Housing

Removing the Flywheel Housing

Fitting the Flywheel Housing

Rear Main Bearing Housing

Overview of the rear main bearing housing and its components.

Removing the Bearing Housing

Procedure for removing the rear main bearing housing.

Refitting the Main Bearing Housing

Steps for correctly refitting the main bearing housing.

Main Bearing Housing Oil Seal

Fitting the Oil Seal

Crankshaft Pulley

Crankshaft

Overview of the crankshaft, its bearings, and main housings.

Removing the Crankshaft

Procedure for removing the crankshaft assembly.

Inspecting the Crankshaft

Refitting the Crankshaft

Steps for correctly refitting the crankshaft and its bearings.

Crankshaft End Float

Checking Crankshaft End float

Crankshaft Main Bearings

Details on removing and fitting crankshaft main bearings.

Removing Main Bearings

Procedure for removing crankshaft main bearings.

Fitting New Bearings

Steps for correctly installing new crankshaft main bearings.

Fitting Centre Main Bearings

The Oil Strainer and Pump

Information on the oil strainer and pump assembly.

Removing the Pump and Strainer

Procedure for removing the oil pump and strainer.

Refitting the Pump and Strainer

Steps for correctly refitting the oil pump and strainer.

The Water Cooling System

Overview of the engine's water cooling system components and operation.

Radiator Cooling

Engine Block Coolant Capacity

Draining the Cooling System

Coolant Concentrate

The Thermostat

Replacing the Thermostat

Testing the Thermostat

The Radiator

Removing the Radiator

Replacing the Radiator

The Radiator Fan

Water Circulating Pump

Overview of the water pump system, including removal and fitting.

Removing the Water Pump

Procedure for removing the water pump assembly.

Fitting the Water Pump

Steps for correctly refitting the water pump assembly.

The Governor

Overview of the engine governor system and its components.

Removing the Governor

Procedure for removing the engine governor assembly.

Fitting the Governor

Steps for correctly fitting the engine governor assembly.

Governor Weights and Springs

Changing Governor Weights

Setting the Governor

Procedures for setting the engine governor parameters.

Governor E Setting

Method for setting the governor's 'E' parameter for correct lever operation.

Governor G Setting

Procedure for setting the governor's 'G' parameter for fuel delivery.

Adjusting the Engine Speed

Guidelines for adjusting engine speed settings after governor setup.

Idling Speed Adjustment

Procedure for adjusting the engine's idling speed.

Speed Adjustment Setscrews

Identification and adjustment of screws used for engine speed control.

Crankcase Vacuum

Engine Fluids

Engine Fluids - Lubricating Oil

Engine Fluids - Fuel

Engine Fluids - Coolant Concentrate

Operating Instructions

Industrial Engine Operating Instructions

Heater and Glow Plugs

Starting - LPW

Starting - LPWS

Starting - LPWS 400 Series

Starting - LPW(S)T

Stopping the Industrial Engine

Preliminary Instructions

Essential safety and preparatory steps before starting any engine.

Starting

Stopping the Engine

Routine Maintenance

Preliminary Instruction

Waste Disposal Precautions

Initial Attention

Interim Maintenance

Oil and Filter Change Periods

Schedule for engine oil and filter changes based on operating hours.

Routine Maintenance - Schedule Hours

Comprehensive maintenance schedule based on operating hours.

Every Year - LPW and LPWS

Every Year - All Engines

Every Two Years

Sealing Compounds

Spanner Torques

Stator Motor Terminal Torques

Decarbonising

Dimensions of Wearing Parts

Cylinder Bore Wear

Piston Ring Wear

Long Term Storage

Preparing the Engine for Storage

Returning the Engine to Service

Troubleshooting

Preliminary Information

Method of Troubleshooting

Dismantle and Rebuild

Dismantling an Engine

Comprehensive list of steps for dismantling the engine.

Rebuilding an Engine

Guidelines and torque values for reassembling the engine.

California Proposition 65 Warning

Lister Petter alpha Series Specifications

General

Engine Type	Diesel
Cylinders	3 or 4
Cooling System	Liquid Cooled
Configuration	Inline
Speed	1500 - 3000 rpm
Aspiration	Naturally Aspirated
Emissions Compliance	Varies by model