Lister Petter T Series, Operator'S Handbook Manual

Page 1: ...GENERATING SET OPERATORS HANDBOOK T SERIES ...

Page 2: ...TR Engines Operators Handbook LPG 027 08265 1 T series ...

Page 3: ...hereof 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 organisation cannot be re...

Page 4: ...ne Features 5 Introduction 7 1 Safety Information 8 2 Technical Data and Information 14 3 Starting and Stopping 15 4 Engine Fluids 19 5 Routine Maintenance 21 6 Troubleshooting 29 7 Maintenance Record 31 8 Warranty 41 ...

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Page 6: ...ENGINES operators handbook Features of the T series air cooled diesel engines Engine Features TR2 Lifting eye Oil filter TR3 Decompressor lever Oil filler Starting handle housing Fuel tank Flywheel Fuel filter TR1 ...

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Page 8: ...dangerous You must not attemptitunlessyouhavethenecessary knowledge and experience Read each section thoroughly and carefully taking note of the all 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 or the index to find the section you need Where instructions ar...

Page 9: ... 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 DRAWSATTENTION TO SPECIAL information OR PROCEDURES WHICH must be strictly OBSERVED Failure to do so may result in serious injury or death 1 1 General Safety Information Starting and operating any diesel engine is p...

Page 10: ...ing parts at all times WARNING Keep the body and clothing clear of moving or hot parts atalltimes Contactofmoving parts with unprotected skin can cause severe burns Entanglement with rotating equipment can cause serious injury or death Tie long hair close to your head Wear close fitting clothing Do not wear a necktie scarf loose clothing or necklace when working close to a running engine Where pos...

Page 11: ...oil compressedair or fuel oil This could lead to serious injury or death 1 4 Fuel System Precautions WARNING NeverALLOWANYUNPROTECTED SKINTOCOMEINTOCONTACTWITH THE INJECTOR SPRAY AS FUEL MAY ENTER THE BLOODSTREAM WITH FATAL RESULTS WARNING N e v e r m a k e u n a u t h o r i s e d adjustments to the fuel injection pumps This could be dangerous and invalidates warranty claims When priming or checki...

Page 12: ...es if burnt 1 6 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 remo...

Page 13: ...d any possibility of chafing Charge Winding Precautions Never connect a battery into the system without checking that the voltage and polarity are correct Always ensure cables are fitted to their correct terminals Never flash any connection to check the current flow Never experiment with any adjustments or repairs to the system Caution Ensure that the battery is correctly connected Failure to do s...

Page 14: ... lifting equipment is designed to give a vertical lift from directly above the engine lifting eye Check that the engine lifting eye is not damaged and that it is secure The engine lifting eye is suitable for lifting the engine and accessory assemblies originally fitted by Lister Petter WARNING Engine lifting eyes must not be used to lift the complete plant WARNING Do not work under any plant that ...

Page 15: ...r an engine derate factor Theenginesareabletorunsatisfactorily at ambient temperatures up to 25 C 77 F without derating Above this temperature the rated power must be reduced in accordance with the relevant standard Engines ISO 3046 Generating Sets ISO 8528 The maximum permitted ambient temperature is 52 C 125 F 2 2 Cooling System The engine is air cooled by means of an integral flywheel fan The c...

Page 16: ...e manufacturers instructions WARNING DO NOT BREATHE EXHAUST GASESAS THEYCONTAIN CARBON MONOXIDE A COLOURLESS ODOURLESS AND POISONOUS G A S T H A T C A N C A U S E UNCONSCIOUSNESS AND DEATH 3 2 Excess Fuel Device The engines are fitted with an automatic excess fuel device which becomes operative ready for the next start when the engine is stopped If the engine stops other than by the operation of t...

Page 17: ...h the engine Always use the correct starting handle which has been designed for the engine Ensure there are no burrs on that part of the handle which fits onto the engine Ensure the handle grip is clean dry and free to turn on its shaft Clean and lightly oil that part of the handle which fits onto the engine Firmly hold the handle grip with the thumb on top of the grip during the starting procedur...

Page 18: ...ng handle housing 8 Retaining a firm grip on the handle remove it from the housing WARNING Do not pull the starting handle away from the engine while cranking Figure 3 4 5 Moving the decompressor lever towards the gear 9 If a variable speed control is fitted reduce the speed as required 3 5 Electric Starting If an oil pressure switch bypass button is fitted it must be depressed during cranking and...

Page 19: ...me hot it is advisable to use suitable hand protection when stopping the engine Engines without a fuel control solenoid 1 Turn the engine control Figure 3 2 anti clockwise to the STOP position and hold it there until the engine comes to rest 2 After the engine has stopped turn the start key if fitted to the OFF position Caution Turning the start key to the OFF position will not stop the engine unl...

Page 20: ... 4 are more commonly available than API CC The use of these oils in new engines is acceptable for topping up the first fill and following the first 100 hours when running in has been completed These oils are particularly suited to engines running at a high load factor or in conjunction with high ambient temperatures They must also be used where the sulphur content of the fuel exceeds 0 5 The oil m...

Page 21: ...nded for continuous full load operation at this temperature Monograde SAE 40 oils are not recommended 4 3 Fuel Specification The fuel used in your engine must be diesel fuel oil which conforms to one of the following BS 2869 1988 Class A2 BS EN590 1995 Class A1 USASpecificationASTM D 975 77 Grades No 1 D and 2 D BSMA 100 Class M1 for marine use The fuel must be a distillate and not a residual oil ...

Page 22: ...ist engine running in all engines are despatched with an initial fill lubricating oil which must be changed after the engine has completed 100 running hours After the engine has run 25 hours and again after it has run 250 hours you should attend to the following Check the valve clearances and adjust if necessary Check and tighten nuts bolts and unions paying particular attention to the fuel system...

Page 23: ...ing at peak performance with trouble free operation The instructions are based on average operating conditions Air cleaners lubricating oil and fuel filters will require more frequent attention if conditions are very dusty Decarbonising may be required more often if the engine has been running on light loads for long periods Caution Long periods of light or no load running early in the engine s li...

Page 24: ...erating sets 5 4 Changing the Oil Filter Before changing the filter read 1 5 Precautions with Filters and Elements 1 Using a suitable strap wrench unscrew and remove the old filter 2 Thoroughly clean the crankcase filter housing face 3 Apply a small amount of clean engine oil to the oil filter sealing joint 4 Screw on the new oil filter by hand until the sealing joint is just touching the crankcas...

Page 25: ...h enables it to drain into the crankcase If the oil is poured in too quickly it can flood the crankcase breather holes and escape into the inlet manifold and cylinders 5 7 Changing the Fuel Tank Filter The fuel filter is an essential part of the engine The engine must never be run without a filter and the element should be renewed every 500 hours or more frequently if for any reason the fuel is di...

Page 26: ...llow the water to drain 2 Using a suitable strap wrench unscrew the cartridge A from the head B 3 Screw a new cartridge onto the head and hand tighten it 4 Prime the fuel system 5 Run the engine and check for fuel leaks Figure 5 9 The cartridge agglomerator 5 10 Priming the Fuel System If a self venting fuel system is fitted it should not be necessary to manually prime it 1 Fill the tank with fuel...

Page 27: ...lease the cover clips and remove the end cap 2 Remove the outer element A and clean or replace it as necessary 3 Replace the element 4 Replace the cover with the inlet facing downwards CAUTION After the outer element A has been cleaned three times the inner element B must be replaced Do not attempt to clean the inner element Figure 5 12 Cyclonic type air cleaner 5 13 Valve Clearance Adjustment The...

Page 28: ...loves and goggles 2 Clean the top of the battery filler plug area 3 Remove the filler plugs and check that the electrolyte level is 6 0 9 0mm 0 25 0 37in above the tops of the separators 4 If necessary top up with distilled water To prevent freezing In cold weather dis tilled water should only be added immediately before running the engine 5 Replace and tighten the filler plugs 6 Check that the te...

Page 29: ...e the batteries and store them fully charged after coating the terminals with petroleum jelly 7 Grease all external bright metal parts and the speed control linkage 8 Tie labels on the engine clearly stating what steps have been taken to inhibit the engine during storage Returning the Engine to Service 1 Refer to the appropriate sections for the relevant detailed instructions as necessary to compl...

Page 30: ...ings first 2 Before starting to remove or dismantle any com ponents double check your observations 3 During dismantling keep all cylinder related items together in their respective groups and correct order to ensure they are refitted in their original places 4 In the case of electrical problems always check the battery first Troubleshooting Problem Cause Solution Difficulty starting or failure to ...

Page 31: ...oss of electrical supply to the fuel pump solenoid Check the electrical feed Automatic shutdown if protective devices are fitted Investigate the cause and rectify Lack or loss of power Loss of compression Check the piston rings and the valves Choked air filter Dismantle and clean the cap and element Choked exhaust system Dismantle and clean Overload Reduce the load Choked fuel filter Replace the f...

Page 32: ...the timings and procedures described in this manual You must be familiar with the routine tasks set out in 5 Routine Maintenance and their correct frequency as described in 5 3 Maintenance Schedule Details of the maintenance work carried out during the first 5000 hours except the daily checks must be recorded in the spaces allocated in this section pages 30 34 for routine servicing and pages 35 39...

Page 33: ...32 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 34: ...33 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 35: ...34 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 36: ...35 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 37: ...36 T SERIES ENGINES operators handbook 7 2 Non Routine Maintenance Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 38: ...37 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 39: ...38 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 40: ...39 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 41: ...40 T SERIES ENGINES operators handbook Hours run Work done by Details of service Distributor Dealer Stamp Date ...

Page 42: ...ty Cover In order to extend the warranty period beyond the initial two year period you must register the engine with a Lister Petter dealer within 28 days of receipt A list of dealers is available at www lister petter co uk The extended warranty gives five year 5000 hour cover beginning on the date of delivery to the original retail purchaser and is transferable It includes the following Years 1 a...

Page 43: ...does not accept responsibility for any business costs or other losses which may result from the warrantable failure The seller is not responsible for failures resulting from misapplication abuse or neglect including operating with inadequate cooling the use of non approved or contaminated fuels or lubricants lack of or incorrect maintenance incorrect repair improper storage incorrect starting stop...

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Page 45: ... to cause cancer birth defects and other reproductive harm T SerIeS engIneS oPerATorS hAndbooK LPG 027 08265 1 edITIon 1 MARCH 2016 td uk LISTER PETTER GLOBAL DISTRIBUTION LIMITED Unit 2 Hurricane Close Sherburn in Elmet Leeds LS25 6PB England TEL 44 0 1977 800372 E mail sales listerpettergroup com www lister petter co uk ...

Page 46: ...LPG 027 08074 1 SLG SLL 16 18 SERIES Alternator Operators Handbook ORIGINAL INSTRUCTIONS ...

Page 47: ...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 carriedoutattheplaceofmanufacture This Companydoesnotguaranteethatthesame results will be obtained elsewhere under different conditions Par...

Page 48: ...3 CONTENTS Introduction 4 Safety Precautions 5 Application 6 Service and Maintenance 9 ...

Page 49: ...her detailed information is available on request Using this Operators Handbook It is recommended the individual steps contained in the various maintenance Introduction or repair operations are followed in the sequence in which they appear When a diesel engine is operating or being overhauled there are a number of associated practices which may lead to personal injury or product damage Your attenti...

Page 50: ...ect installation maintenance and good practice Many accidents are attributable to a failure to follow basic rules and precautions WARNING Electrical shock can cause serious injury or death Ensure the installation meets or exceeds all applicable electrical and safety requirements and that competent suitably qualified personnel carry out that work Do not operate the equipment with any covers or guar...

Page 51: ...3mm water gauge 0 1 SLG164 SLL 164 0 13m3 sec 0 16m3 sec 277cfm 341cfm SLG184 SLL 184 0 13m3 sec 0 16m3 sec 277cfm 341cfm SLG162 0 19m3 sec 0 23m3 sec 398cfm 490cfm SLG182 0 19m3 sec 0 23m3 sec 398cfm 490cfm Automatic Voltage Regulation See illustration on page 11 The following jumper connections on the AVR should be checked to ensure that they are set correctly for the application Frequency Selec...

Page 52: ...ormally be supplied with the right side panel as viewed from the non drive end available for glands for cable exit This panel is removable for drilling punching and is interchangeable with the left side panel Sufficient cable length to the AVR is provided for this purpose To prevent swarf entering any electrical components the panel should be removed for drilling punching Incoming cables should be...

Page 53: ...le of supplying 1 0A AnAC ammeter is required to measure the winding lead current Set the DC voltage to 0V Start the set and slowly increase the DC voltage to pass current through the winding The current level should not exceed the rated current of the alternator Normally 1 hour should be sufficient to dry the winding by this method The short circuit must not be applied with the AVR in the circuit...

Page 54: ... required for AVR Function Test 3 Connect a 0 12V 1 0A DC supply to leads F and F positive to F and negative to F Generator Winding and Rotating Diodes CAUTION The resistances quoted apply to a standard winding For alternators having windings or voltages other than those specified refer to factory for details Ensure all disconnected leads are isolated and free from grounding This procedure is carr...

Page 55: ...s in the field winding from damaging the diodes This device is not polarised and will show a virtual infinite resistance reading in both directions If it is defective it will normally fail to short circuit and show visible signs of disintegration Main Excitation Windings If after establishing and correcting any fault on the rectifier assembly the output is still low when separately excited then th...

Page 56: ... Measure insulation resistance between sections and each section to earth Unbalanced or incorrect winding resistances to earth indicate rewinding of the stator is required AVR Function Test 1 Remove exciter field leads F and F from the AVR Terminals 2 Connect a 240V 60W bulb across the AVR Terminals 3 Set the AVR Volts potentiometer clockwise 4 Connect a 12V 1 0A d c supply to the leads F and F 5 ...

Page 57: ...rnia to cause cancer birth defects and other reproductive harm ALTERNATOR Operators Handbook LPG 027 08074 EDITION 1 MARCH 2016 td Uk LISTER PETTER GLOBAL DISTRIBUTION LIMITED Unit 2 Hurricane Close Sherburn in Elmet Leeds LS25 6PB England TEL 44 0 1977 800372 E mail sales listerpettergroup com www lister petter co uk ...

Page 58: ...LPG 027 08175 1 The ECO28 Alternator Operators Handbook ...

Page 59: ...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 carriedoutattheplaceofmanufacture This Companydoesnotguaranteethatthesame results will be obtained elsewhere under different conditions Par...

Page 60: ...ts 1 Introduction 4 2 Safety Precautions 6 3 Coupling the Alternator and Engine 9 4 Electrical Connections 11 5 Routine Maintenance 13 6 Repair Procedures 16 7 Troubleshooting 20 8 Electrical Wiring Diagrams 21 ...

Page 61: ...important that the installation commissioning and maintenance of the set is undertaken by relevant competent engineers If in doubt consult your local Lister Petter distributor 1 Introduction 1 2 Using this Operators Handbook To assist in the use of this handbook each major section title is given at the top of each page and on the Contents page It is recommended the individual steps contained in th...

Page 62: ...h ease The casing is made of steel the shields of cast iron and the shaft of C45 steel and it has a keyed fan The mechanical protection level meets standard IP21 Insulation materials meet Class H requirements and all rotating components are epoxy resins impregnated higher voltage parts such as the stators are vacuum treated Radio interference suppression meets the requirements of grade N of VDE 06...

Page 63: ...and understanding of the information contained in this instruction manual 2 Safety Precautions as well as specific skills necessary to perform installation adjustment maintenance cleaning and or repair operations Caution This symbol identifies the type of operator in charge of the operation described This qualification requires a complete knowledge and understanding of the information contained in...

Page 64: ... set must be installed in a well ventilated room If there is not enough air a malfunction or overheating may occur All entry doors into the generator room should be clearly marked Authorized Persons Only Ensure the foundations are suitable to bear the total weight of the set The machine has been designed to give the rated output when it is installed in rooms having a maximum temperature of 40 C an...

Page 65: ...rectly above the lifting eyes must be used Check that all lifting eyes are not damaged and that they are secure The lifting eyes fitted to the engine and alternator are only suitable for lifting these items WARNING Individual engine or alternator lifting eyes must not be used to lift the complete plant 2 6ShortCircuitProtection The degree of protection of the alternator is IP21 No attempt must be ...

Page 66: ... rotating the rotor locate the relevant clamp screw on the hub Figure 3 1 1 3 Using a suitable hexagonal wrench slacken the M8 setscrew anti clockwise until the cooling fan is free to rotate Figure 3 1 2 4 Positiononeofthediskholesnear tothe upperpartofoneofthesideopenings Place the slit that is on one of the fan blades in the same position Figure 3 1 3 5 Supporting the alternator and keeping it s...

Page 67: ...at this procedure for all the other holes 9 Check to ensure the alternator disk and the engine flywheel are exactly concentric with each other 10 Using a suitable wrench tighten all the setscrews 11 Using a suitable hexagonal wrench torque the alternator cooling fan setscrew to 12Nm 10 Figure 3 1 6 Note The radial position of the alternator cooling has no effect on the operation of the alternator ...

Page 68: ... the new nominal voltage value When changing from 50 to 60 Hz the alternator power and nominal voltage will increase by 20 but the current does not change from 4 2 Output Terminal Links 6 wire Figure 4 2 1 Connection Schematic Diagram The alternator must always be earthed by sufficiently rated cable using one of the inside or outside terminals After the output connections have been made ensure tha...

Page 69: ...ich senses the exciter field voltage value Should this field voltage value exceed the nominal value for a period of more than 20 seconds then again the alternator voltage is automatically reduced to a safe operating level This overload function has a built in delay to allow for the overload when starting motors normally 5 10 seconds The operating threshold of this protection device is adjustable b...

Page 70: ...imental effect or cause short circuits 5 Routine Maintenance Danger Under no circumstances must hydro cleaners or detergent fluids be used for cleaning purposes 5 2 Bearing Lubrication The alternator is fitted with sealed bearings which have been packed with SKF28 or similar grease on assembly No maintenance is necessary for their entire working life 5 3 Unusual Noises The operator should check fo...

Page 71: ...e smaller than 1MΩ the windings must be adequately dried up This can be done by directing a jet of hot air of about 50 60 C into the generator air inlets or outlets Alternatively the stator windings can be electrically connected and a voltage can be passed through them by means of a DC power supply The amount of current in the windings depends on the alternator size even though it must be fixed ac...

Page 72: ...or operators handbook The torque settings given in the table must be adhered to 5 7 Torque Values All torque values are as given 7 Thread Diameter Of Nm M5 3 M6 6 M8 11 M10 steel 30 M12 36 M14 54 M16 80 M18 100 Figure 5 7 1 ...

Page 73: ...e fault finding and repair operations have been taken 6 1 Bearings Periodical checks must be made to detect overheating and noise If the bearing is worn it can cause excessive in which case it must be replaced Replacing Bearings Remove the alternator from the engine and securely position it in a safe working area 1 Remove the front cover 6 Repair Procedures Figure 6 1 1 Front Cover 2 Using a suita...

Page 74: ...tablish if any cleaning is required If the alternator is used in a dry and clean environment an annual inspection may be suitable In cases of severe conditions more frequent inspections must be carried It is highly recommended that a check should be done regardless of the schedules in the following cases a In cases of rust b In cases of corrosion c When the insulation is damaged d When there is du...

Page 75: ...sition of each terminal board wire and remove them 2 Remove the four regulator retaining setscrews 3 Fit the new regulator into position 4 Replace and tighten the four retaining setscrew 5 Replace the terminal board wires 6 7 Residual Voltage Check The residual voltage check is applied to ensure that the generator is not over excited If it is over excited although it still rotates at nominal speed...

Page 76: ...producing the nominal voltage indicated on the plate 6 8 Winding Resistance Values The figures shown in the table are at 20 C ambient Alternator Resistance Ω Exciter Resistance Ω Type Volts Hz Stator 1 2 Rotor Auxiliary Windings Stator Rotor ECO28S 115 200 230 400 50 0 283 1 260 4 060 10 60 0 39 ECO281L 0 197 1 537 2 250 ECO282L 0 140 1 806 2 150 ECO28VL 0 100 1 860 2 170 ...

Page 77: ...e speed Check the alternator windings High voltage at no load Reset the voltage VOLT potentiometer Replace the AVR On On load conditions the voltage is lower than the rated value Reset the voltage VOLT potentiometer Current too high power factor lower than 0 8 speed lower than 4 of rated speed Replace the AVR Check the diodes disconnect the cables On On load conditions the voltage is higher than t...

Page 78: ...21 THE eco28 alternator operators handbook 8 Electrical Wiring Diagrams Figure 8 1 Schematic Diagram 6 Wire Connection ...

Page 79: ...22 THE eco28 alternator operators handbook Figure 8 2 Terminal Box Layout ...

Page 80: ...23 THE eco28 alternator operators handbook Figure 8 3 Series Star and Series Delta Connections ...

Page 81: ...to cause cancer birth defects and other reproductive harm THE ECO28 alternator Operators Handbook LPG 027 08175 EDITION 1 MARCH 2016 td uk LISTER PETTER GLOBAL DISTRIBUTION LIMITED Unit 2 Hurricane Close Sherburn in Elmet Leeds LS25 6PB England TEL 44 0 1977 800372 E mail sales listerpettergroup com www lister petter co uk ...