ALPHA Series

Long-Running
LLD Genset
Operators' Handbook
Supplement

P027-08373

1
 Copyright Lister Petter Limited, Dursley GL11 4HS, England.
All rights reserved.

Associated Publications
ALPHA LLD Generating Set Operators' Handbook,
publication P027-08108.

1. Drawing of the long-running LLD generating set with oil reservoir in the base.

Disclaimer
The information, specifications, illustrations, instructions and statements contained within this publication are
given with Lister Petter's 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 Companys 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.
The Company does not guarantee that the same results will be obtained elsewhere under different conditions.

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 Contents
1. Introduction ......................................3
2. Tank Preparation ..............................4
3. Tank Installation ...............................5
4. Engine Adaption ...............................6
5. Bypass Filter and Expansion Tank ..8
1. Introduction
This publication is a supplement to the
ALPHA LLD generating set operators' hand-
book, publication P027-08108. It gives
specific instructions for the commissioning
and installation of the long-running ALPHA
generating set. This set differs from the
standard ALPHA generating set in having
an oil reservoir in the base. It has been
designed to reduce the frequency of oil
changes, enabling the generating set to
run for longer periods without servicing.
Figure 1 shows some key features of
this generating set model, notably the oil
reservoir (denoted by the dotted line in the
base) and the lubricating oil bypass filter.
Principle of Operation
The basic principle of the system is that the
standard mechanical lube oil pump effec-
tively does two functions. One is drawing
the oil from the external oil tank and the
second is pumping it around the engine.
The standard engine oil pickup is re-
moved and replaced with a pipe that leads
out to a union in a modified crankcase
door. From this there is then a flexible pipe
with screwed unions to connect between
the door and the 65-litre base mounted
lube oil tank. The oil is drawn up this pipe
into the oil pump and then circulated
around the engine in the normal way. The
oil fed to the engine then drips down into
6. Lubricating Oil Tank Drain Pipe .....10
7. Commissioning .............................. 11
8. Checklist for Warranty .................. 12
9. Parts List ........................................ 14
the engine sump and is gravity returned
into the external lube tank via a large
return pipe in the crankcase door.
The system is also fitted with a balance
pipe to equalise pressures between the
engine crankcase and the supplementary
oil tank.
The system is basically a dry sump sys-
tem; however because of the position of
the return pipe approximately 2 litres of
oil remain in the engine sump at any one
time, the rest being within the external
lube oil tank.
To ensure that the oil is maintained in
good operational condition throughout
the long running period, approximately
40 litres an hour are pressure fed through
the specially developed Lister Petter HD
bypass filter.
The unit is also fitted with a coolant
expansion bottle, which will capture any
coolant expelled during the extended run-
ning. This will automatically be returned to
the radiator when the engine cools.
The supplementary lube oil tank replac-
es the standard fuel tank and is located
immediately below the engine. Fuel supply
to the engine must come from an external
fuel tank, located as close as practicable
to the genset. The genset canopy is fitted
with suitable connections for this external
supply.
3
 2. Tank Preparation
Figure 2 represents the lubricating oil tank. Bypass Return (B)
Prepare the tank according to the follow- 4. Fit copper washer 013-22350 to union
ing numbered instruction (the letters and 103-00106.
headings allude to the figures). 5. Apply 110B thread sealant.
6. Spanner tighten (no specific torque).
Breather Return (A)
1. Fit copper washer 013-22350 to coned
pipe union 366-01100.
2. Apply 110B thread sealant.
3. Spanner tighten (no specific torque).

A. Fitting
the washer
on the pipe
B. Applying thread sealant to the union of the
union of the
bypass return.
breather
return.

2. Lubricating oil
tank, part number
803-03037.
A: Breather return;
B: Bypass return;
C: Lubricating oil
supply to engine;
D: Oil level;
E: Lubricating oil tank
filler;
F: Oil return.

D B
F C

E
OIL RETURN

OIL FILLER

4
Lube Supply To Engine (C)
7. Fit copper washer 291-30640 to suc-
tion pipe assembly 803-03038.
8. Apply 110B thread sealant.
9. Spanner tighten (no specific torque).

Oil Level (D)

10.Insert dipstick assembly 803-03043
into the lubricating oil tank.

Lube Tank Fill (E)

11.Fit filler cap 366-08126 onto filler neck
and secure if not present.

Oil Return (F)

NB. The oil return pipe 803-03041 is not
fitted until later in the process.

C. Fitting the copper washer to the suction pipe

assembly 803-03038 (detail bottom).

3. Tank Installation
1. Fit the prepared lubricating oil tank into
the space in the base of the generating
set. Figure 3 shows the tank in place
prior to the fitting of the engine and
alternator.
2. Fit the fuel feed adaptor (A) and the
leak-off adaptor (B) into the base.
The engine and alternator can now be
fitted as normal by a suitably qualified
engineer.

A B

3. The lubricating oil tank in place in

the base of the generating set prior to
the fitting of the engine and alternator.
A: Fuel feed adaptor
B: Leak-off adaptor

5
 4. Engine Adaption
When the fuel tank, engine and alternator
have been fitted it is necessary to adapt
the engine as outlined in the following
A
numbered instructions.
Where instructions are given to tighten a
connection you should use a spanner, but
there is no specific torque (unless stated
otherwise).

Return Hose Adaptor

Refer to figure 4.1. 4.1. Engine adaption.
1. Fit the return hose adaptor 803-03047 A. Return hose adaptor 803-03047
(A) with the bonded seal 803-03042.
2. Apply sealant.
3. Tighten (no specific torque).
The oil feed 803-03035 and retaining
D E
nut 027-00689, along with the seal
031-66806 and the copper washer B
291-30640, will already have been fitted
as part of the engine assembly.

Breather Return Elbow and Pipe C

Refer to figure 4.2.
4. Apply sealant and assemble elbow
821006 (B) into reducing bush 804-
01104/004 (C).
5. Apply sealant and assemble union 356- 4.2. Engine adaption.
31610 (D) into elbow 821006 (B) and B. Elbow 821006
tighten. C. Reducing bush 804-01104/004
6. Fit coned pipe and " BSP union nut D. Union 356-31610
803-02991 (E) onto union (D) and E. Coned pipe 803-02991
tighten.
7. Apply sealant and thread complete as-
sembly into breather hole and tighten, E F G
ensuring assembly is correctly orien-
tated.

Breather Pipe Fitment

Refer to figures 4.3 and 4.4.
8. Fit a clip 027-05878 (F) onto hose 027-
04651 (G).
9. Push hose onto coned pipe 803-02991
(E) and tighten clip. 4.3. Engine adaption.
10. Feed hose (G) around engine (F/W/E) E. Coned pipe 803-02991
and down to lubricating oil tank. F. Clip 027-05878
G. Hose 027-04651
11. Fit a coned pipe 803-02991 (H) onto

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 union 108-00106 (I) and tighten.
12. Fit a clip 027-05878 (J) on to hose
(G). J G
13. Push hose onto coned pipe (H) and
tighten.

Return Pipe Fitment

Refer to figure 4.5.
14. Fit a clip 027-04231 (K) over one end H
of the return elbow 803-03041 (L). I
15. Push return elbow over hose adaptor
803-03047 (M) and tighten clip.
16. Fit another clip 027-04231 (N) over 4.4. Engine adaption.
the other end of the return elbow (L). G. Hose 027-04651
17. Push return elbow over lube return H. Coned pipe 803-02991
I. Union 108-00106
stub pipe (O) in tank and tighten clip. J. Clip 027-05878
18. Replace oil filter 328-11500 (P) and
tighten.
M
Suction Pipe Fitment
Refer to figures 4.5 and 4.6. Q
19. Fit suction hose 803-03048 (R) onto P
oil feed adaptor 803-03035 (Q).
20. Fit suction hose (R) onto lubricating oil K
tank suction pipe 803-03038 (S).
21. Tighten both ends of the suction hose
(R).
L R
N O
4.5. Engine adaption.
K. Clip 027-05878
L. Return pipe 027-04651
M. Hose adaptor 803-03047
N. Clip 027-05878
O. Lubricating oil return filler neck
P. Oil filter 328-21600
Q. Oil feed adaptor 803-03035
R. Suction hose 803-03048

4.6. Engine adaption.

S
R. Suction hose 803-03048
S. Lubricating oil tank suction pipe 803-03038

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 5. Bypass Filter and Expansion Tank
Bypass Filter Preparation
Refer to figures 5.1, 5.2 and 5.3.
1. Using bypass filter bracket 803-02972
(B) as a template, mark out desired
position for bypass filter on cubicle sup-
port.
2. Drill four holes as marked (A, figure
5.1).
3. Fit bypass filter bracket (B) and secure
A
using four bolts 272-00706 (C).
4. Fit unions 803-03001 (D) into the
bypass filter.
5. Fit pre-cut lengths of synthetic rubber
hose 027-04650 (E) and secure using
hose clips 751-15210.

5.1. Marks (A) on cubicle support.

E C

D
5.2. Fitting bypass bracket (B) to cubicle support
using four bolts (C).

5.3. Bypass filter fitted with lengths of synthetic

rubber hose (E) by means of unions (D).

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Expansion Tank
Refer to figures 5.4, 5.5 and 5.6. F L K
6. Fit bracket 803-03040 (F) and secure.
7. Align expansion bottle 803-03045 (G)
to bracket (F) and fasten.
8. Ensure that inlet is tapped to take union
103-00106 (H).
9. Fit hose stem adaptor 803-03046 to
union (H) and tighten.
10. Fit inlet pipe (I) to hose stem adaptor
and run pipe down through the engine. H D
11. Cable tie the inlet pipe as illustrated
in figures 5.5 and 5.6 (J).
12. Fit expansion pipe (K) and secure.
13. Run expansion pipe (K) down the side
of the crankcase and away from the
engine.
14. Fit pressure cap 362-03324 (L) to
expansion bottle (G) and tighten.
15. Fit radiator filler cap 803-03039 (M) 5.5. Fitting of the expansion tank.
to engine radiator and tighten. G. Expansion tank 803-03045
H. Union 103-00106
K. Expansion pipe
L. Pressure cap 362-03324

5.4. Fitting of the expansion tank.

F. Bracket 803-03040
G. Expansion tank 803-03045
H. Union 103-00106
I. Inlet pipe
J. Cable tying of inlet pipe
K. Expansion pipe
L. Pressure cap 362-03324 5.6. Fitting of the expansion tank.
M. Radiator filler cap 803-03039 J. Cable tying of inlet pipe.

M F G L

K I
J

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Bypass Filter Fitment
Refer to figures 5.7, 5.8 and 5.9.
16. Align bypass filter 803-02985 (A) with
pre-drilled bracket holes and fit and
tighten with bolts 272-00707 (B).
17. Fit union 366-07038 (F) into distribu-
tion block and coned pipe 803-02993
to union.
5.7. Bypass filter.
A. Bypass filter 803-02985
B. Bolts 272-00707
C. Entry point of lubricating oil to filter
D. Exit point of lubricating oil from filter
B
A F
D C
6. Lubricating Oil Tank Drain Pipe
Refer to figures 6.1 and 6.2.
1. Fit copper washer 013021778 to union
201-47720.
2. Apply thread sealant and fit into lubri-
cating oil drain hole (A).
6.1. Lubricating oil tank drain hole.
A
10
18. Lubricating oil comes in from E which
is attached to point C. Ensure clip is
tightened at distribution block.
19. Lubricating oil returned to the tank
goes down from point D to point G, the
coned pipe 803-03001 in the external
lubricating oil tank. Ensure clip is tight-
ened at lubricating oil tank connection.
5.8. Exit point of lubricating oil 5.9. Re-entry point of
from tank. lubricating oil into tank.
E. Exit point G: Re-entry point
F. Union 366-07038
E
G
3. Fit hose assembly 804-02404 (B) onto
union and tighten.
4. Ensure coned plug 803-10098 is fitted
to hose before filling tank with oil.
6.2. Hose assembly (drain pipe).
B
 7. Commissioning
NOTE
The units are supplied tested but for
shipment the oil is drained both from the
engine and tank.
1. Prior to starting the unit, fill the bulk oil
tank with 15 litres of oil, as follows:
Naturally aspirated engines: API CC or
CD 15W40.
Turbocharged engines: Shell Rimula X
10W-30 or equivalent.
Alternatively, Lister Petter can supply the
genset filled with specially formulated
running oil (for an additional charge).
2. Connect a suitable fuel supply and run
leak-off back to tank.
3. Fill the cooling system with coolant
concentrate. A mix of 40% protects the
system from damage and corrosion
under all operating conditions. Ensure
that the radiator level is full right up to
and into the filler neck. Unless the cool-
ing system is totally full the expansion
bottle system will not operate correctly.
The radiator is fitted with a twin seal
closed system filler cap. Fill the expan-
sion bottle to the level marked.
4. Connect the unit to a suitable load bank
to ensure that the unit can operate at
75% of its rated load.
5. To ensure that the engine oil system
is primed prior to starting the engine,
motor the engine with the fuel control
solenoid de-energised for 15 seconds.
The engine may then be started.
6. Once the engine has obtained operating
speed apply 75% load and run for 100
hrs. This exercise is essential to ensure
that the engine is run in prior to com-
missioning. It also necessary to reduce
the future risk of problems linked to
light-load running.
7. On completion of the 100 hrs:
Drain the oil tank and then refill with 55
litres of new lubricating oil as specified
in 1. above.
Renew the engine-mounted oil filter.
(The bypass filter element does not
need replacing at this time.)
Check the coolant level and top up if
necessary.
Check all connections to ensure the
integrity of the system.
NOTES
Running hours (2000) are based on the
following parameters:
Engine is maintained in good opera-
tional condition.
Engine installation is correct and well
ventilated.
Oil consumption does not exceed 0.5%
of the fuel consumption.
Fuel is clean and to the correct speci-
fication, BSS2869 Class A1.
Engine has an adequate supply of clean
combustion air (In dusty operating
conditions additional air filtration may
be necessary).
Average running load of the unit does
not drop below 40% of its rated load.
11
 8. Checklist for Warranty
These guidelines are intended to outline
the various engineering aspects that must
be considered for fitting the Lister Petter
long running system to your generating
sets. The guidelines are general and are
to ensure you retain the Lister Petter
warranty.
Full details of all aspects of your system
and test data will be required by Lister
Petter prior to commencement of supply
of production engines. This data should
be provided by completing the attached In-
stallation Check Test Report and sending
it to Phil Downes, Manager of Applications
Engineering at Lister Petter (for address
see back cover).
In addition to this, a full installation
check may also be required by our Applica-
tions Engineering Department. This will be
at Lister Petter's discretion.
Suction Head
This must be less than 350mm. All external
pipes linking the tank to the engine oil
pump must be smooth bore and have
a bore. Any bends in this pipe must
have smooth radii. No acute bends are
permitted. The hose must be fabric
reinforced and impervious to oil and fuel.
Oil Tank Capacity
Tank capacity can vary dependent on the
number of operating hours required: the
maximum limit is 2000 hours.
When calculating the tank size an oil
consumption of 0.5% of fuel consumption,
and a 70% load, should be used.
Calculate:
Fuel consumption at 70% load (L/hr)
x Hrs run
x 0.5%.
12
For example: a 4 cylinder LPWS4 op-
erating at 1800r/min will require a
minimum capacity of 40 litres.
Lister Petter HD Bypass Oil Filter
The Lister Petter HD Bypass Oil Filter
is a requisite part of any long-running
system. This is because Lister Petter have
proven its capability to filter down to 3
microns over many thousands of hours
development. This filter, installed correctly,
will ensure the condition and integrity of
the oil over continious running periods of
up to two thousand hours.
To ensure adequate engine oil pressure
the flow rate through the Lister Petter HD
Bypass filter is to be set at less than 40
L/hr. Flow restrictors must not be less
than 1.2 mm diameter. The filter should
be positioned to ensure a gravity return to
the oil tank, and the return pipe must be
free from any unnecessary restrictions.
Pipe size must be bore for supply and
return.
The filter must not be engine mounted
and should be located in an area that is
subject to only low levels of vibration.
Crankcase breathing system
The engine has a closed circuit crankcase
breathing system to ensure that the engine
remains free from oil leaks. It is essential
that this concept is maintained and special
care is required to ensure that the main oil
tank operates via a balance pipe linked
to the engine, which operates under a
vacuum of nominally 100mm H2O. Hence
all hose connections from the engine to
the tank must be airtight and secured
every 200mm. The balance pipe must be
bore, fabric reinforced and impervious
to oil and fuel.
Oil Tank
This is to be of steel construction. All
connection points are to be welded and
the whole construction cleaned to NAS 8
cleanliness specification. The tank must
incorporate oil drain points and should
have if practical an inspection cover to
permit internal cleaning of the tank.The
suction pipe should be fitted with a strainer
at the inlet.
The tank must also incorporate a dip-
stick and filler cap,both of which must
be airtight to ensure that the crankcase
vacuum is maintained. The bore of the
return pipe must not be less 1. A low oil
level electronic switch may also be fitted
if required.
Protection devices
1. Oil pressure
The engine oil pressure switch will operate
at approx 0.7 bar. Normal oil pressure
will be 2.5 bar and care must be taken to
ensure that the feed to the bypass system
will not affect the pressure at the switch
during start up.
2. Expansion tank
The radiator is fitted with a twin seal closed
system filler cap which allows for the
fitment of an expansion tank. The radiator
must be connected via the overflow pipe
to an expansion bottle.The bottle must be
vented to atmosphere and have suitable
connections to allow coolant to flow in and
out. The position of this tank relative to
the radiator is important and will have to
be approved if changed from the specified
Lister Petter position.
Application sign off
1. Normal warranty will apply following sat-
isfactory sign-off from the Lister Petter
Applications Engineering group.
2. Sign off criteria will require the following
data to be measured/submitted:
Ambient temperature (degrees C)
Engine oil pressure cold and hot (bars)
Oil tank temperature (after 8 hours' run-
ning on full load)
Exhaust temperature (after 8 hours'
running at full load)
Oil tank capacity (litres) and hours run-
ning required
Bypass oil flow rate (L/hr)
Lister Petter HD By pass filter perform-
ance
Time to prime from cold start at normal
ambient (secs)
Crankcase and oil tank vacuum
Tank internal construction details
Detailed oil analysis over a number of
hours agreed with Lister Petter.
3. The Installation Check Test Report will
need to be completed.
13
 9. Parts List
Tank and Piping Adaptation
Item Number Quantity Description Item Number Quantity Description
803-03037 1 Lube oil tank Crankcase door: L/R lube
803-03033 1
366-08126 1 Filler cap (MR) system, LPWT4
Dipstick assembly (u/w 754-10804 1 Joint
803-03043 1
803-03037 lubricating oil tank) 803-03047 1 Hose adaptor: 1 x 38 I dia.
803-03038 1 Suction pipe: BSP, 180 long 803-03042 1 Bonded seal: 1 BSP
291-30640 1 Copper washer: " BSP 803-03035 1 Suction Pipe
803-03041 1 Oil return hose elbow 754-44130 2 O Ring
027-0423 1 2 Hose clip: 35/50 mm dia. 031-66806 1 Seal washer: " dia.
366-01100 1 Connector 027-00689 1 Locknut: " BSP
013-22350 1 Copper washer: " BSP Coned pipe and BSP union
803-02991 1
Coned pipe and BSP union nut
803-0299 1 1
nut 804-01104/ Reducing bush: 1 BSP and
1
027-04651 0.8 m Hose: I/D, synthetic rubber 004 " BSP
027-05878 2 Hose clip: 11/16 mm dia. 821006 1 Elbow
013-2 1778 1 Copper washer: " BSP 356-31610 1 Union: BSP x " BSP
201-47720 1 Connection 013-21778 1 Copper washer: " BSP
804-02404 1 Hose assembly: oil drain
366-07038 1 Union: MR
808-10098 1 Coned plug
803-02993 1 Coned Pipe and BSP
Hose: " BSP, 90 x 135 x 385
803-03048 1 027-01619 1 Dowel: dia. x
long

Bypass Filter Kit Radiator Expansion

Item Number Quantity Description Item Number Quantity DescripLion
803-02985 1 Filter: chaining oil bypass Radiator filler cap for expansion
803-03039 1
803-02972 1 Oil filter bracket system
272-00707 4 Screw: M10 x 25, zinc plate 803-03040 1 Expansion tank bracket
272-00706 4 Screw: M10 x 25 zinc plate 601-41700 3 Spacer
272-00311 8 Lock washer: M10, zinc plate 272-00788 3 Stud
272-0068 1 8 Nut: M10, zinc plate (TX-ST) 272-00679 3 M6x1 .0 6H zinc plate
103-00106 3 Union: "BSP 803-03045 1 Modified expansion tank
013-22350 3 Copper washer: " BSP 362-03324 1 Pressure cap
Coned Pipe and " BSP union 272-00662 2 Screw M6x20 zinc plate
803-03001 3
nut 782378 1 SpringwasherM5
027-04650 1.3 m Hose: " I/D, synthetic rubber 272-00679 2 M6x1 .0- 6H zinc plate
751-15210 4 Hose clip (MN) Hose stem adaptor DSP
803-03046 1
382-08257 2 Clip cable x8 i/d
103-00106 1 Union DSP
803-03052 1 Fle Nylon Pipe 12 O/Dx8 Dore
803-03053 1 Flexi Nylon Pipe 12 O/D x8 Dore
783001 1 Hose clip
382-05032 5 Cable tie

14
15
 CALIFORNIA
Proposition 65 Warning
Engine exhaust and some of its constituents are
known to the State of California to cause cancer,
birth defects, and other reproductive harm.

UK
Lister Petter Limited, Dursley, Gloucestershire GL11 4HS England
Tel: +44 (0)1453 544141; Fax: +44 (0)1453 546732
E-mail: sales@lister-petter.co.uk http://www.lister-petter.co.uk

USA
Lister Petter Americas Inc. 815 E. 56 Highway, Olathe, Kansas 66061 USA
Tel: +1 913 764-3512; Fax: +1 913 764-5493
E-mail: info@lister-petter.com; http://www.lister-petter.com

FRANCE
Lister Petter France, 9 Avenue de lEscouvrier, Zone dActivites,
95842 Sarcelles Cedex, France
Tel: +33 (0)1 39330420; Fax: +33 (0)1 34195760;
E-mail: commercial@lister-petter-france.fr

INDIA
Lister Petter India (P) Limited, 32/2/5/1, Kondhawa (BK), Pune 411048, India
Tel: +91 20 2693 2688/3644/3645; fax: +91 20 2693 3286
Email: smith@listerpetterindia.com

CHINA
Lister Petter China, Jinan Fuqiang Power Co. Ltd, Shandong Zhangqiu Industrial Area
Jinan 250220, China
Tel: +86 531 8558 4852; fax: +86 531 8558 4820

ALPHA Long-Running LLD Generating Set Operators' Handbook

P027-08373; copyright Lister Petter Ltd, July 2008

16