Lister Petter K1 64 Operator'S Handbook Manual Download Page 1 | Manualshive

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K Series

Operators' Handbook

K1 64, K1 72 Engines

P027-10504, Issue 2

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Summary of Contents for K1 64

Page 1: ...1 K Series Operators Handbook K1 64 K1 72 Engines P027 10504 Issue 2 ...

Page 2: ...blication 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 manu facture The Company does not guarantee that the...

Page 3: ...oduction 4 2 Engine Features 5 3 Safety Information 6 4 General Information 10 5 Operating Instructions 11 6 Engine Fluids 14 7 Engine Servicing 15 8 Troubleshooting 22 9 Maintenance Record 25 10 Warranty 36 11 Index 38 ...

Page 4: ... not guarantee that the same results will be obtained elsewhere under different conditions Using this Operators Handbook It is recommended the individual steps contained in the various maintenance or repair operations are followed in the se quence 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 ...

Page 5: ...ne Features K1 72 2 Engine Features Air cleaner Exhaust silencer Decompressor lever Fuel tank filler Fuel tank Recoil start Oil drain plug Fuel injection pump Speed control assembly Oil filler dipstick Fuel tap ...

Page 6: ...d oil leaks as soon as practicable and clean any spills when they occur g Remove any build up of grease oil or debris h Batteries contain sulphuric acid if the acid has been splashed on the skin eyes or clothes flush it away with copious amounts of fresh water and seek medi cal aid Personal Safety a Tie long hair close to your head b Do not wear a necktie scarf loose cloth ing or necklace when wor...

Page 7: ...ot in contact with any rough surfaces or sharp corners so as to avoid any pos sibility of chaffing taking place Charge Winding Precautions The following points must be strictly observed when charge windings are fitted otherwise serious damage can be done a Never remove any electrical cable while the battery is connected in the circuit b Only disconnect the battery with the engine stopped and all s...

Page 8: ...hese joints f It is most important that all fuel joints are tight and leak proof g Always fill the fuel tank through a fine strainer preferably at the end of the engine work period Starter Battery Precautions WARNING Sulphuric acid in battery electrolyte is poisonous is strong enough to burn skin eat holes in clothing and cause blindness if splashed into the eyes a Do not smoke near the batteries ...

Page 9: ...clothing clear of all moving or hot parts f Never allow any part of the body to come into contact with high pressure fuel oil for example when testing fuel injection equipment g Thoroughly clean any lubricating or fuel oil from the skin as soon as possible h Rectify all fuel and oil leaks as soon as practicable and clean any spillages when they occur Before Starting Precautions WARNING Starting an...

Page 10: ...ent cm 305 418 Electrical system 12v negative earth 12v negative earth Battery charging system Charge windings Charge windings Lubricating oil consumption after running in period 0 75 of fuel consumption at full load Minimum lubricating oil pressure at 3000r min bar lbf in 1 5 21 Oil sump capacity litre 1 1 1 65 pints 1 95 2 9 USquarts 1 2 1 75 Capacity between dipstick marks litre 0 4 0 55 pints ...

Page 11: ...D DEATH The engines are able to run satisfacto rily at ambient temperatures up to 25 C 77 F without derating Above this tem perature the rated power must be reduced in accordance with the relevant ISO BS or DIN Standards The maximum ambient operating tem perature is 40 C 104 F and if it is desired to run at higher temperatures the local Lister Petter Distributor or Dealer should be consulted WARNI...

Page 12: ...the engine does not start repeat proc ess from 3 6 again 5 Operating Instructions 5 3 Electric Key Start 1 Ensure the decompressor lever is in the running position Figure 5 3 1 Decompressor Lever Run posi tion 2 Move the engine control lever A to the RUN position Figure 5 3 2 Engine Control 3 If a variable speed control is fitted select the fast position 4 Turn the starter key clockwise to the ON ...

Page 13: ...com pressor lever 1 On fixed speed engines not fitted with a fuel control solenoid press the lever marked B downwards to release the speed control lever Figure 5 4 1 Engine Control After the engine has stopped turn the start key if fitted to the STOP position 2 If a fuel control solenoid is fitted turn the start key to the STOP position 3 On variable speed engines release the screw C and move it b...

Page 14: ... 2 D 6 Engine Fluids d BSMA 100 Class M1 for marine use The fuel must be a distillate and not a residual oil or blend Vaporising oils are not suitable as fuels for these diesel engines The user is cautioned that although the engines may operate on fuels outside the above specifications such operation may well result in excessive wear and damage CAUTION The fuel injection equipment is manu factured...

Page 15: ...Manual When re assembling an engine lubricate all moving parts with engine oil Renew nuts and bolts that have been taken from high stress locations In particular nuts and or bolts from the connecting rods should be renewed The fuel injector can only be checked and set off the engine using suitable specialist test equipment WARNING ON NO ACCOUNT ALLOW ANY UNPRO TECTED SKIN TO COME INTO CONTACT WITH...

Page 16: ...s specified in 7 14 Maintenance schedule hours 7 4 Priming the Fuel System The engine is fitted with a self priming fuel system it should not be necessary to prime the system 7 5 Valve Clearance Adjustment The valve clearance for both inlet and exhaust valves set with the engine cold is 0 15mm 0 006in Figure 7 5 1 Valve Clearance 1 Remove the valve rocker box cover 2 With the piston at TDC on the ...

Page 17: ...ec tion 7 8 5 Fill the sump through the oil filler to the top mark on the dipstick The oil level on the dipstick must be measured without the dipstick being screwed in Figure 7 7 2 Oil dipstick 6 Start the engine run it for a few minutes and check that the drain plug does not leak 7 Stop the engine allow the oil to settle and check the level on the dipstick 8 Add more oil if necessary 3 Withdraw t...

Page 18: ...ng screw A to 10Nm 7 5lb ft CAUTION The retaining screw must not be over tightened 8 Run the engine and check for any oil leaks 7 11 Changing the Fuel Filter Before changing the filter read 7 2 Precautions for Oil Filters and Elements 1 Drain the fuel tank 2 Remove the two 6mm nuts which secure the fuel tap assembly 7 Engine Servicing A 9 Stop the engine allow the oil to settle and check the level...

Page 19: ...t 4 Fit injector clamp over the two studs 5 Replace the two clamp nuts leaving them finger tight 6 Replace the fuel pump to injector pipe and tighten the unions finger tight 7 Tighten the unions a further half turn with a spanner 8 Torque load the injector nuts to 10 12Nm 7 5 9lbf ft 9 Replace the leak off pipe 10 After the initial run following an injector replacement re torque the two clamp nuts...

Page 20: ...r filter element Change fuel filter Replace Check fuel injection pump Change Check fuel injection nozzle Check fuel pipes Change if necessary Check and adjust inlet and exhaust valve clearance Initial Check inlet and exhaust valve and seat condition Replace piston rings Check battery electrolyte Monthly replenish with distilled water as necessary Note means if you need special tools please contact...

Page 21: ... sump The crankshaft should NOT be turned until the engine is again required for service The inhibition fluid should be left in the fuel system e Seal all openings on the engine with tape f Remove the batteries and store them fully charged after coating the terminals with petroleum jelly g Grease all external bright metal parts and the speed control linkage h Tie labels on the engine clearly stati...

Page 22: ... is choked Refill the tank or replace the filter Fuel tap in OFF position Switch to ON position Water or dirt in the fuel system Drain flush refill and prime the fuel system Faulty injector or fuel pump Replace the injector or pump or have it serviced Discharged battery or poor battery connections Recharge or replace the battery Check the terminals are tight Overheating Overload Reduce the load Lu...

Page 23: ... element Overload Reduce the load Overheating See the Overheating section Loss of compression Check the piston rings and the valves Lack or loss of power Loss of compression Check the piston rings and the valves Choked air filter Dismantle and clean or replace the element Choked exhaust system Dismantle and clean Overload Reduce the load Choked fuel filter Replace the filter Worn engine Give the e...

Page 24: ...e amounts of water Battery case leaking Clean surrounding area an replace the battery Defective battery Test or replace the battery Charging rate is too high Refer to the Workshop Manual Battery will not charge Loose or corroded connections Clean and tighten the connections Worn out battery Replace the battery Faulty charge windings Refer to the Workshop Manual Starter motor does not operate Loose...

Page 25: ...ual You must be familiar with the routine tasks set out in 7 Engine Servicing and their correct frequency as described in 7 14 Mainte nance Schedule Details of the mainte nance work carried out on the engine during the first 1000 hours except the daily checks must be recorded in the spaces allocated in this section pages 25 31 for routine maintenance and pages 32 35 for records of non routine main...

Page 26: ...26 Hours run Work done by Details of service Distributor Dealer Stamp Date 9 Maintenance Record Routine Servicing ...

Page 27: ...27 Hours run Work done by Details of service Distributor Dealer Stamp Date 9 Maintenance Record Routine Servicing ...

Page 28: ...28 Hours run Work done by Details of service Distributor Dealer Stamp Date 9 Maintenance Record Routine Servicing ...

Page 29: ...29 Hours run Work done by Details of service Distributor Dealer Stamp Date 9 Maintenance Record Routine Servicing ...

Page 30: ...30 Hours run Work done by Details of service Distributor Dealer Stamp Date 9 Maintenance Record Routine Servicing ...

Page 31: ...31 Hours run Work done by Details of service Distributor Dealer Stamp Date 9 Maintenance Record Routine Servicing ...

Page 32: ...32 9 Maintenance Record Non Routine Servicing Hours run Work done by Details of non routine service Distributor Dealer Stamp Date ...

Page 33: ...33 9 Maintenance Record Non Routine Servicing Hours run Work done by Details of non routine service Distributor Dealer Stamp Date ...

Page 34: ...34 9 Maintenance Record Non Routine Servicing Hours run Work done by Details of non routine service Distributor Dealer Stamp Date ...

Page 35: ...35 9 Maintenance Record Non Routine Servicing Hours run Work done by Details of non routine service Distributor Dealer Stamp Date ...

Page 36: ... only following the sale of genuine parts to a competent engineer intended to be used on the warrantable Lister Petter engine Evidence will be required of engine hours run and should be entered in 9 Maintenance Record Evidence of equip ment used to record engine hours may be requested in the event of a warranty claim If no hour recorder is fitted twelve hours per calendar day will be used as a bas...

Page 37: ...der warranty Engine Serial Number Purchased from Purchase Date Date Registered with Lister Petter Plant Type Plant Number 10 Warranty 10 5 Repairs under Warranty Lister Petter must be contacted and au thorisation given before any warrantable work is commenced 10 6 Contacting Lister Petter Lister Petter Limited Dursley GL11 4HS England telephone 44 0 1453 546732 website www lister petter co uk ...

Page 38: ...0 N Nomenclature 10 O Oil Filter cleaning 17 Oil specification 14 Operating instructions 11 Other Publications 2 P Priming the fuel system 16 Publications 2 R Running in 4 S Safety information 6 Safety information and precautions 6 Safety precautions 6 15 Safety precautions electrical system 7 Safety precautions waste disposal 8 Safety symbols 9 Safe working practices 6 Serial number 10 Starting e...

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Page 40: ...lication P027 10504 January 2011 Lister Petter Limited all rights reserved 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 www lister petter co uk UAE Lister Petter FZE Dubai Silicon Oasis Headquarters PO Box 341077 Dubai UAE Tel 971 4 372 4331 Fax 971 4 372 4318 E mail sales listerpettergroup com www list...

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