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Section 02

Engine Servicing and Adjustments

- cylinder head cover and breather

02.10 THE CYLINDER HEAD COVER

The light alloy cylinder head cover, which is bolted

to the top of the cylinder head, gives access to the
breather box, decompressors, injector and valve gear.

The TS/TR engine mounted fuel tank is secured to

the side of the cylinder head cover at the gear end by
three setscrews (two on early engines) and by two
setscrews in the side shield.

The Crankcase Breather

On the majority of TS and TR engines a plate

locates over the breather tube and forms an oil
separator box in the cylinder head cover which
connects with the inlet manifold port via a copper pipe
brazed to the plate. The breather plate has a metal
contact with the cylinder head cover and is secured
with three self tapping screws. A felt washer is fitted
around the top of the tube between the cylinder head
and breather plate and care must be taken to ensure
the washer is refitted on re-assembly. The breather
tube forms an interference fit in the cylinder head.

Removing the Cylinder Head Cover

1. Remove the lifting eye and fuel tank securing bolts

if necessary.

2. Remove the four bolts securing the cover.
3. Lift off the cover being careful not to damage the

joint or leak-off pipe.

Refitting the Cylinder Head Cover

1. On TS/TR engines ensure the breather plate is

securely retained in position and that the felt washer
is fitted round the breather tube.

2. Clean the cover and cylinder head joint area.
3. Place the joint on the cylinder head.
4. Move the decompressor lever, if fitted, into the

vertical position.

5. Replace the cylinder head cover ensuring the

decompressor lever, if fitted, is located between
the two stops and the fuel injector leak-off pipe is
located snugly in the recess provided.

6. Fit the four bolts with new washers.

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Summary of Contents for TR1

Page 1: ...TS TR TX Workshop Manual Edition 12 May 2005 Publication P027 08221 ...

Page 2: ...page 2 ...

Page 3: ...s 13 Section 03 Engine Fluids 67 Section 04 Operating Instructions 71 Section 05 Routine Maintenance 75 Section 06 Troubleshooting 85 Section 07 Flywheel Charge Windings 89 Section 08 Electrical Wiring Diagrams 97 Section 09 Technical Data 105 Section 10 Conversion Factors 111 Section 11 Index 115 Manual Contents page ...

Page 4: ...users should in their own interests always specify Genuine Lister Petter Parts and quote the Description of the Part and the Engine Serial Number Associated Publications Technical Handbook P027 09212 Master Parts Manual TS TR P027 08030 TX P027 08929 Operators Handbook English P027 08185 French P027 08185 fre Spanish P027 08185 spa German P027 08185 ger Various technical sales leaflets are availab...

Page 5: ... not overfill the fuel tank e Thoroughly clean any lubricating or fuel oil from the skin as soon as possible f Rectify all fuel coolant and 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 a...

Page 6: ...y into the system without checking that the voltage and polarity are correct d Never flash any connection to check the current flow or experiment with any adjustments or repairs to the system e Thebatteryandalternator charge windings mustbe disconnectedbeforecommencinganyelectricwelding whenapolestrapisdirectlyorindirectlyconnectedto theengine f Starting engines that are fitted with charge winding...

Page 7: ...dusty conditions Wash them before and after use and wrap them up when not required or fill the tank direct from a small mouthed screw capped fuel can i The fuel injection equipment is manufactured to very accurate limits and the smallest particle of dirt will destroy its efficiency Fuel free from water and contaminants is of the utmost importance Precautions for Oil Filters and Elements a Used liq...

Page 8: ...page 8 01 2 SAFETY SYMBOLS This section identifies the ISO 8999 symbols currently used by Lister Petter Section 01 General Information safetysymbols ...

Page 9: ...page 9 Section 01 General Information engine features 01 3 ENGINE FEATURES TS TR1 TS TR2 TS TR3 TX2 TX3 ...

Page 10: ...lly aspirated axial fan air cooled diesel engines Engine Serial Number The engine serial number is stamped on a plate attached to the engine It is necessary to identify the type and build of each engine to enable the correct maintenance procedures as described later in this publication to be carried out An example number is shown below 03 001234 TS3 A 01 03 Year code 03 2003 001234 Unique engine n...

Page 11: ...nd charge voltage are approximately the same Discontinue charging and allow the battery to cool if the temperature rises above 40 C 110 F Note Tropical climates apply to those countries or areas where the average temperature of any month of the year exceeds 27 C 80 F Connecting Batteries It is most important to ensure that the starter battery or batteries are properly connected and all connections...

Page 12: ...similar In these applications wherever possible means should be provided to overcome such loads by the inclusion of clutches and unloading valves etc Heavy Duty Batteries are recommended for all applications and for temperatures below 18 C 0 F high discharge low resistance Arctic or Alkaline batteries must be used Battery Charging Battery charging is by means of the alternator flywheel mounted cha...

Page 13: ...may be necessary to remove others before the relevant instructions can be carried out a Disconnect or isolate any non electric starting systems b Disconnect and remove the battery c Drain the diesel fuel and lubricating oil d Disconnect all services e Remove any accessories or components that may be susceptible to damage when the engine is turned out of its normal plane Because of the various engi...

Page 14: ... element is gained by undoing the cruciform headed screw in the centre of the main body of the the filter casing If the element is found to be dirty it must be replaced The Cyclonic Air Cleaner The air cleaner can be engine or remote mounted It should be cleaned daily under very dusty operating conditions and as specified in 5 4 Routine Maintenance schedule hours The air cleaner mounting bracket b...

Page 15: ...d of the cup B with the same type of lubricating oil as used in the engine Figure 2 3 1Cold Start 3 Replace the plunger and inject the oil just before starting the engine CAUTION The device must not be used more than three times in succession during the same attempt to start the engine TX Engines The TX inlet manifold may have a cold weather glowplug fitted and care must be taken to ensure the bat...

Page 16: ...ndard exhaust silencer which has provision for fitting a tail pipe or a lightweight extension the outlet of the silencer tail pipe must face away from the engine Section 02 Engine Servicing and Adjustments manifolds Removing the Manifolds TS TR 1 Remove the air cleaner and exhaust silencer 2 Remove the nuts spring washers and distance pieces 3 Unscrew and remove the cold start pots if fitted 4 Rem...

Page 17: ...eaner if necessary 2 Remove the flywheel end air shield 3 Remove the axial fan cowling 4 Isolate or drain the fuel before disconnecting the fuel pipes to and from the fuel filter 5 Remove the fuel filter 6 Removethegear endair shield itmaybenecessary to slacken the axial fan before the shield can be removed The Air Baffles The air baffles are fitted between the cylinder barrels and extreme care mu...

Page 18: ...is replaced and after the drive belt has been fitted it must be correctly tensioned 02 08 DRIVE BELT TENSION It is important that the tension of the drive belt is checked after the first 50 hours after an overhaul after a new belt has been fitted and as specified in Maintenance Schedule The measurements shown in the table are taken in the centre of the longest span after the belt has been turned t...

Page 19: ...ews A felt washer is fitted around the top of the tube between the cylinder head and breather plate and care must be taken to ensure the washer is refitted on re assembly The breather tube forms an interference fit in the cylinder head Removing the Cylinder Head Cover 1 Remove the lifting eye and fuel tank securing bolts if necessary 2 Remove the four bolts securing the cover 3 Lift off the cover ...

Page 20: ...lightly coated with Wellseal All cylinder head nuts should be fitted with the machined grade symbol facing upwards to ensure a good seal between the nut and the head It is strongly recommended that cylinder head nuts and push rod seals are replaced at every major overhaul 1 Renew or replace the push rod seals in the cylinder head and crankcase 2 Lightly coat both ends of the push rod tubes with He...

Page 21: ...ment is not correct it can be adjusted by adding or removing 0 07mm or 0 25mm 0 003 or 0 010in thick shims placed between the cylinder head and the gasket 11 Replace the cylinder head 12 Re check the head clearance TX Engines The cylinder head clearance is maintained by 0 07mm 0 13mm or 0 38mm 0 003in 0 005in 0 015in metal shims placed between the cylinder barrel and crankcase 1 From two 50mm x 1 ...

Page 22: ...ace the cylinder on its side on a bench and place the rocker arm into position for refitting the stub shaft 3 Fit the slide hammer tool on to adaptor 4 Align the stub shaft with the stub shaft hole Section 02 Engine Servicing and Adjustments valve rocker stub shafts 5 Grasp the slide hammer with one hand while positioning the rocker arm with the other and refit the stub shaft by striking the end o...

Page 23: ... TS TR The guides are marked IN TOP and EX TOP inlet or exhaust valve guide top position and are a press fit into the two halves of the cylinder head assembly A rubber ring and a retaining plate are located around the top of the inlet guide on early engines later engines have sealing caps on both valves The rubber sealing ring must be inserted in the top plate recess before pressing in the inlet v...

Page 24: ... pressing in the inserts at ambient temperature the head should be heated to 100 150 C 212 302 F for a minimum of 45 minutes and the insert chilled to 65 to 75 C 85 to 103 F for a minimum of 30 minutes The width of the TS TR seatings must be Inlet 1 65 2 29mm 0 065 0 090in Exhaust 1 35 1 78mm 0 053 0 070in If necessary metal must be ground or cut from the top of the insert or recess The valves are...

Page 25: ...r is being replaced care must be taken to ensure the lever is vertical between the two stops The decompressor lever is spring loaded towards the cylinder head and is located by a plain washer and a split pin or circlip fitted through the decompressor shaft A seal fitted on the outside of the cylinder head prevents oil seepage along the spindle On engine builds not fitted with a decompressor the dr...

Page 26: ...it turning The pulley is secured by a torque loaded left hand thread nut Figure 2 20 1 Flywheel Locking Tool 4 Remove the pulley retaining nut by turning it clockwise 5 Pull off the crankshaft pulley 6 Remove the locking tool Refitting the Pulley 1 Fit the flywheel locking tool into the tapped hole in the flywheel housing check that the flywheel will not turn 2 Replace the crankshaft pulley 3 Repl...

Page 27: ...ankcase and cover 6 If necessary push out the oil seal by using the oil seal tool or a suitable plug press Removing the End Cover TX 1 Remove the drive belt and crankshaft pulley 2 If necessary remove the alternator and axial fan 3 Insert the oil seal tool into the end cover to protect the seal 4 Remove the seven end cover bolts 5 Remove the end cover 6 Clean all traces of the joint from the crank...

Page 28: ...he cylinder head cover and air cowl bracket Replacing the Fuel Tank TS TR 1 Support the tank and replace the bolts securing the top of the tank to the cylinder head cover and air cowl bracket 2 Replace the two nuts securing the base of the tank to the air shield and end cover bracket 3 Reconnect the fuel pipe at either the fuel pumps or fuel tank 4 Push the leak off pipe into the top of the tank S...

Page 29: ... Fit a new joint to the element adapter the retaining bolt and the filter head 5 Place the new element onto the adapter 6 Replace the element bowl and retaining bolt 7 Fill the fuel tank and prime the fuel system The Cartridge Agglomerator Several types of filter agglomerator have been used but the following instructions are valid for all types The cartridge agglomerator is an essential part of th...

Page 30: ...00244 TX2 38 00242 TX3 With the introduction of the Pienne pump a new fuel control solenoid arrangement and a new speed control cable anchor bracket 366 07912 were introduced The Pienne pump has since been replaced by a Corona C lift pump The pump push rod and joint are interchangeable for all types of pump Figure 2 25 1 Fuel Lift Pumps A AC Delco B Pienne C Corona Section 02 Engine Servicing and ...

Page 31: ...nto the slide hammer and tighten the screw C into the injector leak off hole see Note Or b Screw the adaptor A into the slide hammer c Fittheadaptornylonbushoverthehighpressure pipe connection Figure 2 26 1 Injector Removal Tool with Early Type Adaptor 6 Use the slide hammer to remove the injector WARNING Care must be taken to ensure that any part of the hand is not likely to become trapped betwee...

Page 32: ...ct with the spray as the fuel may enter the blood stream with fatal results Injector Back Pressure The leak off rate is 6 27 seconds between 172 142bars 170 140atmos on an injector tester using Calibration C fluid at a temperature of 15 5 C 60 F Replacing an Injector If the injector sealing washer has been used more than once it will become compressed and may adversely affect combustion Care shoul...

Page 33: ...rly TS TR B Later TS TR and all TX 8 Move the rack operating lever on the pump to the central position 9 Remove the fuel pump holding down bolts 10 Gently lift out the pump taking care to retain the timing shims which are between the pump flange and crankcase CAUTION If more than one pump is being removed care must be taken to retain the timing shims with their respective pump Fuel Pump Maintenanc...

Page 34: ...rnor link and the fuel pump interconnecting linkage as shown When re fitting the new type of linkage to the fuel pumps it is important to ensure that the radiused shackles follow the pump radius Figure 2 27 3 Fuel Pump Linkage A Early TS TR B Later TS TR and all TX 6 Re connect the speeder spring to the spigot If the spigot was turned when the pumps were removed it must be turned until the hole ax...

Page 35: ...e fuel supply and bleed the fuel filter and pump 12 Carefully turn the flywheel against rotation until fuel is flowing from the spill pipe 13 Turn the flywheel very slowly in the direction of rotation until the fuel flow from the spill pipe just stops dripping this is known as the Spill Point 14 Check the flywheel timing mark The flywheel timing mark FP which can be seen through an aperture in the...

Page 36: ...timing mark FP which can be seen through an aperture in the fanshroud should align with the arrow on the fanshroud 12 If the flywheel mark is not correct the shims under the fuel pump must be adjusted see Timing Shims Figure 2 28 3 Flywheel Timing Marks Section 02 Engine Servicing and Adjustments fuel pump timing gauge and timing tables If the timing is Advanced Add Shims Retarded Remove Shims App...

Page 37: ...angeable if the pivot blocks are changed the return springs must also be changed All of the above changes were introduced on the following engines and in later text dealing with the governor these changes will be referred to as being applicable to early engines or later engines 35 01614 TS1 36 00001 TR1 35 07495 TS2 36 00011 TR2 35 06047 TS3 36 00141 TR3 The Governor Linkage The fuel pump governor...

Page 38: ...06 07 2700 3000 2100 3000 1300 2099 1 850 950 QW2 18W2 2 08 09 10 11 08 09 08 09 1200 2000 LWS4 13WS4 2 12 13 12 13 LY2 TX2 TX3 01 02 03 04 05 06 07 08 12 13 20 21 52 01 02 03 04 05 06 07 08 12 13 14 52 2700 3000 1800 3000 1500 1799 850 950 SU2 09 10 11 09 10 11 51 1200 2000 LUS4 Notes The speed ranges given in the table do not necessarily relate to the full load build speeds due to flywheel limit...

Page 39: ...pport block Figure 2 30 1 Variable Speed Return Spring e Check that the governor lever assembly is perfectly free to move Changing Governor Weights A table of governor weight and spring combinations is given in Governing Ranges to BS5514 Current enginesarefittedwithanimprovedcamshaftgearwheel design the weights remain the same although on current engines they are retained in position by sintered r...

Page 40: ...n with a 1 5mm punch or stiff wire they are drilled at one end only therefore care must be taken on re assembly to ensure they are fitted with the holes facing outwards Take care to retain the endfloat shims and check that the governor lever assembly is perfectly free to move The small return spring which is only fitted to variable speed engines is fitted to the fuel pump side end of the lever ass...

Page 41: ...in line simultaneously while the distance A is maintained 7 Release the governor lever assembly and check that all parts of the governor move freely Governor G Setting The G setting is used to ensure that the fuel pumps deliver the correct amount of fuel as dictated by the engine build number The various settings are given in 02 32 Governor G Setting and Timing Tables For intermediate speeds not g...

Page 42: ... TX 3 Slacken the collar grubscrew sufficiently and screw the collar along the adjusting screw B until it just touches the plate E 4 Turn the collar back half a turn and tighten the collar grubscrew 5 Move the stop control fully anti clockwise and release it checking that the engine goes freely into the excess fuel position 6 Gentlymovethegovernorassemblyleverawayfrom the camshaft until the excess...

Page 43: ...0 1500 A1 100 0 045 10 20 1800 A1 100 0 045 16 20 2000 B1 90 100 0 045 17 20 2500 B1 90 100 0 045 18 20 2200 A1 90 100 0 045 62 20 1500 A1 100 0 045 101 20 1500 A1 100 0 045 102 103 20 2500 B1 90 100 0 045 106 20 2500 B1 90 100 0 045 TR1 Builds Timing BTDC Speed Class Load Rating G Setting 01 02 20 2500 B1 90 100 0 040 03 23 3000 B1 90 100 0 055 06 07 20 2500 B1 100 0 040 08 09 20 1500 A1 100 0 05...

Page 44: ... Class Load Rating G Setting 01 20 2500 B1 90 100 0 045 02 22 2500 B1 100 0 069 03 24 3000 B1 90 100 0 043 04 24 2800 B1 100 0 071 05 22 2500 B1 100 0 069 09 20 1500 A1 90 100 0 042 10 20 1800 A1 100 0 056 1800 A1 13 24 2900 B1 90 100 0 043 14 22 2500 B1 100 0 069 16 17 22 2500 B1 90 100 0 069 52 22 2000 B1 90 100 0 045 ...

Page 45: ...rolled by the tension of the speeder spring which is internally attached to the speed control which in turn can be operated either by a cable or rod The idling speed must not be set below 850r min 1 Move the speed control until it is against the adjusting screw A 2 Turn the adjusting screw A anti clockwise until it has no further effect on reducing the engine speed 3 Turn A clockwise until the no ...

Page 46: ...ove the spring D from its location on the excess fuel lever 6 Remove the excess fuel lever assembly B and spring E while withdrawing the control lever F and plate assembly G 7 Examine and renew the 0 ring H if necessary 8 Replace the cam spring A if removed to the lever assembly B 9 Replace the control lever F and plate assembly G through the crankcase into the spring E and the excess fuel lever a...

Page 47: ... 5 Remove the tappet guide Replacing a Tappet 1 Replace the guide into the crankcase taking extreme care to ensure the end with the two flats enters first and the locating holes in the crankcase and guide are correctly aligned 2 Replace the guide locating bolt and a new copper washer 3 Replace the tappet 4 Replace the tappet insert with the smaller section on the outside CAUTION Failure to fit a n...

Page 48: ...m in their highest positions 2 Carefully replace the camshaft into the crankcase keeping it square at all times take care to line up the 0 timing marks on the crankshaft and camshaft gears exactly Figure 2 36 1 Gear Timing Marks 3 Release the cam followers 4 Replace the oil pump sump fuel pumps governor and end cover Camshaft Endfloat The end float maintained with a single metal shim between the c...

Page 49: ... hub and any sharp edges around the hole must be removed any burrs will affect the operation of the governor thrust sleeve Fit the camshaft gearwheel in the reverse order to dismantling ensuring the thin flat washer is removed and that the gearwheel abuts against the shoulder F CAUTION Ensure no pressure is applied to the outer ring of the gear at any time Changing the Camshaft Ball Race 1 Remove ...

Page 50: ...from the gear end 5 Place the guide 10 over the screw to align the bush in the housing 6 Fit the bridge 8 and thrust nut 9 7 Using the correct size of spanner and checking the tool and bush alignment very carefully tighten the thrust nut until the bush is central across its housing 8 Remove the tool Section 02 Engine Servicing and Adjustments camshaftbushes Centre Bush Removal 1 Fit the nut 2 onto...

Page 51: ... assist in aligning the tool 3 Insert the bolt through the flywheel end camshaft hole place the washer and bush over the bolt with the flat face towards bolt head and screw it into the plug until the bush and washer abuts the centre camshaft bearing hole 4 Checking the tool and bush alignment very carefully gently screw the bolt until the centre bearing is fully located in the centre web bearing h...

Page 52: ...the piston ring gaps are staggered and fit the piston into the cylinder barrel while compressing the rings 5 If necessary fit new big end bearing shells ensuring they are correctly located in both the connecting rod and cap 6 On TS TR engines Coat the bottom jointing face surface of the cylinder barrel with Hylomar PL32M Fit a new joint and coat it with Hylomar PL32M 7 On TX engines Clean and dry ...

Page 53: ...ston 1 Remove the cylinder barrel together with the piston 2 Withdraw the piston from the barrel 3 Release the circlip from one end of the gudgeon pin 4 Push out the gudgeon pin If the pin is tight place the piston in hot water until it can be removed it may be necessary to protect the hands 5 Using a suitable piston ring expander remove the piston rings Inspection and Servicing a Clean the piston...

Page 54: ...lts entering the flywheel must not exceed 20 0mm 0 79in Figure 2 41 1 Flywheel Tools A Early Locking Tool B Current Locking Tool C Puller D Mandrel Section 02 Engine Servicing and Adjustments flywheel Flywheel Removal 1 Remove the starter motor 2 Fit the flywheel locking tool into the tapped hole in the fanshroud 3 If the flywheel locking tool is not available wedge the crankshaft with a suitable ...

Page 55: ...rder and it is recommended that new tabwashers are fitted and correctly locked after the bolts have been torque loaded to 43 5Nm 32 0lbf ft The tabwashers and bolts can be replaced with the current self locking setscrews which must be torque loaded to 88 0Nm 65 0lbf ft CAUTION If the sump has been removed the procedure detailed in Replacing the Oil Sump must be followed when refitting the fanshrou...

Page 56: ...ntre bearing dowel B leave the bolt in the dowel until it is refitted to ensure the dowel is fitted the correct way round Figure 2 43 1 Centre Bearing Dowel 3 Remove the bolts securing the main bearing housing 4 On early TS engines remove the charge winding adaptor adapter 5 Remove the bearing housing if it is tight use two M8 setscrews through the threaded holes provided and jack it off 6 Drift o...

Page 57: ...he crankshaft pinion Figure 2 44 1 Crankshaft Gear Removal Tool 3 Remove the pinion gear Woodruff key if necessary 4 Remove each centre bearing locating dowel securing screw A Figure 2 44 2 Centre Bearing Dowel Section 02 Engine Servicing and Adjustments crankshaft 5 Using a fuel pump securing bolt remove each centre bearing dowel B Leave the bolt in the dowel until it is refitted to ensure the do...

Page 58: ...ough the crankcase wall and into the centre bearing housing Figure 2 44 3 Centre Bearing Dowel CAUTION Ensure the dowel has gone fully home and that it is not abutting the main bearing housing shoulder or capscrew recess Figure 2 44 4 Dowel Hole Alignment A Dowel Hole B Capscrew Head Recess 6 Replace the locating dowel securing screw and torque load it to 20 5Nm 15 0lbf ft 7 Remove the fuel pump b...

Page 59: ...gines may have paper and 0 076mm 0 003in metal shims assembled dry or with Wellseal 5 After the bearing housing has been replaced the housing bolts are torqued to 27 0Nm 20 0lbf ft Section 02 Engine Servicing and Adjustments crankshaft endfloat bearing clearance 02 46 CHECKING BEARING CLEARANCE 1 Place a piece of the correct size Plastigauge approximately 6 35mm 0 25in off centre across the full w...

Page 60: ... are correctly located in the crankcase 11 Remove the tool taking care to prevent it dropping onto the new bearing 12 Check that the oil holes in the crankcase and bearings align Flywheel End Main Bearing Removal 1 Remove the thrustwashers and the oil seal from the bearing housing 2 Fit the nut 2 onto the screw 1 3 Hold the nut firmly across its flats in a vice 4 Place both dollies 5 6 onto the sc...

Page 61: ...re aligned If not correctly aligned oil restriction or starvation may occur 1 Position the sleeve B on a flat surface with the locating lug facing downwards 2 Slide the two halves of the new bearing into the top of the sleeve together ensure the ends of the new bearings are at 90 to the locating lug 3 Fit the correct bearing locating ring C onto the plug A Four bearing rings are available for stan...

Page 62: ...heel retainer to 474 5Nm 350 0lbf ft Crankshaft Extension Spanner 317 50060 The tool is used when it is not possible to torque direct at the gear end with the flywheel locked Figure 2 48 1 Extension Spanner 317 50060 1 Fit the open ended section behind the pinion or onto the shaft 2 Place the bolt through the boss and into the crankcase 3 With the engine decompressed turn the flywheel using a 65mm...

Page 63: ...screw 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 crankcase and tighten a further half turn Figure 2 49 1 Changing the Oil Filter 5 Run the engine and check for any oil leaks 6 Stop the engine allow the oil ...

Page 64: ...eceptacle 2 Remove the oil level dipstick A polypropylene handled dipstick is currently fitted refer to 02 50 The Oil Dipstick 3 Stand the engine on its flywheel using a suitable piece of wood or similar material on which to rest the flywheel but not the fanshroud this will enable the engine to be rotated and ease subsequent dismantling 4 Remove the sump bolts and spring washers noting that two bo...

Page 65: ...ustments oil strainer and pump Oil Pump The camshaft operated oil pumps are the self regulating plunger type and they are not interchangeable across the ranges Removing the Oil Pump 1 Drain the oil 2 Remove the dipstick and sump 3 Lift out the oil pump 4 Using long nosed pliers remove the oil pump push rod from the crankcase 5 Dismantle the oil pump making a careful note of the component positions...

Page 66: ...sing and press out the old seal 2 Place the new seal squarely into the housing do not use any jointing compound 3 Hold the oil seal tool 317 50065 onto the outside face of the seal and drive in the seal until the tool shoulder is against the bearing housing In an emergency if the tool is not available a suitable plug preferably hard wood can be used The Rotary Oil Seal if a rotary seal requires ch...

Page 67: ...deposits and bearing corrosion in diesel engines and also from rust corrosion and low temperature deposits in gasoline engines These oils were introduced in 1961 API Service Category CD Service typical of certain naturally aspirated turbocharged or supercharged diesel engines where highly effective control of wear and deposits is vital or when using fuels with a wide quality range including high s...

Page 68: ...signed for this service have been in existence since 1994 The Oil Specification To help assist engine running in all engines are despatched with an initial fill lubricating oil which must be changed after 100 hours 1 The temperatures mentioned in the table are the ambient temperatures at the time when the engine is started However if monograde oils are used and running ambient temperatures are sig...

Page 69: ...teristics of any recommended grade it is essential that oil changes are made within the Lister Petter recommendations An oil change is recommended immediately if the engine fails to reach its normal cold start cranking speed due to excessive oil viscosity Fuel dilution of the lubricating oil will adversely affect cold starting and oil consumption 3 SAE 30 and 10W 30 oils may be used at up to 52 C ...

Page 70: ...ass A2 b BS EN590 1995 Class A1 c USA Specification ASTM D 975 77 Grades No 1 D and 2 D 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 Lister Petter engines The user is cautioned that although the engines may operate on fuels outside the above specifications such operation may well result in excessive w...

Page 71: ...signed 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 Section 04 Operating Instructions preliminaryinstructions Section 04 Operating Instructions Firmly hold the handle grip with the thumb on top of the grip durin...

Page 72: ...ges 5b If using a limited kick back handle Swivel the starting handle housing cover A to one side and insert the correct handle refer to B in Figure 4 1 1 into the housing Slowly rotate the handle in the direction of cranking until it fully engages Figure 4 2 4Starting Handle Housing 6 If the cold starting aid was not used turn the engine slowly for up to 20 turns to prime the combustion chamber a...

Page 73: ...OP position and release it Figure 4 3 2The Engine Control 3 If a variable speed control lever is fitted move it to the fast position 4 If the ambient temperature is below 10 C 14 F refer to items 2 and 3 in Cold Starting Aid TS TR 5a If a start key is being used Turn the start key clockwise and hold it at position 3 until the engine fires and then release it immediately Figure 4 3 3Start Key 5b If...

Page 74: ...er 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 unless an optional fuel control solenoid is fitted 2 On engines fitted with a fuel control solenoid turn the key to the OFF position CAUTION Never stop the engine by operating the decompressor lever or valve damage may occur Section 04 Operating Inst...

Page 75: ...hedule hours are based on average operating conditions and cover the minimum requirements to keep an engine running at peak performance with trouble free operation Under very dusty conditions air cleaners lubricating oil and fuel filters will require more frequent attention Decarbonising may be required more often if the engine has been running on light loads for long periods Before carrying out a...

Page 76: ...ment Clean or replace the injectors if the exhaust is dirty Renew the fuel filter element if the fuel being used is not perfectly clean Check the TX axial fan drive belt tension Every 500 Hours The above and the following items Replace the air cleaner element Examine the exhaust and induction systems for leaks damage or restrictions Renew the fuel filter element Check the battery charge winding sy...

Page 77: ...page 77 Section 05 Routine Maintenance spanner torques 05 03 SPANNER TORQUE SETTINGS The tolerance for all spanner torque settings is 5 0 and for practical purposes the figures have been rounded ...

Page 78: ...ce jointing compounds 05 4 JOINTING COMPOUNDS Some engines will have been assembled with jointing compounds that have been superseded Providing ail traces of the old compound and joint are removed the later specified compounds can be used ...

Page 79: ...rt The clearance is not to be measured at the top of the bore When cylinders are rebored the lower skirt should be etched or painted with the amount of the over size Piston Ring Wear The ring gaps given in the table are those to be anticipated when checking rings in an unworn part of the bore For every 0 01mm 0 0004in by which the actual bore size exceeds the initial dimension the ring gap will in...

Page 80: ...page 80 Section 05 Routine Maintenance TS TR wearing parts TS TR Wearing Parts ...

Page 81: ...page 81 Section 05 Routine Maintenance TS TR wearing parts TS TR Wearing Parts ...

Page 82: ...page 82 Section 05 Routine Maintenance TX wearing parts TX Wearing Parts ...

Page 83: ...page 83 Section 05 Routine Maintenance TX wearing parts TX Wearing Parts ...

Page 84: ...ng oil from the 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 engin...

Page 85: ...tling procedure the following should be considered a Do you know and understand the engine and all the related systems b Do you have sufficient electrical and mechanical knowledge and skills to understand the symptoms c Do you have suitable electrical diagnostic equipment available d Do you have or access to the necessary Lister Petter spare parts before you commence dismantling 06 2 METHOD OF TRO...

Page 86: ...ean Unsuitable fuel Use fuel of the correct specification Unsuitable lubricating oil Use oil of the correct viscosity and specification Continuous low or no load running Investigate your load management programme White Exhaust Smoke Water in the fuel system Drain flush refill and prime the filter Faulty fuel pump Contact a Lister Petter distributor Light Blue Exhaust Smoke Generally as a result of...

Page 87: ...ter Dismantle and clean the cap and element Choked exhaust system Dismantle and clean Overload Reduce the load Choked fuel filter Replace the filter Worn engine Give the engine a major overhaul Overheating Overload Reduce the load Lubricating oil level too low Add oil of the correct specification and viscosity Incorrect fuel Drain the system add fuel of the correct specification Recirculation of e...

Page 88: ...lean surrounding area and replace the battery Deffective battery Test or replace the battery Battery charging rate is too high Check the alternator output or battery charging system Battery will not Charge Loose or corroded connections Clean and tighten the connections Worn out battery Replace the battery Loose alternator drive belt Replace or re tension the drive belt Starter Motor does not Opera...

Page 89: ...tifier regulator and the battery during periods of running the indicator light will remain unlit unless there is a fault in the charging system The battery charge indicator light will always be lit to indicate a charging fault The light will also be switched on with a fully serviceable system under the following circumstances a If the charge rate drops below 2 Amps at normal engine speed and the b...

Page 90: ...page 90 Section 07 Flywheel Charge Windings Syncro Syncro Fault Finding Flow Charts ...

Page 91: ...page 91 Section 07 Flywheel Charge Windings Syncro Syncro Fault Finding Flow Charts ...

Page 92: ...nstruments are necessary to carry out the tests 1 0 20A moving coil ammeter 2 0 20V moving coil voltmeter or a DC multimeter 3 0 200V moving iron voltmeter or an AC multimeter 4 0 5 Ohm meter or multimeter Figure 7 3 1 Test Instrument Connection Diagram X Removed B Battery Terminal Stator Winding Resistance at 20 C 68 F Leads Resistance Yellow to Yellow 0 45 0 55 Red to one Yellow 0 225 0 275 Red ...

Page 93: ...page 93 Nicsa Fault Finding Flow Charts Section 07 Flywheel Charge Windings Nicsa ...

Page 94: ...page 94 Section 07 Flywheel Charge Windings Nicsa Nicsa Fault Finding Flow Charts ...

Page 95: ...page 95 Section 07 Flywheel Charge Windings Nicsa Nicsa Fault Finding Flow Chart ...

Page 96: ...page 96 ...

Page 97: ...The small numbered boxes shown attached to some cables are cable identification numbers The heater plug 17 is an optional accessory Key to all Diagrams 1 Flywheel alternator stator 2 Control keyswitch 3 Engine temperature switch The air temperature switch must be wired in irradiated PVC cable suitable for temperatures up to 120 C 248 F 4 Fuel control solenoid circuit breaker 5 Fuel control solenoi...

Page 98: ...page 98 Section 08 Electrical Wiring Diagrams ...

Page 99: ...page 99 Section 08 Electrical Wiring Diagrams ...

Page 100: ...page 100 Section 08 Electrical Wiring Diagrams ...

Page 101: ...page 101 Section 08 Electrical Wiring Diagrams ...

Page 102: ...page 102 Section 08 Electrical Wiring Diagrams ...

Page 103: ...page 103 Section 08 Electrical Wiring Diagrams ...

Page 104: ...page 104 ...

Page 105: ... 0 3 t a d e e p s n o t s i p n a e M c e s m 1 4 7 1 4 7 1 4 7 n i m t f 8 5 4 1 8 5 4 1 8 5 4 1 n a e m e r u s s e r p l i o g n i t a c i r b u L r a b 0 2 0 2 0 2 n i f b l 2 0 9 2 0 9 2 0 9 2 y t i c a p a c p m u s l i o g n i t a c i r b u L e r t i l 7 2 0 4 5 5 t p 7 4 0 7 8 5 t q S U 8 2 2 4 8 5 y t i c a p a c k n a t l e u f d e t n u o m e n i g n E e r t i l 5 3 1 5 2 8 5 3 1 5 3 1...

Page 106: ...speed at 3000r min m sec 8 47 8 47 8 47 ft min 1667 1667 1667 Lubricating oil pressure mean bar 2 0 2 0 2 0 lbf in2 29 0 29 0 29 0 Lubricating oil sump capacity litre 2 7 4 0 5 5 pt 4 7 7 0 5 8 US qt 2 8 4 2 5 8 Engine mounted fuel tank capacity litre 8 25 13 5 13 5 13 5 pt 14 5 23 7 23 7 23 7 US qt 8 7 14 2 14 2 14 2 Maximum crankshaft end thrust kg 132 132 132 lb 290 290 290 Number of flywheel g...

Page 107: ...ft min 2000 2000 Lubricating oil pressure minimum at 1000 r min bar 0 7 0 7 lbf in2 10 0 10 0 Lubricating oil pressure nominal at 1500 r min bar 1 25 1 25 lbf in2 18 0 18 0 Lubricating oil sump capacity litre 4 0 6 0 pt 7 0 10 6 US qt 4 2 6 3 Engine mounted fuel tank capacity litre 25 0 25 0 pt 43 9 43 9 US qt 26 3 26 3 Maximum crankshaft end thrust kg 132 132 lb 290 290 Number of flywheel gear ri...

Page 108: ...in with overload high speed flywheel 10 Genset Build I5OOr min with overload 11 Genset Build 1800r min with overload 12 Genset Build 3OOOr min with overload 13 Genset Build 3000r min with overload 14 Dumper Build variable speed up to 2500r min with overload 15 Dumper Build variable speed up to 2500r min with overload 16 Variable speed up to 2000r min with overload sheet metal fanshroud 18 Genset B...

Page 109: ... min with overload provision for hydraulic pump 06 Variable speed up to 2500 r min 2000r min on TR1 with overload provision for hydraulic pump 07 Variable speed up to 2500 r min 2000r min on TR1 with overload provision for hydraulic pump 08 TR1 Genset Build 1500 r min with overload heavy flywheel TR2 3 Genset Build up to 1800 r min with overload heavy flywheel 09 Fixed speed up to 1500 r min with ...

Page 110: ...riable speed up to 2800 r min with overload 05 Variable speed up to 2500 r min with no overload 06 Variable speed up to 2500 r min with no overload 07 Variable speed up to 3000 r min with no overload 08 Variable speed up to 2800 r min with no overload 09 Fixed speed 1500 r min with no overload 10 Fixed speed up to 1800 r min with overload 11 Fixed speed up to 1800 r min with overload 12 Fixed spee...

Page 111: ...The temperature unit in most practical use in many countries is the degree Celsius C however the terms Centigrade C and Fahrenheit F are still in use The Fahrenheit scale is not formally defined but it is generally recognised that the temperature difference of 1 F is equal to five ninths of the temperature difference of one degree C 1 C 5 F 32 9 1 F 9 C 32 5 The refinements of temperature scales a...

Page 112: ...known as the imperial pint 2 Also known as the imperial gallon 1 UK gallon 1 2009 US gallon 1 US gallom 0 8325UK gallon Volume cubic metre m3 litre l cubic inch in3 cubic foot ft3 1 cubic metre 1000 0 61023 8 35 3147 1 litre 0 0010 61 0238 0 0353 1 cubic inch 1 6387 x 10 5 0 0164 5 7870 x 10 4 1 cubic foot 0 0283 28 3168 1728 0 1 dm3 1litre 1 in3 16 3871cm3 Linear Velocity metre per second m sec f...

Page 113: ... square in lbf in2 1 bar 0 9869 1 0197 14 5038 1 atm 1 0132 1 0332 14 6959 1 kgf cm2 0 9807 0 9678 14 2233 1 lbf in2 0 0689 0 0680 0 073 Pressure Table 3 inch of water in H2 O foot of water ft H2 O millimetre of mercury mm Hg inch of mercury in Hg 1 in H2 O 0 0833 1 8683 0 0735 1 ft H2 O 12 000 22 4198 0 8827 1 mm Hg 0 5352 0 0446 0 0394 1 in Hg 13 5951 1 1329 25 400 1in H2 O 0 00248 bar Torque Mo...

Page 114: ...r Table 1 kilowatt kW metric horsepower CV brake horsepower bhp British thermal unit per hour Btu h 1 kW 1 3596 1 3410 3412 14 1 CV 0 7355 0 9863 2509 63 1 bhp 0 7457 1 0139 2544 43 1 Btu h 0 00029 3 9846 x 10 4 3 9301 x 10 4 Power Table 2 watt W kilo calorie per hour k cal h British thermal unit Btu 1 watt 0 08598 3 4121 1 k cal h 1 1630 3 9683 1 Btu 0 2930 0 2519 Specific Fuel Consumption pounds...

Page 115: ...page 115 Section 11 Index Section 11 Index a ...

Page 116: ...art 73 End cover 27 oil seal 27 66 Engine control assemblies 46 features 9 fluids 67 specifications TS 105 TR 106 TX 107 Excess fuel device 71 fuel trip TX 42 Exhaust manifold 16 F Fanshroud 55 Filter fuel tank 29 Flywheel 54 housing 55 Formulae 111 Fuel injector 31 lift pump 30 pump 33 pump timing 35 pump timing gauge 36 pump timing tables 36 specification 70 tank 28 G Gear end cover 27 oil seal ...

Page 117: ...ance schedule hours 76 S Safety precautions and safe working practices 5 symbols 8 Screw type oil seal 66 Spanner torque settings 77 Speed adjustment 45 control lever 46 Starting electric 73 hand 72 Stopping 74 Storing the engine 84 Sump 64 Syncro charge windings 89 T Technical data TS 105 TR 106 TX 107 Timing 35 gauge 36 tables 36 Torque settings 77 Training 4 Troubleshooting charge windings 89 9...

Page 118: ...Publication P027 08221 Edition 12 2003 Copyright Lister Petter Limited all rights reserved Published in May 2005 Printed in the United Kingdom Lister Petter Limited Dursley GL11 4HS England ...

Page 119: ...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 ...

Page 120: ... 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 17 Avenue de L escouvrier Zone d Activites 95842 Sarcelles Cedex France Tel 33 0 1 39330420 Fax 33 0 1 34195760 E mail commercial lister petter france fr INDIA Lister Petter Private Limited 102 Beaver Gradeur Baner Pune 411045 India Tel 91 20 729 3284 ...

Page 121: ...Technical Library http engine od ua ...

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