Lister Petter TS1 Workshop Manual
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Lister Petter TS1 Workshop Manual

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TS, TR, TX
Workshop Manual
Edition 12: May 2005
Publication P027-08221

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TENDAYI DICK GWESHE
April 29, 2025

Please can you confirm what model this is and where I can get parts and manuals

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Summary of Contents for Lister Petter TS1

  • Page 1 TS, TR, TX Workshop Manual Edition 12: May 2005 Publication P027-08221...
  • Page 2 page 2...

  • Page 3: Table Of Contents

    Edition 12: May 2005 Manual Contents page Introduction................4 Section 01. General Information ..........5 Section 02. Engine Servicing and Adjustments ....13 Section 03. Engine Fluids ........... 67 Section 04. Operating Instructions ........71 Section 05. Routine Maintenance ........75 Section 06. Troubleshooting ..........85 Section 07.

  • Page 4: Introduction

    A full cross reference 'Index' appears at the back of engines and not to any one particular engine. In cases the manual. of difficulty the user should consult the local Lister Petter Distributor or Dealer for further advice and technical It is recommended the individual steps contained in assistance.

  • Page 5: Section 01. General Information

    Starting any diesel engine can be dangerous in suitable for lifting the engine and accessory the hands of inexperienced people. Engine assemblies originally fitted by Lister Petter. They operators must be instructed in the correct must not be used to lift the complete plant.
  • Page 6 Section 01 General Information - safety when a pole strap is directly or indirectly connected to Rotating Machinery the engine. a. Entanglement with any rotating equipment can cause serious injury or death. f. Starting engines that are fitted with charge windings which have been disconnected from the batter will b.
  • Page 7 Section 01 General Information - safety Precautions for Oil, Filters and Elements Fuel System Precautions a. Used liquid filters and elements contain some of a. When priming or checking the fuel injection pump the filtered liquid and should be handled and timing, care must be taken to wipe spilled fuel from disposed of with care.

  • Page 8: General Information

    Section 01 General Information - safety symbols 01.2 SAFETY SYMBOLS This section identifies the ISO 8999 symbols currently used by Lister Petter. page 8...
  • Page 9 Section 01 General Information - engine features 01.3 ENGINE FEATURES TS/TR2 TS/TR1 TS/TR3 page 9...
  • Page 10 Section 01 General Information - engine identification 01.4 ENGINE IDENTIFICATION Nomenclature TS and TR - one, two and three cylinder, direct injection, naturally aspirated flywheel fan air cooled diesel engines. TX - two and three cylinder, direct injection, naturally aspirated, axial fan air cooled diesel engines. Engine Serial Number The engine serial number is stamped on a plate attached to the engine.
  • Page 11 Arctic or Alkaline batteries must be used. Lister Petter recommend that a battery should WARNING provide a minimum cranking period of 60 seconds from Do not allow the jumper lead free ends to directly, or a 70% charged 12 volt battery, with a minimum voltage indirectly touch the engine at any time.
  • Page 12 Section 01 General Information - battery cold cranking Battery Cold Cranking Performance The cold cranking battery performance rating figures given relate to the cranking current required from a starter battery when tested at -18°C (0°F) and not the current available from the battery at the engine operating ambient temperature stated.

  • Page 13: Section 02. Engine Servicing And Adjustments

    Section 02 Engine Servicing and Adjustments - preliminary instructions Section 02. Engine Servicing and Adjustments Because of the various engine configurations, and 02.1 PRELIMINARY INSTRUCTIONS installations in which the engine can be fitted, it is not WARNING possible to give detailed instruction for each one. Maintenance must be performed by qualified persons When assembling the engine, use the same type who are conversant with the hazards of fuels, electricity...
  • Page 14 Section 02 Engine Servicing and Adjustments - air cleaner 02.2 THE AIR CLEANER Inlet Manifold Loading A conventional air cleaner may be mounted direct on the manifold, or on a light extension which must be no more than 152mm (6ins) long. Heavy air cleaners must be remotely mounted, or mounted on the engine using a special bracket, and connected by means of flexible pipe or hose, with no...
  • Page 15 Section 02 Engine Servicing and Adjustments - cold start aid 02.3 THE COLD START AID TX Engines The TX inlet manifold may have a cold weather glowplug fitted and care must be taken to ensure the TS and TR Engines battery is isolated and the cable removed before The cold starting aid may be fitted to the combustion attempting to remove the manifold from the engine.
  • Page 16 Section 02 Engine Servicing and Adjustments - manifolds Removing the Manifolds - TS/TR 02.4 THE MANIFOLDS 1. Remove the air cleaner and exhaust silencer. Manifold Loading 2. Remove the nuts, spring washers and distance A small, light exhaust silencer may be mounted pieces.
  • Page 17 Section 02 Engine Servicing and Adjustments - air cowling and cylinder fins 02.5 THE AIR COWLING Removing the Air Cowling - TX 1. Remove the air cleaner if necessary. Three sides of the engine are encased in an air cowl and two sides shields, which together with the 2.
  • Page 18 If a later guard is being fitted in place of and crankcase external cooling fins. a metal type the end cover must be modified. Drawing SK2204/91 is available from Lister Petter for this WARNING purpose. The axial fan belt must be changed every 2000 hours, irrespective of its condition.
  • Page 19 Section 02 Engine Servicing and Adjustments - cylinder head cover and breather 02.10 THE CYLINDER HEAD COVER Removing the Cylinder Head Cover 1. Remove the lifting eye and fuel tank securing bolts The light alloy cylinder head cover, which is bolted if necessary.
  • Page 20 Section 02 Engine Servicing and Adjustments - cylinder head 6. Tighten down the cylinder head nuts diagonally and 02.11 THE CYLINDER HEAD evenly to a final torque of: On and after the TX engine serial numbers shown, TS/TR - 68.ONm (50.0lbf ft). two spring disc washers were fitted under each cylinder bolt head instead of one plain washer.
  • Page 21 Section 02 Engine Servicing and Adjustments - cylinder head clearance 02.12 CYLINDER HEAD CLEARANCE TX Engines The cylinder head clearance is maintained by 0.07mm, 0.13mm or 0.38mm (0.003in, 0.005in, TS and TR Engines 0.015in) metal shims placed between the cylinder 1.
  • Page 22 Section 02 Engine Servicing and Adjustments - valve rocker stub shafts 5. Grasp the slide hammer with one hand while 02.13 THE VALVE ROCKER STUB positioning the rocker arm with the other and refit SHAFTS - TS/TR the stub shaft by striking the end of the tool nearest The removal of the stub shafts is necessary when the cylinder head with the slide hammer.
  • Page 23 6. Replace the valve rocker cover. obtained from Lister Petter. Valve Guides - TX After the outside of the valve guides have been coated with Wellseal they are pressed into the cylinder head.
  • Page 24 Up to the TS/TR serial numbers shown the measurements were: inlet valves: 1.02-1.27mm (0.040-0.050in). Exhaust valves: 0.89-1.14mm (0.035-0.045in). 36 00199 TS1 36 00025 TR1 36 00480 TS2 36 00020 TR2 36 00307 TS3 36 00043 TR3 On later TS/TR engines the measurements are: Inlet valves: 0.63-0.94mm (0.025-0.037in).
  • Page 25 Section 02 Engine Servicing and Adjustments - valve clearance and decompressor 02.18 VALVE CLEARANCE 02.19 THE DECOMPRESSOR The valve clearance must be measured and The decompressor is fitted to the exhaust valve on adjusted when the engine is cold. It is important that some engines.
  • Page 26 Section 02 Engine Servicing and Adjustments - crankshaft pulley 02.20 THE CRANKSHAFT PULLEY - TX The pulley is secured by a torque loaded left hand thread nut. Removing the Pulley 1. Slacken the alternator mounting bolts and move the alternator as far as it will go towards the crankcase.
  • Page 27 Section 02 Engine Servicing and Adjustments - gear end cover 02.21 THE GEAR END COVER Removing the End Cover - TX 1. Remove the drive belt and crankshaft pulley. The light alloy end cover is located on two dowels and is secured to the crankcase by seven setscrews 2.
  • Page 28 Section 02 Engine Servicing and Adjustments - fuel tank 02.22 THE FUEL TANK Removing the Fuel Tank - TX 1. Drain the fuel into a clean receptacle. Various sizes of engine mounted fuel tanks are available as shown in the table below. 2.
  • Page 29 Section 02 Engine Servicing and Adjustments - fuel filter, agglomerator, priming 02.23 THE FUEL FILTER The Cartridge Agglomerator Several types of filter/agglomerator have been used One of three types of filter will be fitted and a but the following instructions are valid for all types. combined filter and agglomerator is available when no tank is fitted.
  • Page 30 02.25 THE FUEL LIFT PUMP A Pienne (B) fuel lift pump was first fitted from the engines below and differs from the older AC Delco (A) type. 38 02253 TS1 38 00287 TS2 38 00262 TS3 38 00754 TR1 38 00003 TR2...
  • Page 31 It is recommended that injectors onto the injector. are changed as a set rather than individually. For further information please contact any Lister Petter distributor. Removing an Injector - TS/TR 1. Remove the cylinder head cover.
  • Page 32 Section 02 Engine Servicing and Adjustments - fuel injector Cleaning an Injector Replacing an Injector • A thoroughly cleaned container holding a supply of If the injector sealing washer has been used more clean, fresh fuel oil should be available for washing than once it will become compressed and may dismantled parts.
  • Page 33 The 'ring' type are available in 0.127, 0.762, 1.016 hole axis is parallel to the camshaft before removing and 1.276mm sizes and were first fitted on: the spring. 40 00213 TS1 40 00113 TR1 7. Disconnect the governor and pump interconnecting 40 00297 TS2 40 00135 TR2 linkage at the pumps.
  • Page 34 Section 02 Engine Servicing and Adjustments - fuel pump 7. Check the governor setting; refer to "02.31 Setting Refitting the Fuel Pumps the Governor". 1. If 'ring' type shims are being fitted place them onto the fuel pump taking care not to damage the pump 8.
  • Page 35 Section 02 Engine Servicing and Adjustments - fuel pump spill timing 02.28 FUEL PUMP TIMING Fuel pump components are manufactured to exacting limits and care must be taken to ensure they are returned to their respective pumps if more than one pump is dismantled at a time.
  • Page 36 TX - 22.0Nm (16.0lbf ft). Fuel Pump Timing Tables The values given in the first table apply to early TS/ TR engines with serial numbers up to those shown. 36 00489 TS1 36 03079 TR1 36 00314 TS2 36 05126 TR2...
  • Page 37 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...
  • Page 38 Section 02 Engine Servicing and Adjustments - governing ranges 02.30 THE GOVERNOR Governing Ranges to BS5514 r/min Ranges to BS5514 Build Number Full Load Full Load Governor Class A1 Class B1 Outside 10% Idling Limits Code 01 02 03 01 02 03 01 02 03 04 06 07 04 05 06...
  • Page 39 Section 02 Engine Servicing and Adjustments - governor Changing Governor Weights Dismantling the Governor A table of governor weight and spring combinations 1. Remove the gear end cover. is given in "Governing Ranges to BS5514". Current 2. Remove the fuel pump inspection door/s. engines are fitted with an improved camshaft gearwheel 3.
  • Page 40 Section 02 Engine Servicing and Adjustments - governor 'E' and 'Q' settings 02.31 SETTING THE GOVERNOR Governor 'Q' Setting 1. Gently move the governor plate forward sufficiently Before setting the governor refer to "Governing to ensure the chamfered spacers behind the Ranges to BS5514"...
  • Page 41 Section 02 Engine Servicing and Adjustments - governor 'A' and 'G' settings the calibration marks (X) on all pumps are in Governor 'A' Setting line simultaneously while the distance 'A', is 1. Set the distance 'A', between the end of the thrust maintained.
  • Page 42 Section 02 Engine Servicing and Adjustments - limited excess fuel trip Limited Excess Fuel Trip - TX This device may be fitted to some TX2 Build 20 engines. Adjusting the Trip Care must be taken to ensure the governor 'G' and 'Q' settings are correct before attempting to adjust the trip.
  • Page 43 Section 02 Engine Servicing and Adjustments - governor 'G' setting and timing tables 02.32 GOVERNOR 'G' SETTING AND TIMING TABLES Timing Speed/ Load Builds BTDC Class Rating Setting 01, 02 20° 2500 B1 90/100% 0.040" Timing Speed/ Load 23° 3000 B1 90/100% 0.055"...
  • Page 44 Section 02 Engine Servicing and Adjustments - governor 'G' setting and timing tables TX2, 3 Timing Speed/ Load Builds BTDC Class Rating Setting 20° 2500 B1 90/100% 0.045" 22° 2500 B1 100% 0.069" 24° 3000 B1 90/100% 0.043" 24° 2800 B1 100% 0.071"...
  • Page 45 Section 02 Engine Servicing and Adjustments - speed adjustment 02.33 SPEED ADJUSTMENT The speed of the engine is controlled by the tension of the speeder spring which is internally attached to the speed control. The control has two adjustable screws which are adjusted and locked to give the rated full on-load or variable speed as determined by the engine Build.
  • Page 46 The control knob, spindle and plate assembly was modified on and after the following TS engines: When the lever is assembled it must be free to rotate. 35 01203 TS1 35 06483 TS2 35 05021 TS3 On later TS and all TR and TX engines the knob and spindle are one assembly and the location plate is a separate item.
  • Page 47 Section 02 Engine Servicing and Adjustments - fuel pump tappet 02.35 THE FUEL PUMP TAPPET Removing a Tappet 1. Remove the fuel pump. 2. With the fuel pump removed use long nosed pliers to remove the tappet insert (A) from the top of the tappet assembly (B).
  • Page 48 Section 02 Engine Servicing and Adjustments - camshaft 02.36 THE CAMSHAFT Camshaft Endfloat The end float, maintained with a single metal shim The steel camshaft is carried in plain bearings in between the camshaft thrust washer and the camshaft the crankcase at both the flywheel end and in the centre gearwheel hub, is 0.08-0.2mm (0.003-0.008in).
  • Page 49 Section 02 Engine Servicing and Adjustments - camshaft gearwheel 02.37 THE CAMSHAFT GEARWHEEL Removing the Gearwheel 1. Drift pin (A) into the camshaft (B) until it clears the gearwheel (C). Figure 2.37.1 Camshaft Gearwheel 2. Press off the gearwheel sufficiently to allow a thin metal washer to be placed between the bearing (D) and the gearwheel to prevent dirt entering the bearing.
  • Page 50 Section 02 Engine Servicing and Adjustments - camshaft bushes Centre Bush Removal 02.38 THE CAMSHAFT BUSHES 1. Fit the nut (2) onto the screw (1). A new bush should be immersed in clean engine 2. Fit the large dolly (12) into the bush, on three lubricating oil for four hours before fitting.
  • Page 51 Section 02 Engine Servicing and Adjustments - camshaft bushes Flywheel End Bush Removal Camshaft Bush Tool 317-50006 1. Place the plug (A) against the bush. Notes: 2. Insert the bolt (H) with plate (G) through gear end The camshaft bush tool, 317-50006, has been replaced camshaft bearing housing and screw it into the plug.
  • Page 52 Section 02 Engine Servicing and Adjustments - cylinder barrel 10.On TS/TR engines: 02.39 THE CYLINDER BARREL Ensure the deeper cylinder barrel fins will be facing Before removing any cylinder barrel it should be towards the manifold side and 'CAMSHAFT SIDE' marked to ensure it is replace to its original orientation.
  • Page 53 Section 02 Engine Servicing and Adjustments - piston and con rod 02.40 THE PISTON AND CONNECTING Refitting a Piston 1. Fit the piston to the connecting rod. On TS/TR engines ensure the wording 'CAMSHAFT The piston is manufactured from low expansion alloy SIDE' on the piston crown is the same side as the and has a machined recessed combustion chamber identification marks on the connecting rod big end.
  • Page 54 Later engines are fitted with a locking washer and nut. 7. Remove the puller and locking tools. 35 00630 TS1 36 00255 TR1 8. Remove the flywheel screw or nut and fit the correct 35 06716 TS2...
  • Page 55 Section 02 Engine Servicing and Adjustments - flywheel fanshroud and housing 02.42 THE FANSHROUD - TS/TR 02.43 FLYWHEEL HOUSING - TX An aluminium fanshroud is fitted to all engines Removing the Flywheel Housing except Build 16 which has one of sheet metal. 1.
  • Page 56 Section 02 Engine Servicing and Adjustments - main bearing housing 02.43 MAIN BEARING HOUSING Refitting the Main Bearing Housing When refitting the housing ensure that the oil supply The main bearing housing is secured to the holes line up and the grooved bearing shell is fitted at crankcase at the flywheel end and has an oil drain the top.
  • Page 57 Early crankshaft balance weights were secured replaced using either Service Tool 393235 or 317- with only one retaining bolt up to the following engines: 50006 as described in "02.47 Crankshaft Main 35 00630 TS1 36 00255 TR1 Bearings". 35 06716 TS2 36 00073 TR2 b.
  • Page 58 Section 02 Engine Servicing and Adjustments - crankshaft 8. Refit the crankshaft balance weights, with the Refitting the Crankshaft stamped part numbers facing each other, and 1. If necessary fit new bearing shells to the main torque load to 57.0Nm (42.0lbf ft). bearing housing, centre bearing housing/s and the gear end crankcase main bearing.
  • Page 59 Section 02 Engine Servicing and Adjustments - crankshaft endfloat, bearing clearance 02.45 CRANKSHAFT END FLOAT 02.46 CHECKING BEARING 1. Set a dial test indicator so that the actuating plunger CLEARANCE makes contact with the flywheel end face of the 1 Place a piece of the correct size 'Plastigauge' crankshaft.
  • Page 60 Section 02 Engine Servicing and Adjustments - crankshaft main bearings 9. Fit the thrust nut (9). 02.47 CRANKSHAFT MAIN BEARINGS 10.Using the correct size of spanner tighten the thrust nut (9) until the depth plate is tight to the sleeve. Main Bearing Tool 393235 When the plate is tight to the sleeve the bearing shells are correctly located in the crankcase.
  • Page 61 Section 02 Engine Servicing and Adjustments - crankshaft main bearings 12.Check that the oil holes in the housing and bearings Gear End Main Bearing Replacement align. The top section of the gear end main bearing shell has an oil groove but no locating lug. When fitting new Intermediate Main Bearing shells extreme care must be taken to ensure that the The grooved bearing shell must be fitted to the top...
  • Page 62 Section 02 Engine Servicing and Adjustments - gear end drives 02.48 GEAR END DRIVES These must be correctly torque loaded to 362.0Nm (267.0lbf ft). Where it is not possible to torque direct at the gear end: 1. Apply torque to the flywheel screw or nut with the engine decompressed.
  • Page 63 TX engines and were introduced on TS engines mounted oil filters are available for all engines. from: Genuine Lister Petter approved filters should be 35 01426 TS1 used as these have the correct bypass valve pressure 35 06750 TS2...
  • Page 64 Section 02 Engine Servicing and Adjustments - oil sump 02.51 THE OIL SUMP Removing the Sump 1. Remove the drain plug from the sump and drain The sump is manufactured from cast iron and is the oil into a suitable receptacle. secured to the crankcase by bolts and spring washers;...
  • Page 65 Section 02 Engine Servicing and Adjustments - oil strainer and pump 02.52 THE OIL STRAINER AND PUMP Oil Pump The camshaft operated oil pumps are the self- regulating, plunger type and they are not The Oil Strainer interchangeable across the ranges. The engines are fitted with a coarse lubricating oil strainer on the suction side of the oil pump;...
  • Page 66 The seals used must be the approved type as achieve the correct spacing between the impeller and supplied by Lister Petter and they are fitted without the inner edge of the retaining cap and to ensure the any jointing compound being applied.

  • Page 67: Section 03. Engine Fluids

    API Service Category CE - 1983: in your country. In cases of difficulty, it is suggested contact Service typical of certain turbocharged or be made with a reputable oil supplier or any Lister Petter supercharged heavy-duty diesel engines, Distributor. manufactured since 1983 and operated under both low speed, high load and high speed, high load conditions.
  • Page 68 5. For engines in long running installations Lister Categories CD, CE, and CF-4. Oils designed for this Petter should be consulted. service have been in existence since 1994. CAUTION Lister Petter recommend that oils of different brands or types are not mixed together. page 68...
  • Page 69 2. In order to maintain the cold starting characteristics 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.
  • Page 70 Section 03 Engine Fluids - fuel 03.2 ENGINE FLUIDS - fuel Low Temperature Fuels Special winter fuels are often available for use at ambient temperatures below 0°C (32°F). The Fuel Specification The engine must only be used with diesel fuel oil These fuels have a lower viscosity and limit the which conforms to one of the following: formation of wax at low ambient temperatures.

  • Page 71: Section 04. Operating Instructions

    Section 04 Operating Instructions - preliminary instructions Section 04. Operating Instructions • Firmly hold the handle grip, with the thumb on 04.1 PRELIMINARY INSTRUCTIONS top of the grip, during the starting procedure. The following information is of a general nature and should be read in conjunction with, or substituted by, the equipment manufacturers instructions.
  • Page 72 Section 04 Operating Instructions - hand starting 5b.If using a limited kick-back handle: 04.2 HAND STARTING Swivel the starting handle housing cover (A) to one Before attempting to start the engine refer to side and insert the correct handle, refer to 'B' in "Starting Handle Precautions".
  • Page 73 Section 04 Operating Instructions - electric starting 5a.If a start key is being used: 04.3 ELECTRIC STARTING Turn the start key clockwise and hold it at position If an oil pressure switch bypass button is fitted it ‘3’, until the engine fires and then release it must be depressed during engine cranking and until immediately.

  • Page 74: Stopping The Engine

    Section 04 Operating Instructions - stopping 04.4 STOPPING THE ENGINE 1. On engines not fitted with a fuel control solenoid, turn the engine control anti-clockwise to the ‘STOP’ position and hold it there until the engine comes to rest. Figure 2.7.1 The Engine Control After the engine has stopped turn the start key, if fitted, to the OFF position.

  • Page 75: Section 05. Routine Maintenance

    Genuine Lister Petter Parts. work. This work can only be carried out if the necessary hand and service tools are available. When the user...
  • Page 76 Section 05 Routine Maintenance - schedule hours 05.2 ROUTINE MAINTENANCE - SCHEDULE HOURS Daily Every 1000 Hours Check the fuel and lubricating oil levels. The above and the following items. Check for fuel and oil leaks. Check the valve clearances. Clean or replace the air cleaner element under very D ecarboni se i f the engi ne performance has dusty conditions.
  • 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 77...
  • Page 78 Section 05 Routine Maintenance - 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 78...
  • Page 79 Section 05 Routine Maintenance - wearing parts 05.5 DIMENSIONS OF WEARING PARTS The following information is given as a guide to the extent by which components may reasonably be expected to wear, without appreciable loss of performance. To maintain the engine in good running order it is therefore recommended that when the "Maximum Clearance"...
  • Page 80 Section 05 Routine Maintenance - TS, TR wearing parts TS, TR Wearing Parts page 80...
  • Page 81 Section 05 Routine Maintenance - TS, TR wearing parts TS, TR Wearing Parts page 81...
  • Page 82 Section 05 Routine Maintenance - TX wearing parts TX Wearing Parts page 82...
  • Page 83 Section 05 Routine Maintenance - TX wearing parts TX Wearing Parts page 83...
  • Page 84 Section 05 Routine Maintenance - long term storage Returning the Engine to Service 05.5 LONG TERM STORAGE Refer to the appropriate sections for the relevant detailed instructions as necessary to complete this Preparing the Engine for Storage work. The following routine should be carried out when it is known that the engine will not be required for a.

  • Page 85: Section 06. Troubleshooting

    Section 06 Troubleshooting - preliminary information Section 06. Troubleshooting 06.1 PRELIMINARY INFORMATION 06.2 METHOD OF TROUBLESHOOTING Troubleshooting mechanical engine problems can 1. Diagnose the problem by eliminating the easiest be difficult. This section lists possible engine problems things first. that could be encountered with possible causes and 2.
  • Page 86 Fuel pump solenoid not energised. Check the electrical supply. Poor battery connections. Clean, replace and coat with petroleum jelly. Faulty fuel pump. Contact a Lister Petter distributor. Excessive Carbon Deposits Choked air filter. Dismantle and clean the cap and element. Choked exhaust system.
  • Page 87 Section 06 Troubleshooting - mechanical and electrical Problem Method of Correction Engine Stops Lack of fuel. Check the system. Refill the tank. Air in the fuel system. Prime the fuel filter. Water in the fuel system. Drain, flush, refill and prime the fuel filter. Choked fuel filter.
  • Page 88 Section 06 Troubleshooting - mechanical and electrical Problem Method of Correction Undercharging Excessive electrical load from added accessories. Remove accessories. Poor electrical connections to alternator or battery. Inspect, clean and rectify the cause. Faulty battery. Test, recharge or replace. Faulty alternator or charge windings Test or replace.

  • Page 89: Section 07. Flywheel Charge Windings

    1000 2. Nicsa - TS and TR first fitted on the following 1500 12.5 engines: 2000 15.0 41 00433 TS1 41 00240 TR1 41 01651 TS2 41 00281 TR2 3000 17.0 41 01568 TS3 41 00301 TR3 The Syncro and Nicsa charge winding components Fault Finding are not interchangeable.
  • Page 90 Section 07 Flywheel Charge Windings - Syncro Syncro Fault Finding Flow Charts page 90...
  • Page 91 Section 07 Flywheel Charge Windings - Syncro Syncro Fault Finding Flow Charts page 91...
  • Page 92 Section 07 Flywheel Charge Windings - Nicsa Output Charge Rate - voltage held at 12.5 volts 07.3 NICSA CHARGE WINDINGS r/min Amps Fault Finding The most common faults associated with this 1000 5.5 - 7.0 system are dealt with in the flow charts on the following 1500 10.0 - 11.5 pages.
  • Page 93 Section 07 Flywheel Charge Windings - Nicsa Nicsa Fault Finding Flow Charts page 93...
  • Page 94 Section 07 Flywheel Charge Windings - Nicsa Nicsa Fault Finding Flow Charts page 94...
  • Page 95 Section 07 Flywheel Charge Windings - Nicsa Nicsa Fault Finding Flow Chart page 95...
  • Page 96 page 96...

  • Page 97: Section 08. Electrical Wiring Diagrams

    Section 08 Electrical Wiring Diagrams - general information Section 08. Electrical Wiring Diagrams 08.01 WIRING DIAGRAMS All cables must be PVC insulated automobile cable to BS6862. The cable sizes given relate to the cables between the control panel, or loose components, and the engine being a maximum length of 1.5m (4.9ft) with "Syncro' charge windings and 2.0m (6.6ft) with 'Nicsa' charge windings, and the cables between the battery and...
  • Page 98 Section 08 Electrical Wiring Diagrams page 98...
  • Page 99 Section 08 Electrical Wiring Diagrams page 99...
  • Page 100 Section 08 Electrical Wiring Diagrams page 100...
  • Page 101 Section 08 Electrical Wiring Diagrams page 101...
  • Page 102 Section 08 Electrical Wiring Diagrams page 102...
  • Page 103 Section 08 Electrical Wiring Diagrams page 103...
  • Page 104 page 104...

  • Page 105: Section 09. Technical Data

    Section 09 Technical Data - engine specifications Section 09. Technical Data 09.1 ENGINE MECHANICAL DATA - TS n i l n i l y l f i t n i t n i t n n i l t i l n i l y t i l a t...
  • Page 106 Section 09 Technical Data - engine specifications 09.2 ENGINE MECHANICAL DATA - TR Injection Direct Direct Direct Cooling Cooling fan Flywheel Flywheel Flywheel Direction of rotation - looking on flywheel end Anti-clock Anti-clock Anti-clock 98.42 98.42 98.42 Nominal bore - not to be used for machining purposes 3.875 3.875...
  • Page 107 Section 09 Technical Data - engine specifications 09.3 ENGINE MECHANICAL DATA - TX Injection Direct Direct Cooling Cooling fan Axial Axial Direction of rotation - looking on flywheel end Anti-clock Anti-clock 100.00 100.00 Nominal bore - not to be used for machining purposes 3.937 3.937 101.6...
  • Page 108 Variable speed up to 3OOOr/min with no overload. Variable speed up to 2500r/min with overload, provision for hydraulic pump. Variable speed up to 2500r/min (2000r/min on TS1) with overload, provision for hydraulic pump. Variable speed up to 2500r/min (2000r/min on TS1) with overload, provision for hydraulic pump.
  • Page 109 When new parts are required for such a build it is suggested that reference be made to Lister Petter to determine the exact engine specification and which parts are non-standard. Where an engine number appears with GTS this indicates that it was built into a generating set by Lister Petter.
  • Page 110 When new parts are required for such a build it is suggested that reference be made to Lister Petter to determine the exact engine specification and which parts are non-standard. Where an engine number appears with GTS this indicates that it was built into a generating set by Lister Petter.

  • Page 111: Section 10. Conversion Factors

    Section 10 Conversion Factors - formulae Section 10. Conversion Factors 10.1 FORMULAE Temperature The temperature unit in most practical use in many countries is the degree Celsius (°C), however the terms BMEP Centigrade (°C) and Fahrenheit (°F) are still in use. Bar = kW x 60000 x 20000 The Fahrenheit scale is not formally defined but it is...
  • Page 112 Section 10 Conversion Factors - length, liquid, volume, linear velocity, rate of flow 10.2 CONVERSION FACTORS The conversion tables in this section have been derived from BS350 To use the tables the left hand base unit is multiplied by the relevant conversion factor given in one of the right hand columns.
  • Page 113 Section 10 Conversion Factors - rate of flow, pressure, torque, force Rate of Flow - Volume cubic metre per litre per second cubic foot per UK gallon per second - m /sec l/sec second - ft /sec second - gal/sec /sec 1000.0 35.3147...
  • Page 114 Section 10 Conversion Factors - energy, power, fuel consumption Energy - Table 1 kilowatt hour kilogram-force foot-pound force horsepower hour metre - kgf m ft lbf hp h 1 kWh 3.6709 x 10 2.6552 x 10 1,3410 1 kgf m 2.7240 x 10 7.2330 3.6530 x 10...

  • Page 115: Section 11. Index

    Section 11 Index Section 11. Index page 115...
  • Page 116 Section 11 Index Excess - fuel device ............. 71 Agglomerator ............ 29 - fuel trip - TX ........... 42 Exhaust manifold ..........16 - baffles ............17 - cleaner ............14 - cowling ............17 Fanshroud ............55 Associated publications ........4 Filter - fuel tank ..........
  • Page 117 Section 11 Index Oil ..............67 Technical data - specification ..........68 - TS ..............105 - pump ............65 - TR ..............106 - seals ............. 66 - TX ..............107 - strainer ............65 Timing ............... 35 - sump ............64 - gauge ............
  • 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 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, 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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