TS, TR, TX Workshop Manual - David Cornwallis

1 TS, TR, TX. Workshop Manual Edition 12: May 2005 Publication P027-08221. page 2. Edition 12: May 2005. Manual Contents page 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. Flywheel Charge Windings .. 89. Section 08. Electrical Wiring Diagrams .. 97. Section 09. Technical Data .. 105. Section 10. Conversion Factors .. 111. Section 11. Index .. 115. page 3. Introduction Introduction The purpose of this Manual is to give information, Training operating, maintenance and repair procedures for the 'T' Comprehensive training in the correct operation, Series of engines. service and overhaul procedures of engines is available The Manual is designed primarily for use by qualified at the Lister Petter International Product Training Centre.

2 Technicians with electrical and mechanical experience. Please contact Lister Petter for details. This work can only be carried out if the necessary hand and service tools are available. When the user has If Problems Occur insufficient tools, experience or ability to carry out If problems occur with your engine, or any of the Lister adjustments, maintenance and repairs then this work Petter approved accessories fitted to it, your local Lister should not be attempted. Petter Distributor should be consulted. Where accurate measurements, or torque values, are There are Lister Petter Distributors in most countries required they can only be made using calibrated of the world and details for these can be obtained from instruments. any one of the companies listed on the back cover. Under no circumstances should makeshift tools or equipment be used, as their use may adversely affect Using this Workshop Manual safe working procedures and engine operation.

3 Each section title is given at the top of the relevant The specification details given apply to a range of pages and each section has its own Contents' page. engines and not to any one particular engine. In cases A full cross reference 'Index' appears at the back of of difficulty the user should consult the local Lister Petter the Manual . Distributor or Dealer for further advice and technical It is recommended the individual steps contained in assistance. the various maintenance or repair operations are followed The information, specifications, illustrations, in the sequence in which they appear. instructions and statements contained within this At times it may be necessary to refer to other parts of publication are given with our best intentions and are the section, or to a different section, for more specific or believed to be correct at the time of going to press.

4 Our detailed information. policy is one of continued development and we reserve the right to amend any technical information with or without prior notice. Caution and Warning Symbols Whilst every effort is made to ensure the accuracy of When an engine is operating or being overhauled the information contained within this publication, neither there are a number of associated practices which may the Manufacturer, Distributor or Dealer shall in any lead to personal injury or product damage. circumstances be held liable for any inaccuracy or the Your attention is drawn to the symbols shown and consequences thereof. described below which are applied throughout this The information given is subject to the Company's Manual . 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.

5 This CAUTION. Company does not guarantee that the same results will This caution symbol draws attention to special instructions or procedures which, if not correctly followed, may result be obtained elsewhere under different conditions. in damage to, or destruction of, equipment. Parts that have not been approved by the Lister Petter organisation cannot be relied upon for correct material, WARNING. dimensions or finish. This Company cannot therefore, be This warning symbol draws attention to special instructions responsible for any damage arising from the use of such or procedures which, if not strictly observed, may result in parts and the guarantee will be invalidated. personal injury. When purchasing parts or giving instructions for repairs users should, in their own interests, always specify WARNING. Genuine Lister Petter Parts and quote the Description of A WARNING SYMBOL WITH THIS TYPE OF TEXT.

6 The Part and the Engine Serial Number. DRAWS ATTENTION TO SPECIAL INSTRUCTIONS OR. PROCEDURES WHICH, IF NOT STRICTLY OBSERVED, Associated Publications MAY RESULT IN SEVERE PERSONAL INJURY, OR. Technical Handbook .. P027-09212 LOSS OF LIFE. Master Parts Manual : TS, TR .. P027-08030 Note: TX .. P027-08929 A note is used to draw your attention to additional or Operators Handbook: important information. English .. P027-08185. French .. P027-08185/fre Spanish .. P027-08185/spa German .. P027-08185/ger Various technical/sales leaflets are available; please contact your Lister Petter Distributor or Dealer for details. page 4. Section 01. General Information - safety Section 01. General Information SAFETY PRECAUTIONS AND SAFE WORKING PRACTICES. At all times follow the recommended precautions and safe operating and working practices. The following are of a general nature and more specific information appears where it is relevant.

7 Caution and Warning Symbols e. Thoroughly clean any lubricating or fuel oil from the skin as soon as possible. CAUTION f. Rectify all fuel, coolant and oil leaks as soon as This caution symbol draws attention to special instructions practicable and clean any spills when they occur. or procedures which, if not correctly followed, may result in damage to, or destruction of, equipment. 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 WARNING away with copious amounts of fresh water and seek medical aid. This warning symbol draws attention to special instructions or procedures which, if not strictly observed, may result in personal injury. Personal Safety a. Tie long hair close to your head. b. Do not wear a necktie, scarf, loose clothing or WARNING necklace when working close to a running engine.

8 A WARNING SYMBOL WITH THIS TYPE OF TEXT c. It is advisable to remove rings and other jewellery DRAWS ATTENTION TO SPECIAL INSTRUCTIONS OR to prevent possible entanglement in moving parts. PROCEDURES WHICH, IF NOT STRICTLY OBSERVED, These items could also cause an electric short MAY RESULT IN SEVERE PERSONAL INJURY, OR circuit if any part of the electrical system is being LOSS OF LIFE. worked on. d. Ensure any lifting equipment to be used has the Follow All Safety Instructions correct capacity to lift the engine. a. Carefully read all safety messages in this Manual e. Lifting equipment must be designed to give two and the safety and informative symbols on your vertical lifts from directly above the engine lifting engine and plant. eyes. b. Starting any diesel engine can be dangerous in f. The engine lifting eyes fitted to the engine are the hands of inexperienced people.

9 Engine suitable for lifting the engine and accessory operators must be instructed in the correct assemblies originally fitted by Lister Petter. They procedures before attempting to start any engine. must not be used to lift the complete plant. c. Do not make any unauthorised modifications as g. Do not work under any plant that is only held by these may affect the safe operation of the engine overhead lifting equipment. and put the operator at risk. d. Ensure all starting devices are removed, or isolated, Personal Protective Clothing and Equipment before commencing any work on the engine or plant. a. Wear close fitting clothing and personal protective clothing and safety equipment appropriate to the Emergency Considerations work being done. a. Be prepared with suitable equipment, and b. Wear suitable ear protection to protect against knowledge, in case a fire starts.

10 Objectionable or uncomfortable loud noise. b. Know where to make calls to the emergency Prolonged exposure to loud noise can cause services from. impairment, or loss of hearing. c. Ensure a third party knows where you are working c. The use of music or radio headphones could cause and when you leave the working area. a loss of concentration. Handling Fluids Safely Handling Chemical Products Safely a. When working with fuel or batteries do not smoke a. Direct exposure to hazardous chemicals can cause or work near to heaters or other fire hazards. serious injury. b. Store flammable liquids away from fire hazards. b. Potentially hazardous chemicals include such c. Do not expose pressurised containers to heat and items as lubricants, fuel, coolant concentrate, do not incinerate or puncture them. battery acid, paint and adhesives. d. Handle fuel with care and always stop the engine c.