Professional Documents
Culture Documents
T Series Engines OHbk - Issue 5
T Series Engines OHbk - Issue 5
TR Engines
Operators' Handbook
ORIGINAL INSTRUCTIONS
P027-08265
Associated Publications
Master Parts Manual P027-08030
Workshop Manual P027-08221
Technical Information P027-09212
Arrangement Drawings P027-08035
Statement of Indemnity
The information, specifications, illustrations, is based upon results obtained from tests
instructions and statements contained carried out at the place of manufacture. This
within this publication are given with our Company does not guarantee that the same
best intentions and are believed to be results will be obtained elsewhere under
correct at the time of going to press. different conditions.
Our policy is one of continued development Parts that have not been approved by the
and we reserve the right to amend any Lister Petter Power Systems organisation
technical information with or without prior cannot be relied upon for correct material,
notice. dimensions or finish. The Company cannot
Whilst every effort is made to ensure the therefore be held responsible for any
accuracy of the particulars contained within damage arising from the use of such parts,
this publication, neither the Manufacturer, and the guarantee will be invalidated.
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 P027-08265
and Sale; is for the assistance of users; and Copyright © Lister Petter Power Systems
2
Contents
Engine Features........................................................................... 5
Introduction................................................................................... 7
1. Safety Information.................................................................... 8
2. Technical Data and Information��������������������������������������������� 14
3. Starting and Stopping............................................................. 15
4. Engine Fluids.......................................................................... 19
5. Routine Maintenance............................................................. 21
6. Troubleshooting...................................................................... 29
7. Maintenance Record.............................................................. 31
8. Warranty................................................................................. 41
3
4
T SERIES
T SERIES ENGINES
ENGINES OPERATORS'
operators' HANDBOOK
handbook
Engine FEATURES
ENGINE Features
Fuel tank
Flywheel
Lifting eye
Fuel filter
TR1
Decompressor lever
Oil filter
TR2
Features of
Features of the
the T
T series
series air
air cooled
cooled diesel
diesel engines.
engines.
55
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T SERIES ENGINES operators' handbook
Introduction
This handbook explains the operation Using this Handbook
and routine maintenance of Lister Operating or servicing a diesel engine
Petter Power Systems T series (TR) is potentially dangerous. You must not
air cooled diesel engines. attempt it unless you have the necessary
If your engine is part of a Lister Petter knowledge and experience.
Power Systems generating set, there Read each section thoroughly
is a separate operators' handbook for and carefully, taking note of the all
the genset, to explain such features as information and instructions given. This
the control module. is for your safety and to ensure the
correct maintenance of your engine.
Engine Identification For specific aspects of operation
To identify which model of Lister Petter and maintenance, use the table of
Power Systems T-Series diesel engine contents or the index to find the section
you are using refer to the engine serial you need. Where instructions are
number, which is stamped on a plate numbered in sequence, they must be
attached to the engine. It identifies the followed in that order. This applies in
type and build of the engine (see below) particular to maintenance and repair
to enable the correct maintenance procedures (Sections 5 and 6).
procedures to be carried out. Here is In cases of difficulty, or to obtain spare
a sample serial number: parts, please consult your local Lister
Petter Power Systems distributor or
07 001234 TR3 A 01 dealer.
07 Year code (07 = 2007)
001234 Unique engine number Running-in
TR3 Engine series To assist running-in all engines are
A Anti clockwise rotation despatched with an initial fill lubricating
01 Build number oil which must be changed after 100
hours. Your engine does not require
The illustrations on page 4 show gradual light-load running-in. Extended
features of the different engine models. light-load running should be avoided,
When following the instructions in this as this could damage the cylinder bore
handbook you will need to be familiar and allow lubricating oil to enter the
with the parts labelled. (See also table exhaust system.
below.)
7
OPERATORS' handbook
T SERIES ENGINES operators' HANDBOOK
1. Safety
SAFETY Information
INFORMATION
Read the information in this section
carefully and follow all the advice
WARNING
THIS WARNING DRAWS ATTENTION
This
given. Pay especial attention to the INFORMATION OR
TO SPECIAL information
cautions and warnings demonstrated PROCEDURES WHICH mustMUST be
BE
below, which are used throughout this STRICTLY OBSERVED. Failure
strictly FAILURE to
TO
handbook. DO so
do SO may
MAY result
RESULT in
IN serious
SERIOUS
INJURY or
injury OR death.
DEATH.
CAUTION
This caution draws attention to 1.1 General
GENERAL Safety
SAFETY
special information or procedures
INFORMATION
Information
which must be correctly observed,
to avoid damage to, or destruction Starting and operating any diesel
of, equipment. engine is potentially dangerous. Do not
attempt to do so unless you have the
WARNING necessary knowledge and experience.
This warning draws attention to Ensure that anyone attempting to start
special information or procedures and operate your diesel engine has
which must be strictly observed.
been properly trained and instructed
Failure to do so may result in in the correct procedures.
personal injury.
WARNING
Follow all safety instructions
accurately.
1. Safety Symbols
1. Safety
This Symbols
figure This
identifies thefigure identifies
ISO 8999 the ISO
symbols 8999 symbols
currently used bycurrently usedPower
Lister Petter by Lister Petter.
Systems.
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
Technical Data
Rotation Anti clockwise (when looking on the flywheel)
Type of injection Direct
Cooling Air
Method of cooling Integral flywheel fan
Starting Handstart or 12V starter motor
Electrical system 12V negative earth
Starter battery charging 12V engine-mounted charge-windings
Oil pressure, mean 2.0 bar (29.0lbf in2)
Engine-mounted fuel tank 13.5 litre; 23.7 pints; 14.2 US quarts
Oil sump capacity Refer to table 5.6 Oil Sump Capacity (page 21)
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T SERIES ENGINES
T ENGINES operators' HANDBOOK
handbook
T SERIES
SERIES ENGINES OPERATORS'
OPERATORS' HANDBOOK
3. Starting AND
3. STARTING
STARTING and STOPPING
AND Stopping
STOPPING
3.1 Preliminary
3.1 If the engine
engine stops otherother than by by
3.1 PRELIMINARY
PRELIMINARY If
If the
the engine stops
the operation
operation of
stops other than
of the
the engine
than by
engine control
control
Instructions
INSTRUCTIONS the
the operation of the engine control
INSTRUCTIONS the control must
(Figure 3.2), the must be turned
turned
The following operating
The operating instructions (Figure 3.2), the control
(Figure 3.2), control must be
be turned
The following
following operating instructions
instructions anti clockwise
anti clockwise to to the STOP position
the STOP position
are of
are of a
a general
general nature
nature and should
should be anti clockwise to the STOP position
are of a general nature and
and should bebe and released before
and before the device
device can
read in
read in conjunction
conjunction with,
with, or
or substituted
substituted and released
released before the the device cancan
read in conjunction with, or substituted operate.
operate.
by, the equipment
by, equipment manufacturers' operate.
by, the
the equipment manufacturers'
manufacturers'
instructions.
instructions.
instructions.
WARNING
WARNING
Do not
Do not attempt toto start
start any
any diesel
Do not attempt
engine attempt
unlesstoyou any diesel
starthave
you diesel
been
engine
engine unless
unless you have
have been
been
properly trained.
properly trained. It
It is
is dangerous.
dangerous.
properly trained. It is dangerous.
Before attempting to
Before to start any
any engine
Before attempting
attempting to start
start any engine
engine
the operator
the operator should
should read
read 1.
1. Safety
the operator should read 1. Safety Safety
Precautions and be be conversant withwith
Precautions and
Precautions and be conversant
conversant with
the use
the use of
of the
the engine
engine controls
controls and
and the
the Figure
Figure 3.2
3.2 The
The engine
engine control
control
the use of the engine controls and the
correct starting
correct starting procedures.
procedures.
correct starting procedures.
As
As the
the engine
engine runs
runs upup to
to speed
speed the
the
CAUTION
CAUTION excess fuel device will automatically
excess fuel device will automatically
Ether-based
Ether-based cold
cold start aids
start aids inin reset
reset to
to the
the normal
normal running
running position.
position.
Ether-based
cans cold
aerosol cans must start
not beaids
be in
used
aerosol
aerosol must not used
under anycans
under
must not be used
circumstances.
under any
any circumstances.
circumstances. 3.3
3.3 COLD
Cold STARTING
COLD Starting AID
STARTING Aid
AID
Systems may be
Systems be fitted to
to allow a a The
The cold
cold starting
starting aid
aid may
may be
be fitted
fitted to
Systems maymay be fitted
fitted to allow
allow a fitted to
measured quantity to be injected the
measured
measured quantity
quantity toto be
be injected
injected the combustion
combustion air
air intake
intake ports
ports and
and is
is
into the inlet
inlet manifold, but but these used
into
into the
the inlet manifold,
manifold, but thesethese used when
when the
the ambient
ambient temperature
temperature isis
must be used
must used in accordance
accordance with the the below
below -10°C
-10°C (14°F).
must be
be used in
in accordance withwith the (14°F).
manufacturers' instructions.
manufacturers' instructions.
manufacturers' instructions.
WARNING
DO
D O WARNING
N OTT B
B R E AT
AT H
HE EXEXH A U ST
ST
D O N
NO
GASES OAS B RE
T THEY
RE AT HE H
HAAU
E EXCARBON
CONTAIN U ST
GASES
GASES AS THEY
AS THEY CONTAIN CARBON
MONOXIDE,
MONOXIDE, AACONTAIN CARBON
COLOURLESS,
COLOURLESS,
MONOXIDE,
ODOURLESS AAND
COLOURLESS,
POISONOUS
ODOURLESS
ODOURLESS AND POISONOUS
GA
G ASS T THHAATT AND
C A POISONOUS
C N CCAAUS SE
G A S T H A T
UNCONSCIOUSNESS CAAN N AU USE
ANDCDEATH.
DEATH. E
UNCONSCIOUSNESS AND
UNCONSCIOUSNESS AND DEATH.
3.2 Excess FUEL
3.2 Fuel Device
3.2 EXCESS
EXCESS FUEL DEVICE
Figure
Figure 3.3
3.3 Cold
Cold start
DEVICE start
The engines are
The are fitted with
with an automatic
automatic
The engines
engines are fitted
fitted with an
an automatic 1.With
excess fuel
excess fuel device
device which
which becomes
becomes 1.With the
the fuel
fuel turned
turned on,
on, turn
turn the
the
excess fuel device which becomes engine for up to 20 revolutions
operative, ready
operative, ready for
for the
the next
next start,
start, when
when engine for up to 20 revolutions
operative, ready for the next start, when to
the engine
the engine is
is stopped.
stopped. to prime
prime the
the fuel
fuel and
and lubrication
lubrication
the engine is stopped. systems.
systems.
15
15
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T SERIES ENGINES operators' handbook
T SERIES ENGINES OPERATORS' HANDBOOK
systems. • Ensure the handle grip is clean, dry
fill one
2.Withdraw the plunger (A) and fill and free to turn on its shaft.
third of the cup (B) with the same •• Clean and lightly oil that part of the
type of lubricating oil as used in the handle which fits
fits onto the engine.
engine. •• Firmly hold the handle grip, with
3.Replace the plunger and inject the oil the thumb on top of the grip, during
just before starting the engine. the starting procedure.
CAUTION
The device must not be used more
than three times in succession
during the same attempt to start
the engine.
3.4 HAND
Hand STARTING
Starting
A non-limited kick-back handle ( Figure
3.4.1, A) or limited kick-back handle (B) Figure 3.4.2
3.4.2 Holding
Holding the
the starting
starting handle.
handle.
Figure
system may be fittedfitted to the engine.
To start the engine proceed as
follows:
1. Select
1. Select the excess fuel position by
turning the engine control lever anti
clockwise to the STOP position and
releasing it.
2. If a variable speed control lever is
2. If
fitted move it to the fast position.
fitted
3. Move
3. Move the decompressor lever
Figure 3.4.1
Figure 3.4.1 The
The two
two types
types of
of starting
starting towards the flywheel.
flywheel.
handle.
handle.
WARNING
WARNING
Do not attempt to use a starting
handle if it is damaged in any way.
•• The two types of handle are not
interchangeable and care must be
taken to ensure the correct type is
retained with the engine.
•• Always use the correct starting Figure
Figure 3.4.3
3.4.3 Moving
Moving the
the decompressor
decompressor lever
lever
handle which has been designed for towards
towards the
the flywheel.
flywheel.
the engine.
•• Ensure there are no burrs on that 4. If the ambient temperature is below
4. If
part of the handle which fits
fits onto the -10°C (14°F) refer to 3.3 Cold Starting
engine. Aid.
• Ensure the handle grip is clean, dry 5a. If using a non-limited kick-back
16
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T SERIES ENGINES operators'
OPERATORS' handbook
HANDBOOK
T SERIES ENGINES OPERATORS' HANDBOOK
If usingInsert
5a.handle: a non-limited
the correct kick-back
handle
handle:
(see Figure Insert
3.4.1,theA) correct handle
into the starting
(see Figure
housing. A) into
3.4.1,rotate
Slowly thethe starting
handle in
housing.
the directionSlowly rotate theuntil
of cranking handle in
it fully
the direction of cranking until it fully
engages.
5b.engages.
If using a limited kick-back
5b. If using
handle: a limited
Swivel kick-back
the starting-handle
handle:
housing coverSwivel(A) thetostarting-handle
one side and
housing
insert the cover (A) handle,
correct to one side referandto
insert the correct
'B' in Figure handle,
3.4.1, into refer to
the housing. Figure 3.4.5 Moving the decompressor
'B' in Figure leverMoving
Figure 3.4.5 towardsthe
thedecompressor
gear.
Slowly rotate theinto
3.4.1, the housing.
handle in the
Slowly lever towards the gear.
directionrotate the handle
of cranking in fully
until it the
direction
engages. of cranking until it fully fitted,
9. If a variable speed control is fitted,
6. engages.
If the cold-starting aid was not used 9. reduce the speed
If a variable ascontrol
speed required.
is fitted,
6. If
If the the
6. turn cold-starting
engine slowlyaid wasfor notupusedto reduce the speed as required.
turn
20 turnsthe engine
to primeslowly for up to
the combustion ELECTRIC Starting
3.5 Electric STARTING
20 turns and
chamber to prime the combustion
lubricating oil system. 3.5 ELECTRIC STARTING
If an oil pressure switch bypass button
7. chamber
Firmly hold and thelubricating
handle grip, oil system.
with the is
If anfitted it must be
oil pressure
fitted depressed
switch bypass during
button
7. Firmly
Firmly hold
7. thumb on top the
ofhandle
the gripgrip, with the
as shown in is fitted itand
cranking must untilbe the
depressed during
engine attains
thumb
Figure on top of
3.4.2, andthecrank
grip astheshown
engine in cranking
full speed.and until the engine attains
Figure Whenand
briskly.3.4.2, crank the
sufficient engine
speed is If
fullthe engine fails to start within 30
speed.
briskly.
obtainedWhen movesufficient speed is
the decompressor If the engine
seconds, fails to
release thestart
key,within 30
or start
obtained
lever towards move the the gear
decompressor
end and seconds,
button, and release
attemptthe to key,
restartor after
start
lever
continue towards
to crank theuntil
gearthe end and
engine allowing
button, and sufficient
attempt
sufficient timetofor all moving
restart after
continue
fires. to crank until the engine allowing
parts sufficient time for all moving
to stop.
fires.
fires. parts to stop.
1.Check that the decompressor lever
1.Check
is towards thatthethegeardecompressor
end. lever
2.Turn
is towardsthe engine
the gear control
end. lever anti
2.Turn
clockwise the engine
to the STOP control lever and
position anti
clockwise to the STOP position and
release.
3.Ifrelease.
a variable speed control lever is
fitted,
3.If a variable
fitted, move itspeed control
to the fast lever is
position.
4.Iffitted, move it to
the ambient the fast position.
temperature is below
4.If-10°C (14°F) refer
the ambient to items is
temperature 2 below
and 3
-10°C
in (14°F)
3.4 Cold refer to
Starting items 2 and 3
Aid.
Figure 3.4.4 The starting-handle housing.
in 3.4
5a.If Coldkey
a start Starting Aid. used: Turn
is being
Figure 3.4.4 The starting-handle housing.
the astart
5a.If start key key is beingand
clockwise used:
holdTurn
it at
8. Retaining a firm grip on the handle, position
the start ‘3’, keyuntil the engine
clockwise fires
hold and
and fires it at
8. remove it from
Retaining firmthe
a firm housing.
grip on the handle, position
then ‘3’, until
release the engine fires and
it immediately.
remove it from the housing.
WARNING then release it immediately.
WARNING
Do not pull the starting handle away
from the
Do not engine
pull while cranking.
the starting handle away
from the engine while cranking.
17
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T SERIES ENGINES operators' handbook
Caution
Never stop the engine by operating
the decompressor lever. This could
cause valve damage.
18
T SERIES ENGINES OPERATORS'
operators' HANDBOOK
handbook
4. ENGINE
Engine FLUIDS
Fluids
4.1 OIL
Oil SPECIFICATION
Specification commonly available than API CC. The
To assist engine running-in, all engines use of these oils in new engines is
are despatched with an initial fill acceptable for topping up the first-fill
first-fill
lubricating oil which must be changed, and following the first
first 100 hours when
with the filter,
filter, after the first
first 100 hours. running-in has been completed.
All subsequent oil changes must These oils are particularly suited to
be as specified
specified in 5.2. Maintenance engines running at a high-load factor,
Schedule. or in conjunction with high ambient
The engines must be run on heavy- temperatures. They must also be used
duty lubricating oils that at least where the sulphur content of the fuel
meet the requirements of one of the exceeds 0.5%.
following: The oil must be suitable for 250-hour
APICC
APICC MIL-L-46152B oil changes without undue degradation,
DEF2101D
DEF2101D MIL-L-2104B with sump temperatures reaching
Straight mineral oils are not suitable, 150°C (302°F) under severe tropical
neither are oils of less detergency than conditions, and 120°C (248°F) under
specified.
specified. normal conditions.
Higher specification
specification oils meeting API For engines in long running installations
CD, API CE and API CF-4 are more Lister Petter Power
shouldSystems
be consulted.
should be
consulted.
4.2 The chart shows the recommended oil viscosity grades for different temperature °C ranges.
A: intermittent running; B: synthetic oils only. Note:°F = (1.8 x °C) + 32.
19
T SERIES ENGINES operators' handbook
CAUTION
Wax formation can rapidly reduce
the flow of fuel through the fuel filter
element.
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T SERIES ENGINES operators' handbook
5. Routine Maintenance
This section is designed primarily After the engine has run 25 hours, and
for use by trained technicians but it again after it has run 250 hours, you
does contain sufficient information, should attend to the following:
illustrations and detail to allow the • Check the valve clearances, and
operator to perform basic maintenance adjust if necessary.
work. The recommendations and • Check and tighten nuts, bolts and
instructions cover several engine unions paying particular attention to the
models, therefore they are of a general fuel system.
nature. • Check the lubricating oil level and
top up if necessary.
WARNING • Observe the exhaust at the normal
Routine maintenance must be full load. It must be free from soot. A
performed by trained personnel who black exhaust means that the engine
are conversant with the hazards of is overloaded or that the injection
oil, fuel, electricity and machinery. equipment is out of order.
Work can be carried out only if you have Following this initial attention, the
had suitable training and experience, normal routine maintenance must be
and if the necessary hand and service carried out as given in 5.3 Maintenance
tools are available. Do not attempt to Schedule.
carry out adjustments, maintenance or
repairs if you have insufficient tools, Caution
experience or ability. Do not allow the engine to run with
Where accurate measurements a dirty exhaust without investigating
the cause as this may result in an
or torque values are required they
engine breakdown.
can only be made using calibrated
instruments.
5.2 General Instructions
Caution The frequency with which maintenance
Never use makeshift tools or work should be carried out is given in
equipment. It is dangerous and Section 5.3 below. Detailed instructions
could damage your engine. on how to service your engine are
The engine may include optional given in the remaining sections of this
equipment not specifically covered chapter.
in this book. In this case, refer to the
manufacturer's instructions. Before Servicing
Before starting any dismantling
5.1 Initial Attention procedure read 1. Safety Information.
Consider the following:
To assist engine running-in, all engines • Do you know and understand the
are despatched with an initial-fill engine and all the related systems?
lubricating oil which must be changed • Do you have sufficient electrical
after the engine has completed 100 and mechanical knowledge and skills
running hours.
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OPERATORS' handbook
HANDBOOK
5.10 Priming
PRIMING the
THE Fuel
FUEL
Figure 5.8 The fuel filter
filter
System
SYSTEM
If a self-venting fuel system is fitted,
fitted, it
5.9 Cartridge
CARTRIDGE should not be necessary to manually
Agglomerator
AGGLOMERATOR prime it.
1.Fill the tank with fuel.
The cartridge agglomerator is an
2.Vent the fuel filter
filter through the bleed
essential part of the engine and should
screw (A) until a full air-free flow
flow of
be renewed every 500 hours, or more
fuel is obtained.
frequently if for any reason the fuel
3.Vent the fuel at each pump in turn
is dirty.
through the bleed screws (B) starting
Before changing the agglomerator
with the pump nearest to the fuel tank.
read 1.5 Precautions with Filters and
Elements. A strap wrench is required
to remove the agglomerator from the
engine but it must not be used to fit
fit a
replacement.
1.Drain the water from the agglomerator
by unscrewing the drain tap (C)
sufficiently to allow the water to
drain.
2.Using a suitable strap wrench
unscrew the cartridge (A) from the
head (B).
3.Screw a new cartridge onto the head
and hand-tighten it. Figure 5.10
Figure 5.10 Priming
Priming the
the fuel
fuel system
system
4.Prime the fuel system.
5.Run the engine and check for fuel 5.11 Medium
MEDIUM Duty
DUTY Air
AIR
leaks. CLEANER
Cleaner
The standard
The standard air
air cleaner
cleaner is
is fitted
fitted to
to the
the
air manifold
air manifold adaptor
adaptor byby a
a jubilee
jubilee clip.
clip.
The snout
The snout is
is normally
normally fitted
fitted lying
lying
horizontal and
horizontal and pointing
pointing towards
towards the the
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T SERIES ENGINES operators' handbook
Valve Clearance
GO NOT GO
mm 0.15 0.20
Figure 5.11 Medium duty air cleaner in 0.006 0.008
CAUTION
After the outer element (A) has
been cleaned three times the inner
element (B) must be replaced.
Do not attempt to clean the inner Figure 5.13 Valve clearance
element.
26
T SERIES ENGINES operators' handbook
5.Tighten the locknut whilst restraining 2.Clean the top of the battery filler-
the adjusting screw, and re-check plug area.
to ensure that the clearance is 3.Remove the filler plugs and check
correct. that the electrolyte level is 6.0-9.0mm
6.Repeat for the remaining valve. (0.25-0.37in) above the tops of the
7.Replace the rocker cover, taking care separators.
to ensure that the decompressor 4.If necessary top up with distilled
lever, if fitted, is vertical. water. To prevent freezing In cold
weather, distilled water should only
5.14 Decompressor be added immediately before running
Adjustment the engine.
5.Replace and tighten the filler plugs.
This adjustment should only be made
6.Check that the terminal connections
when the valve clearance is correctly
are tight; petroleum jelly will help to
adjusted.
protect them from corrosion.
1.Remove the cylinder-head cover.
2.Turn the engine until the piston is at
TDC position on the firing stroke for
CAUTION
BATTERIES CONTAIN SULPHURIC
the cylinder being worked on. ACID WHICH CAN CAUSE SEVERE
3.Slacken the locknut (A) and adjust BURNS AND PRODUCE EXPLOSIVE
the screw (B) until it just touches the GASES. If acid is splashed on
exhaust valve rocker when the lever the skin, eyes or clothes,
is vertical. flush with copious amounts
4.Turn the screw half a turn clockwise of fresh water and seek
so that it travels towards the rocker. immediate medical aid.
5.Tighten the locknut whilst restraining
the adjusting screw. 5.16 Long Term Engine
6.Replace the rocker cover, taking care Storage
to ensure the decompressor lever The following routine should be carried
is vertical. out when it is known that the engine will
not be required for some months.
If the procedure is not carried out the
engine should be run on full load for
approximately 45 minutes once a
month.
CAUTION
A s a d ir e ct r e sult of
combustion, the lubricating
oil may contain harmful acids.
Figure 5.14 Decompressor lever
OIL should not be left in the
sump if it is known that the
5.15 Checking the Battery engine will not be used for
1 . We a r p r o t e c t i v e g l o v e s a n d extended periods.
goggles.
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6. Troubleshooting
6.1 Preliminary diagnostic equipment available?
Information • Do you have, or have access to, the
necessary Lister Petter Power Systems
Troubleshooting mechanical engine
spare parts?
problems can be difficult. The list of
problems in this section is of a general
nature as it covers the basic engine; your 6.2 Method of
particular application may be different. Troubleshooting
A comprehensive list of problems and Use the tables to find out probable
the methods of correction is given in causes of problems, together with
the Workshop Manual. If you are in any recommended solutions.
doubt, contact your local Lister Petter 1.Diagnose the problem by eliminating
Power Systems distributor. the easiest things first.
Before starting any dismantling 2.Before starting to remove or dismantle
procedure please read 1. Safety any components double-check your
Information. The following should be observations.
considered: 3.During dismantling keep all cylinder-
• Do you know and understand the related items together in their
engine and all the related systems? respective groups and correct order
• Do you have sufficient electrical to ensure they are refitted in their
and mechanical knowledge and skills original places.
to understand the symptoms? 4.In the case of electrical problems
• Do you have suitable electrical always check the battery first.
Troubleshooting
Problem Cause Solution
Incorrect starting procedure. Refer to section 3.
Unsuitable lubricating oil or fuel. Refer to section 4.
No fuel in the tank or the filter is Refill the tank and prime the fuel
choked. system or replace the filter.
Air in the fuel system. Prime the fuel system.
Difficulty Drain, flush, refill and prime the fuel
starting or Water or dirt in the fuel system.
system.
failure to start
Replace the injector or pump or have
Faulty injector or pump.
it serviced.
Discharged battery or poor battery Recharge or replace the battery. Check
connections. the terminals are tight.
Check the shutdown devices or the
Fuel control solenoid not energised.
electrical system.
Loose or corroded connections. Clean and tighten the connections.
Starter motor
Worn-out battery. Replace the battery.
does not
operate Adjust the connections and/or replace
Faulty starter panel or connections.
the panel.
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T SERIES ENGINES operators' handbook
Troubleshooting
Loose or corroded connections. Clean and tighten the connections.
Battery will not
Worn-out battery. Replace the battery.
charge
Loose alternator drive belt. Replace or re-tension the drive belt.
Radiator fan belt too slack. Adjust belt tension.
Overload. Reduce the load.
Overheating Lubricating oil level too low. Refill the sump.
Recirculation of exhaust gases or cooling Redesign exhaust and ventilation
air. system.
Lack of fuel. Check the system. Refill the tank.
Air in the fuel system. Prime the fuel filter.
Drain, flush, refill and prime the fuel
Water in the fuel system.
system.
Choked fuel filter. Replace the filter.
Dismantle and clean the cap and
Choked air filter.
element.
Engine stops
Overload. Reduce the load.
Overheating. See Overheating section.
Loss of compression. Check the piston rings and the valves.
Loss of electrical supply to the fuel pump
Check the electrical feed.
solenoid.
Automatic shutdown, if protective devices
Investigate the cause and rectify.
are fitted.
Loss of compression. Check the piston rings and the valves.
Dismantle and clean the cap and
Choked air filter.
element.
Lack, or loss, Choked exhaust system. Dismantle and clean.
of power
Overload. Reduce the load.
Choked fuel filter. Replace the filter.
Worn engine. Give the engine a major overhaul.
Excessive electrical load from added Remove accessories or fit higher output
accessories. alternator.
Poor electrical connections to alternator
Undercharging Inspect, clean and rectify the cause.
or battery.
Faulty battery. Test and recharge or replace.
Faulty alternator. Test and if necessary replace.
Overcharging Faulty alternator. Test and if necessary replace.
Clean surrounding area and replace the
Battery requires Battery case leaking.
battery.
excessive
Defective battery. Test or replace the battery.
amounts of
water Check the alternator output or battery
Battery charging rate is too high.
charging system.
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T SERIES ENGINES operators' handbook
7. Maintenance Record
Your Lister Petter Power Systems in 5.3 Maintenance Schedule. Details
T Series engine must be properly of the maintenance work carried out
maintained using the timings and during the first 5000 hours, except the
procedures described in this manual. You daily checks, must be recorded in the
must be familiar with the routine tasks set spaces allocated in this section: pages
out in 5. Routine Maintenance, and 30-34 for routine servicing and pages
their correct frequency as described 35-39 for non-routine servicing.
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
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T SERIES ENGINES operators' handbook
8. Warranty
On receipt of your engine please • Only genuine Lister Petter Power
fill in the section on page 42. This Systems service parts must be used.
information will be required in the • When Lister Petter Power Systems
event of a claim under your two-year parts are purchased from a dealer,
warranty, according to the conditions this must be noted, with the dealer's
set out below. stamp, in 7.Maintenance Record, and
receipts for the parts must be retained.
8.1 Standard Warranty The dealer is authorised to stamp the
Cover maintenance record only following the
The standard warranty includes two- sale of genuine parts, to a competent
year / 2000-hour cover for all non- engineer, intended to be used on
serviceable1 components, parts and the warrantable Lister Petter Power
labour, beginning on the date of Systems engine.
delivery to the original retail purchaser, • Evidence will be required of engine
and is transferable. It is subject to the hours run and should be entered in
conditions set out below in 8.2 Conditions 7.Maintenance Record. Evidence of
of Warranty and the limitations set equipment used to record engine hours
out in 8.3 Limitations of Warranty. may be requested in the event of a
warranty claim. If no hour recorder is
8.2 Conditions of fitted, twelve hours per calendar day
will be used as a basis for the hours-
Warranty
run calculation.
For the warranty to be valid, servicing
• The installation should be in
must be carried out in accordance with
accordance with data supplied by
5.Routine Maintenance and with the
the Lister Petter Power Systems
timings set out in 5.3 Maintencance
Applications Department.
Schedule. Detailed records of servicing
• Long term light load and cold engine
must be kept; see 7.Maintenance
running invalidate the warranty.
Record. Servicing must be by approved
dealers or competent engineers. The
conditions of warranty are: 8.3 Limitations of Warranty
• The maintenance record must be • The seller does not accept
completed. responsibility for any business costs
• Oils and other fluids must be to the or other losses which may result from
specifications/grades given in 4.Engine the warrantable failure.
Fluids or as instructed in the Workshop Continued
Manual.
Notes:
1. Serviceable items (unless defective) include, but are not limited to: air filters, fuel filters, oil
filters, injector nozzles, drive belts and lubricants and coolants (unless used on an authorised
repair).
2. This warranty gives the purchaser specific legal rights; the purchaser may also have other
rights, which vary by country or state.
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T SERIES ENGINES operators' handbook
Purchase Date:.......................................................................................................
Plant Type:..............................................................................................................
Plant Number:........................................................................................................
42
43
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
Head Office
Lister Petter Power Systems Limited
Unit 14 Estuary Court, Broadmeadow Industrial Estate
Teignmouth, TQ14 9FA
T: +44 (0) 1285 702211
Production Facility
Lister Petter Power Systems Limited
Units 13-15 Quadrant Distribution Centre
Hardwicke, Gloucester, GL2 2RN
sales@listerpetter.com
www.listerpetter.com