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TR Engines
Operators' Handbook
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 organisation cannot be relied
technical information with or without prior upon for correct material, dimensions or
notice. finish. The Company cannot therefore
Whilst every effort is made to ensure the be held responsible for any damage
accuracy of the particulars contained within arising from the use of such parts, and the
this publication, neither the Manufacturer, 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 P027-08265
Company’s current Conditions of Tender Copyright: Lister Petter Ltd, Dursley,
and Sale; is for the assistance of users; and Gloucestershire GL11 4HS, England.
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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
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T SERIES ENGINES operators' handbook
Engine Features
Fuel tank
Flywheel
Lifting eye
Fuel filter
TR1
Decompressor lever
Oil filter
TR2
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Introduction
This handbook explains the operation Using this Handbook
and routine maintenance of Lister Operating or servicing a diesel engine
Petter T series (TR) air cooled diesel is potentially dangerous. You must not
engines. attempt it unless you have the necessary
If your engine is part of a Lister Petter knowledge and experience.
generating set, there is a separate Read each section thoroughly
operators' handbook for the genset, and carefully, taking note of the all
to explain such features as the control information and instructions given. This
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
T-Series diesel engine you are using contents or the index to find the section
refer to the engine serial number, which you need. Where instructions are
is stamped on a plate attached to the numbered in sequence, they must be
engine. It identifies the type and build followed in that order. This applies in
of the engine (see below) to enable particular to maintenance and repair
the correct maintenance procedures procedures (Sections 5 and 6).
to be carried out. Here is a sample In cases of difficulty, or to obtain spare
serial number: parts, please consult your local Lister
Petter distributor or dealer.
07 001234 TR3 A 01
07 Year code (07 = 2007) Running-in
001234 Unique engine number To assist running-in all engines are
TR3 Engine series despatched with an initial fill lubricating
A Anti clockwise rotation oil which must be changed after 100
01 Build number hours. Your engine does not require
gradual light-load running-in. Extended
The illustrations on page 4 show light-load running should be avoided,
features of the different engine models. as this could damage the cylinder bore
When following the instructions in this and allow lubricating oil to enter the
handbook you will need to be familiar exhaust system.
with the parts labelled. (See also table
below.)
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1. Safety Information
Read the information in this section
carefully and follow all the advice
WARNING
This WARNING DRAWS ATTENTION
given. Pay especial attention to the TO SPECIAL information OR
cautions and warnings demonstrated PROCEDURES WHICH must be
below, which are used throughout this strictly OBSERVED. Failure to
handbook. do so may result in serious
injury or death.
CAUTION
This caution draws attention to 1.1 General Safety
special information or procedures
which must be correctly observed, Information
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 This figure identifies the ISO 8999 symbols currently used by Lister Petter.
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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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WARNING
Do not attempt to start any diesel
engine unless you have been
properly trained. It is dangerous.
Before attempting to start any engine
the operator should read 1. Safety
Precautions and be conversant with
the use of the engine controls and the Figure 3.2 The engine control
correct starting procedures.
As the engine runs up to speed the
CAUTION excess fuel device will automatically
Ether-based cold start aids in reset to the normal running position.
aerosol cans must not be used
under any circumstances. 3.3 Cold Starting Aid
Systems may be fitted to allow a The cold starting aid may be fitted to
measured quantity to be injected the combustion air intake ports and is
into the inlet manifold, but these used when the ambient temperature is
must be used in accordance with the below -10°C (14°F).
manufacturers' instructions.
WARNING
DO NO T BRE AT HE EXH A U S T
GASES AS THEY CONTAIN CARBON
MONOXIDE, A COLOURLESS,
ODOURLESS AND POISONOUS
G A S T H AT C A N C A U S E
UNCONSCIOUSNESS AND DEATH.
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T SERIES ENGINES operators' handbook
2.Withdraw the plunger (A) and fill one 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 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.
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 3.4.3 Moving the decompressor lever
handle which has been designed for towards the flywheel.
the engine.
• Ensure there are no burrs on that 4. If the ambient temperature is below
part of the handle which 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
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Caution
Never stop the engine by operating
the decompressor lever. This could
cause valve damage.
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4. Engine Fluids
4.1 Oil 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
lubricating oil which must be changed, and following the first 100 hours when
with the filter, after the first 100 hours. running-in has been completed.
All subsequent oil changes must These oils are particularly suited to
be as 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 MIL-L-46152B oil changes without undue degradation,
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. normal conditions.
Higher specification oils meeting API For engines in long running installations
CD, API CE and API CF-4 are more Lister Petter 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.
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CAUTION
Wax formation can rapidly reduce
the flow of fuel through the fuel filter
element.
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5. Routine Maintenance
This section is designed primarily running hours.
for use by trained technicians but it After the engine has run 25 hours, and
does contain sufficient information, again after it has run 250 hours, you
illustrations and detail to allow the should attend to the following:
operator to perform basic maintenance • Check the valve clearances, and
work. The recommendations and adjust if necessary.
instructions cover several engine • Check and tighten nuts, bolts and
models, therefore they are of a general unions paying particular attention to the
nature. fuel system.
• Check the lubricating oil level and
WARNING top up if necessary.
Routine maintenance must be • Observe the exhaust at the normal
performed by trained personnel who full load. It must be free from soot. A
are conversant with the hazards of black exhaust means that the engine
oil, fuel, electricity and machinery. is overloaded or that the injection
Work can be carried out only if you have equipment is out of order.
had suitable training and experience, Following this initial attention, the
and if the necessary hand and service normal routine maintenance must be
tools are available. Do not attempt to carried out as given in 5.3 Maintenance
carry out adjustments, maintenance or Schedule.
repairs if you have insufficient tools,
experience or ability. Caution
Where accurate measurements Do not allow the engine to run with
or torque values are required they a dirty exhaust without investigating
the cause as this may result in an
can only be made using calibrated
engine breakdown.
instruments.
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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.
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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 i r e ct r e su lt o f
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 • Do you have suitable electrical
Information diagnostic equipment available?
• Do you have, or have access to, the
Troubleshooting mechanical engine
necessary Lister Petter spare parts?
problems can be difficult. The list of
problems in this section is of a general
nature as it covers the basic engine; 6.2 Method of
your particular application may be Troubleshooting
different. Use the tables to find out probable
A comprehensive list of problems and causes of problems, together with
the methods of correction is given in recommended solutions.
the Workshop Manual. If you are in any 1.Diagnose the problem by eliminating
doubt, contact your local Lister Petter the easiest things first.
distributor. 2.Before starting to remove or dismantle
Before starting any dismantling any components double-check your
procedure please read 1. Safety observations.
Information. The following should be 3.During dismantling keep all cylinder-
considered: related items together in their
• Do you know and understand the respective groups and correct order
engine and all the related systems? to ensure they are refitted in their
• Do you have sufficient electrical original places.
and mechanical knowledge and skills 4.In the case of electrical problems
to understand the symptoms? 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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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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7. Maintenance Record
Your Lister Petter T Series engine in 5.3 Maintenance Schedule. Details
must be properly maintained of the maintenance work carried out
using the timings and procedures during the first 5000 hours, except the
described in this manual. You must daily checks, must be recorded in the
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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8. Warranty
On receipt of your engine please includes the following:
fill in the section on page 41. This Years 1 and 2: all non-serviceable1
information will be required in the components, parts and labour.
event of a claim under your two-year Year 3: core engine2, parts and labour.
warranty, according to the conditions Year 4: core engine, parts and labour.
set out below. Year 5: core engine, parts only.
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............................................................................................................................
Purchase Date:.......................................................................................................
Plant Type:..............................................................................................................
Plant Number:........................................................................................................
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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.
UK
LISTER PETTER LIMITED
Long Street, Dursley, Gloucestershire, GL11 4HS, England
TEL: +44 (0)1453 544141; FAX: +44 (0)1453 546732
E-mail: sales@lister-petter.co.uk
www.lister-petter.co.uk
UAE
LISTER PETTER FZE
Dubai Silicon Oasis Headquarters,
PO Box 341077, Dubai, UAE,
TEL: +971 4 372 4331; FAX: +971 4 372 4318
E-mail: sales@listerpettergroup.com;
www.lister-petter.co.uk