Lister Petter TS/TR1 Workshop Manual Download

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TS, TR, TX engines workshop manual

T SERIES ENGINES WORKSHOP MANUAL

3.Fit the slide hammer tool on to adaptor.

4.Align the stub shaft with the stub shaft hole.

5.Grasp the slide hammer with one hand while

positioning the rocker arm with the other and

reﬁt the stub shaft by striking the end of the tool

nearest the cylinder head with the slide hammer.

If the rocker lever bush is not correctly lined up

and is preventing the stub shaft being reﬁtted

gently strike either end of the tool with the slide

hammer while repositioning the rocker arm.

Note:

Ideally, after ﬁtting, the stub shaft hole and

internal hole of the rocker arm bush will be

perfectly aligned. Small 'G' clamps or a second

pair of hands may be required.

2.14 THE VALVE ROCKERS - TX

The removal of the valve rocker assembly is

necessary when it is required to examine or change

the valves, valve seats, rocker arms or rocker arm

bushes.

Removing an Individual Rocker Arm

Individual rocker arms can be removed without

removing the rocker assembly.

1.Remove the rocker cover.

2.With the piston at TDC on the ﬁring stroke screw

the rocker adjusting screw (A) anti-clockwise

until the valve spring is not tensioned.

Figure 2.14.1 Valve Rocker

3.Using suitable circlip pliers remove the circlip (B)

and slide the rocker lever off the stub shaft.

4.With the piston at TDC on the ﬁring stroke and

the adjusting screw turned fully anti-clockwise

slide the rocker lever onto the stub shaft.

5.Using suitable circlip pliers replace the circlip and

check that it is fully seated in the groove.

6.Check and reset the valve clearance.

7.Replace the valve rocker cover.

2.15 THE VALVES

Removing the Valves

1.Remove the cylinder head.

2.Remove the TS/TR valve rockers.

3.Remove the TX valve rocker assembly and oil

restrictor plate.

4.Lay the cylinder head upright on a bench and

place a circular block of wood under the head of

the valve.

5.Place the adapter (A) onto the valve spring carrier

with the two indentations facing outwards.

Figure 2.15.1 Valve Spring Compressor

6.Fit the tool (B) into the two plate indentations.

7.Push down on the tool until the collets can be

removed.

8.Gently release the tool and remove the carrier,

valve cap, valve spring and the valve stem

shields.

TS/TR1 engines are not ﬁtted with an exhaust

valve stem shield.

9.Turn the cylinder head over and remove the

valve.

Reﬁtting the Valves

1.Assemble the valves in the reverse order ensuring

the collets are securely in position with their tops

slightly sunk in the valve spring carrier.

2.Fit the valve stem caps

3.Replace the TS/TR valve rocker and stub shaft.

4.Replace the TX oil restrictor plate and the valve

rocker assembly.

5.Replace the cylinder head and set the valve

clearance.

6.Replace the valve rocker cover.

2.16 THE VALVE GUIDES

It is recommended that valve guides are removed

and reﬁtted with the aid of the Service Tool to

ensure the correct protrusion is obtained.

Figure 2.14.1 Valve Rocker

3. Using suitable circlip pliers remove the circlip (B) and slide

the rocker lever off the stub shaft.

4. With the piston at TDC on the firing stroke and the adjusting

screw turned fully anti-clockwise slide the rocker lever onto

the stub shaft.

5. Using suitable circlip pliers replace the circlip and check that

it is fully seated in the groove.

6. Check and reset the valve clearance.

7. Replace the valve rocker cover.

2.15 The Valves

Removing the Valves

1. Remove the cylinder head.

2. Remove the TS/TR valve rockers.

3. Remove the TX valve rocker assembly and oil restrictor

plate.

4. Lay the cylinder head upright on a bench and place a circular

block of wood under the head of the valve.

5. Place the adapter (A) onto the valve spring carrier with the

two indentations facing outwards.

T SERIES ENGINES WORKSHOP MANUAL

3.Fit the slide hammer tool on to adaptor.

4.Align the stub shaft with the stub shaft hole.

5.Grasp the slide hammer with one hand while

positioning the rocker arm with the other and

reﬁt the stub shaft by striking the end of the tool

nearest the cylinder head with the slide hammer.

If the rocker lever bush is not correctly lined up

and is preventing the stub shaft being reﬁtted

gently strike either end of the tool with the slide

hammer while repositioning the rocker arm.

Note:

Ideally, after ﬁtting, the stub shaft hole and

internal hole of the rocker arm bush will be

perfectly aligned. Small 'G' clamps or a second

pair of hands may be required.

2.14 THE VALVE ROCKERS - TX

The removal of the valve rocker assembly is

necessary when it is required to examine or change

the valves, valve seats, rocker arms or rocker arm

bushes.

Removing an Individual Rocker Arm

Individual rocker arms can be removed without

removing the rocker assembly.

1.Remove the rocker cover.

2.With the piston at TDC on the ﬁring stroke screw

the rocker adjusting screw (A) anti-clockwise

until the valve spring is not tensioned.

Figure 2.14.1 Valve Rocker

3.Using suitable circlip pliers remove the circlip (B)

and slide the rocker lever off the stub shaft.

4.With the piston at TDC on the ﬁring stroke and

the adjusting screw turned fully anti-clockwise

slide the rocker lever onto the stub shaft.

5.Using suitable circlip pliers replace the circlip and

check that it is fully seated in the groove.

6.Check and reset the valve clearance.

7.Replace the valve rocker cover.

2.15 THE VALVES

Removing the Valves

1.Remove the cylinder head.

2.Remove the TS/TR valve rockers.

3.Remove the TX valve rocker assembly and oil

restrictor plate.

4.Lay the cylinder head upright on a bench and

place a circular block of wood under the head of

the valve.

5.Place the adapter (A) onto the valve spring carrier

with the two indentations facing outwards.

Figure 2.15.1 Valve Spring Compressor

6.Fit the tool (B) into the two plate indentations.

7.Push down on the tool until the collets can be

removed.

8.Gently release the tool and remove the carrier,

valve cap, valve spring and the valve stem

shields.

TS/TR1 engines are not ﬁtted with an exhaust

valve stem shield.

9.Turn the cylinder head over and remove the

valve.

Reﬁtting the Valves

1.Assemble the valves in the reverse order ensuring

the collets are securely in position with their tops

slightly sunk in the valve spring carrier.

2.Fit the valve stem caps

3.Replace the TS/TR valve rocker and stub shaft.

4.Replace the TX oil restrictor plate and the valve

rocker assembly.

5.Replace the cylinder head and set the valve

clearance.

6.Replace the valve rocker cover.

2.16 THE VALVE GUIDES

It is recommended that valve guides are removed

and reﬁtted with the aid of the Service Tool to

ensure the correct protrusion is obtained.

Figure 2.15.1 Valve Spring Compressor

6. Fit the tool (B) into the two plate indentations.

7. Push down on the tool until the collets can be removed.

8. Gently release the tool and remove the carrier, valve cap,

valve spring and the valve stem shields.

TS/TR1 engines are not fitted with an exhaust valve stem

shield.

9. Turn the cylinder head over and remove the valve.

Refitting the Valves

1. Assemble the valves in the reverse order ensuring the collets

are securely in position with their tops slightly sunk in the

valve spring carrier.

2. Fit the valve stem caps

3. Replace the TS/TR valve rocker and stub shaft.

4. Replace the TX oil restrictor plate and the valve rocker

assembly.

5. Replace the cylinder head and set the valve clearance.

6. Replace the valve rocker cover.

2.16 The Valve Guides

It is recommended that valve guides are removed and refitted

with the aid of the Service Tool to ensure the correct protrusion

is obtained.

T SERIES ENGINES WORKSHOP MANUAL

Figure 2.16.1 Valve Guide Tool

Valve Guides - TS/TR

The guides are marked 'IN TOP' and 'EX TOP'

(inlet or exhaust valve guide, top position) and are

a press

ﬁt

into the two halves of the cylinder head

assembly. A rubber ring and a retaining plate are

located around the top of the inlet guide on early

engines; later engines have sealing caps on both

valves.

The rubber sealing ring must be inserted in the

guide to prevent damage to the ring as there is no

lead-chamfer to the recess.

After coating the outside of the valve guides with

Wellseal they should be pressed into their correct

positions with the markings uppermost and pointing

towards the opposite guide. The projections of the

valve guides above the top plate surface are:

Exhaust: 17.40-17.90mm (0.685-0.704in).

Inlet: 12.40-1 2.90mm (0.488-0.507in).

These projections will be correct if the Service Tool

is used.

After assembly a gauge 8.707mm (0.343in)

diameter must pass through the exhaust valve

guide. If the gauge does not pass through, the

guide must be reamed square to 8.707-8.727mm

(0.343-0.3436in) diameter.

These measurements also apply to cylinder heads

ﬁtted

with

pre-ﬁnished

valve guides that have been

obtained from Lister Petter Power Systems.

Valve Guides - TX

After the outside of the valve guides have been

coated with Wellseal they are pressed into the

cylinder head.

The projection of the valve guide above the top

plate surface must be 12.45-12.95mm (0.489-

0.509in).

After

ﬁtting

the internal measurement should be

7.910-7.965mm (0.311-0.313in).

Removing Valve Guides

1.Remove the cylinder head.

2.Remove the valves.

3.Remove the valve guide oil seal.

4.Preferably place the cylinder head on its side in

a soft jawed vice.

5.Screw the correct mandrel (B) into the tool (D).

6.Place the sleeve (C) onto the tool.

7.Fit the bevelled adapter (E) into the sleeve (C)

and locate the bevel into the valve seat; it may be

necessary to ﬁt the spacer (F) into the sleeve.

8.Locate the mandrel through the guide.

9.Screw the small threaded sleeve (A) onto the

mandrel.

10.Holding the sliding handle

ﬁrmly

to prevent

rotation, turn the double handled lever clockwise

until the guide is withdrawn through the head.

If it is found

difﬁcult

to start moving the guides a

sharp tap with a copper hammer should break

the seal.

Figure 2.16.2 Valve Guide Tool

Reﬁtting

Valve Guides

1.Fit the correct mandrel into the valve guide hole

from the valve rocker end.

2.Place the valve guide over the mandrel in the top

plate.

3.Place the correct depth stop (G) over the mandrel

and screw on the threaded sleeve (A).

4.Fit the tool complete with the bevelled adapter

(E) onto the mandrel.

5.Hold the sliding handle

ﬁrml

y, to prevent it rotating,

and turn the double handled lever clockwise until

the depth stop prevents any further movement.

At this point the guide will protrude the correct

distance above the cylinder head.

6.Fit a new valve guide oil seal.

2.17 THE VALVE SEATS

The valve seats are cast iron inserts which are

pressed into position to ensure they bed on the

bottom of the recess in the cylinder head. Before

Figure 2.16.1 Valve Guide Tool

Valve Guides - TS/TR

The guides are marked 'IN TOP' and 'EX TOP' (inlet or exhaust

valve guide, top position) and are a press fit into the two halves

of the cylinder head assembly. A rubber ring and a retaining

plate are located around the top of the inlet guide on early

engines; later engines have sealing caps on both valves.

The rubber sealing ring must be inserted in the top plate recess

before pressing in the inlet valve guide to prevent damage to

the ring as there is no lead-chamfer to the recess.

After coating the outside of the valve guides with Wellseal

they should be pressed into their correct positions with the

markings uppermost and pointing towards the opposite

guide. The projections of the valve guides above the top plate

surface are:

Exhaust: 17.40-17.90mm (0.685-0.704in).

Inlet: 12.40-1 2.90mm (0.488-0.507in).

These projections will be correct if the Service Tool is used.

After assembly a gauge 8.707mm (0.343in) diameter must pass

through the exhaust valve guide. If the gauge does not pass

through, the guide must be reamed square to 8.707-8.727mm

(0.343-0.3436in) diameter.

These measurements also apply to cylinder heads fitted with

pre-finished valve guides that have been obtained from Lister

Petter Power Systems.

Summary of Contents for TS/TR1

Page 1: ...P027 08270 edition 8 April 2021 TS TR TX Engines Workshop Manual T SERIES ...

Page 2: ...this publication neither the Manufacturer 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 ofTender and Sale is for the assistance of users and is based upon results obtained from tests carried out at the place of manufacture The Company does not guarantee tha...

Page 3: ...ernor 30 2 32 Governor G Setting and Timing Tables 33 2 33 Speed Adjustment 34 2 34 The Engine Controls 34 2 35 The Fuel Pump Tappet 35 2 36 The Camshaft 35 2 37 The Camshaft Gearwheel 36 2 38 The Camshaft Bushes 37 2 39 The Cylinder Barrel 38 2 40 The Piston and Connecting Rod 39 2 41 The Flywheel 40 2 42 The Fanshroud TS TR 40 2 43 Flywheel Housing TX 41 2 43 Main Bearing Housing 41 2 44 The Cra...

Page 4: ...csa Charge Windings 75 9 Electrical Wiring Diagrams 9 1 Wiring Diagrams 79 10 Technical Data 10 1 Engine Mechanical Data TS 86 10 2 Engine Mechanical Data TR 87 10 3 Engine Mechanical Data TX 88 10 4 Builds TS 89 10 5 Builds TR 90 10 6 Builds TX 91 11 Conversion Factors 11 1 Formulae 92 11 2 Conversion Factors 93 12 Index ...

Page 5: ...refore be responsible for any damage arising from the use of such parts and the guarantee will be invalidated When purchasing parts or giving instructions for repairs users should in their own interests always specify Genuine Lister Petter Parts and quote the Description of the Part and the Engine Serial Number Training Comprehensive training in the correct operation service and overhaul procedure...

Page 6: ...expose pressurised containers to heat and do not incinerate or puncture them d Handle fuel with care and always stop the engine before refuelling Do not overfill the fuel tank e Thoroughly clean any lubricating or fuel oil from the skin as soon as possible f Rectify all fuel coolant and oil leaks as soon as practicable and clean any spills when they occur g Remove any build up of grease oil or deb...

Page 7: ...bles are fitted to their correct terminals A short circuit or reversal of polarity will ruin diodes and transistors Never connect a battery into the system without checking that the voltage and polarity are correct d Never flash any connection to check the current flow or experiment with any adjustments or repairs to the system e The battery and alternator charge windings must be disconnected befo...

Page 8: ...y used by Lister Petter Power Systems 8 When exposed to abnormally high temperatures in excess of 400 C 752 F an extremely corrosive acid is produced which cannot be removed from the skin If signs of decomposition are evident or if in doubt always wear disposable heavy duty gloves Fuel System Precautions a When priming or checking the fuel injection pump timing care must be taken to wipe spilled f...

Page 9: ...TS TR TX engines workshop manual 9 1 3 Engine Features T SERIES ENGINES WORKSHOP MANUAL 9 1 3 ENGINE FEATURES TS TR1 TS TR2 TS TR3 TX2 TX3 ...

Page 10: ...late attached to the engine It is necessary to identify the type and build of each engine to enable the correct maintenance procedures as described later in this publication to be carried out An example number is shown below 03 001234 TS3 A 01 03 Year code 03 2003 001234 Unique engine number TS3 Engine series A Anti clockwise rotation 01 Build number 1 5 BATTERY DETAILS WARNING Battery posts termi...

Page 11: ...alue in Amps 3 Refer to a battery catalogue for the battery required Notes Therecommendationsmadeassumethattheengineisfilledwiththerecommended typeandgradeoflubricatingoilandisnotrequiredtostartagainsthighinertialoads such as concrete mixers tar boilers hydraulic pumps screw pumps and similar In these applications wherever possible means should be provided to overcome such loads by the inclusion o...

Page 12: ...similarly The instructions given deal with individual components and it may be necessary to remove others before the relevant instructions can be carried out a Disconnect or isolate any non electric starting systems b Disconnect and remove the battery c Drain the diesel fuel and lubricating oil d Disconnect all services e Remove any accessories or components that may be susceptible to damage when ...

Page 13: ...quence by the start key Figure 2 3 2 TX Glowplug 2 4 THE MANIFOLDS Manifold Loading A small light exhaust silencer may be mounted direct on the manifold or on a light extension which must be no more than 152mm 6ins long Heavy exhaust silencers and 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 solid exte...

Page 14: ...ES ENGINES WORKSHOP MANUAL 15 3 Replace the glowpiug cable 4 Replace the axial fan air cowling 2 5 THE AIR COWLING Three sides of the engine are encased in an air cowl and two sides shields which together with the air bafﬂe s direct cooling air from the ﬂywheel fan around the cylinders Removing the Air Cowling TS TR 1 Remove the cold start pots if ﬁtted 2 Drain the fuel and remove the engine mount...

Page 15: ...ure the washer is reﬁtted on re assembly The breather tube forms an interference ﬁt in the cylinder head Removing the Cylinder Head Cover 1 Remove the lifting eye and fuel tank securing bolts if necessary 2 Remove the four bolts securing the cover 3 Lift off the cover being careful not to damage the joint or leak off pipe Reﬁtting the Cylinder Head Cover 1 On TS TR engines ensure the breather plat...

Page 16: ...is and 90 to the centre line and just touching the cylinder bore Care must be taken to ensure the wires are not placed over any markings on the piston crown 17 their position for re assembly With the cylinder head in position the air bafﬂe s may be removed by removing the split pin 9 Remove the push rods and tubes and place them with their respective cylinder head if further dismantling is anticip...

Page 17: ...ealing groove nearest to the Figure 2 13 1 Stub Shaft Tool 2 Preferably place the cylinder head into a vice and screw the slide hammer tool onto the adapter 3 Griptheslidehammerinonehandandstrikethesleeveinthe required direction until the stub shaft has been removed 4 Lift out the rocker arm Refitting the Stub Shaft Before fitting check the oil holes are clear fit a new O ring to the recess on the...

Page 18: ...Push down on the tool until the collets can be removed 8 Gently release the tool and remove the carrier valve cap valve spring and the valve stem shields TS TR1 engines are not fitted with an exhaust valve stem shield 9 Turn the cylinder head over and remove the valve Refitting the Valves 1 Assemble the valves in the reverse order ensuring the collets are securely in position with their tops sligh...

Page 19: ...dled lever clockwise until the depth stop prevents any further movement At this point the guide will protrude the correct distance above the cylinder head 6 Fit a new valve guide oil seal 2 17 The Valve Seats The valve seats are cast iron inserts which are pressed into position to ensure they bed on the bottom of the recess in the cylinder head Before pressing in the inserts at ambient temperature...

Page 20: ...sor is fitted to the exhaust valve on some engines When the cylinder head cover is being replaced care must be taken to ensure the lever is vertical between the two stops The decompressor lever is spring loaded towards the cylinder head and is located by a plain washer and a split pin or circlip fitted through the decompressor shaft A seal fitted on the outside of the cylinder head prevents oil se...

Page 21: ...50065 TX is used to protect the oil seal when the end cover is either removed or replaced and it can also be used to remove and replace the seal in the end cover OnTX engines a bracket supporting the axial fan and alternator is fitted to the cover Removing the End Cover TS TR 1 Remove the plastic dustcap in the end cover boss On early engines a Turn the crankshaft until the spring pin A of the sta...

Page 22: ...ithout a fuel filter element The element should be renewed every 500 hours or more frequently if for any reason the fuel is known to be dirty The Fuel Tank Filter Thefuelfilterisanessentialpartoftheengineanditmustnever be run without a filter and the element should be renewed every 500 hours or more frequently if for any reason the fuel is known to be dirty 1 Remove the retaining plug A 2 Remove t...

Page 23: ... tap C sufﬁciently to allow the water to drain A strap wrench is required to remove the agglomerator from the engine but it must not be used to ﬁt a replacement 1 Using a suitable strap wrench unscrew the cartridge A from the head B 2 Screw a new cartridge onto the head and hand tighten it Figure 2 23 3 The Cartridge Agglomerator 2 24 PRIMING THE FUEL SYSTEM If the fuel system is self venting it s...

Page 24: ... spanner to prevent it turning 3 Remove the leak off pipe and union from the injector 4 Unscrew the Allen screw and remove the injector clamp the clamp is located in position by a hole in the side of the cylinder head assembly Either a Screw the adaptor A into the slide hammer and tighten the screw C into the injector leak off hole see Note Or b Screw the adaptor A into the slide hammer c Fit the ...

Page 25: ...mp to injector pipe do not tighten 15 Push the leak off pipe onto the injector 16 Torque the clamp screw to 8 0Nm 6 0Ibf ft 17 Torque all fuel pipe nuts to 28 5Nm 21 0lbf ft 18 Replace the leak off pipe into the fuel tank Figure 2 26 3 Typical Injector Test Rig If a rig is not available it becomes necessary to replace the complete injector by a new or serviced one which has a clean nozzle and has ...

Page 26: ...the pump removed from the engine Figure 2 27 2 Timing Shims The ring type are available in 0 127 0 762 1 016 and 1 276mm sizes and were ﬁrst ﬁtted on 40 00213 TS1 40 00113 TR1 40 00297 TS2 40 00135 TR2 40 00223 TS2 40 00039 TR3 In all instances it is recommended that the thickest shim is ﬁtted next to the crankcase and it Figure 2 27 2 Timing Shims The ring type are available in 0 127 0 762 1 016 ...

Page 27: ...arefully lift out the delivery valve D taking care not to disturb the valve seat 6 Place these components in a suitable container of clean fuel 7 Replace the delivery union body A 8 Fit a suitable spill pipe 9 Ensure the fuel pump rack is in the run position by removing a cylinder fuel pump housing door and manually moving the fuel pump rack towards the gear end 10 Turn the ﬂywheel in the directio...

Page 28: ...ough an aperture in the fanshroud should align with the arrow on the fanshroud 12 If the flywheel mark is not correct the shims under the fuel pump must be adjusted see Timing Shims T SERIES ENGINES WORKSHOP MANUAL Figure 2 28 2 Flywheel Timing Marks If the timing is Advanced Add Shims Retarded Remove Shims Approximately 1 of ﬂywheel movement can be obtained with a 0 127mm 0 005in shim injector 3 ...

Page 29: ...are to retain the timing shims which are between the pump ﬂange and crankcase CAUTION If more than one pump is being removed care must be taken to retain the timing shims with their respective pump The rin and 1 2 In all thickes is advis shims a Reﬁtti 1 If ri onto pump 2 Place retain 3 If sic pump bolts slight Repla crank thickn pump 4 Even 9 0Nm 5 Conn interc Figure 2 29 1 Fuel Pump Linkage A Ea...

Page 30: ...iven in Governing Ranges to BS5514 Current engines are fitted with an improved camshaft gearwheel design the weights remain the same although on current engines they are retained in positionbysinteredretainingplateswithcastslotswhichlocate over the weight pins Both types are shown in Figure 2 30 2 and they are not interchangeable 1 Remove the gear end cover 2 Remove the governor lever and sleeve a...

Page 31: ...ges are seated T SERIES ENGINES WORKSHOP MANUAL 34 CAUTION Extreme care must be taken to ensure that the governor is correctly set for the engine type and build Governor E Setting Adjustment E as shown below should be checked and if necessary shims added or removed to obtain a clearance of 0 12 0 25mm 0 005 0 010in Figure 2 31 1 Governor E Setting The pivot pins B can be withdrawn with a 1 5mm pun...

Page 32: ...n in 02 32 Governor G Setting and Timing Tables For intermediate speeds not given in the tables use the setting for the nearest higher speed All TS and TR engines built from January 1999 have been ﬁtted with fuel pump 201 31305 Mk ll Pump These can be ﬁtted individually as spares to replace the earlier pumps but improved engine idling characteristics can only be gained by changing all pumps in the...

Page 33: ...0 B1 90 100 0 045 17 20 2500 B1 90 100 0 045 18 20 2200 A1 90 100 0 045 62 20 1500 A1 100 0 045 101 20 1500 A1 100 0 045 102 103 20 2500 B1 90 100 0 045 106 20 2500 B1 90 100 0 045 TR1 Builds Timing BTDC Speed Class Load Rating G Setting 01 02 20 2500 B1 90 100 0 040 03 23 3000 B1 90 100 0 055 06 07 20 2500 B1 100 0 040 08 09 20 1500 A1 100 0 053 10 11 20 1800 A1 100 0 053 14 16 20 2500 B1 100 0 0...

Page 34: ...b and spindle are one assembly and the location plate is a separate item Note The current assembly cannot be used with an early type of unmodiﬁed locating plate Removing the Assembly 1 Remove the gear end cover 2 Remove No 1 cylinder fuel pump inspection door 3 Move the automatic excess fuel lever B along the shaft towards the outside of the crankcase and hold it in this position 4 Remove the smal...

Page 35: ...3 Replace the tappet 4 Replace the tappet insert with the smaller section on the outside CAUTION Failure to ﬁt a new washer to the guide locating bolt may allow the bolt to touch the tappet and prevent it operating 2 36 THE CAMSHAFT The steel camshaft is carried in plain bearings in the crankcase at both the ﬂywheel end and in the centre web s A ball bearing attached to the camshaft and ﬁtted behi...

Page 36: ...HAFT 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 Continue to press off the bearing 3 Remove the Woodruff key E 4 Drift pin A out of the camshaft B using a ...

Page 37: ...r engines the ﬂange must be facing the direction in which the bush will be removed 3 Place the screw through the dolly from the end giving the maximum protrusion of the screw outside the crankcase 4 Fit the bridge 8 for the ﬂywheel end centre bush or the depth plate 7 for the gear end centre bush 5 Fit the thrust nut 9 to the screw 6 Using the correct size of spanner tighten the thrust nut until t...

Page 38: ...asher and bush through the centre web of the crankcase 6 Remove the tool complete with bush Centre Bush Replacement 1 Place the sleeve over the plug with the locating lug towards the plug head 2 Place the sleeve and plug into the gear end camshaft bush hole The chamfer on the sleeve will assist in aligning the tool 3 Inserttheboltthroughtheflywheelendcamshafthole place the washer and bush over the...

Page 39: ...Bearing Cap Bolt Head Location 16 Replacetheconnectingrodnutsandtorquethemto43 5Nm 32 0lbf ft It is recommended that connecting rod bolts and nuts are replaced at every major overhaul 2 40 The Piston and Connecting Rod The piston is manufactured from low expansion alloy and has a machined recessed combustion chamber in the crown All pistons are fitted with three cast iron rings except certain TS b...

Page 40: ...g or fan weighs in excess of 54kg 1191bs therefore it is important to bear this point in mind when removing handling or replacing it To prevent damaging the TS or TR stator of the flywheel mounted charge windings the free length of studs or bolts entering the flywheel must not exceed 20 0mm 0 79in 44 to bear this point in mind when removing handling or replacing it To prevent damaging the TS or TR...

Page 41: ...itting is carried out in the reverse order with the self locking setscrews torque loaded to 88 0Nm 65 0lbf ft CAPTION If the sump has been removed the procedure detailed in Replacing the Oil Sump must be followed when refitting the fanshroud to prevent the possibility of distorting it resulting in excessive flywheel to shroud run out 2 43 Main Bearing Housing The main bearing housing is secured to...

Page 42: ...ted Aninterferencefitpinioniskeyedontotheendof thecrankshaft and engages with the camshaft gear Early crankshaft balance weights were secured with only one retaining bolt up to the following engines 35 00630 TS1 36 00255 TR1 35 06716 TS2 36 00073 TR2 35 05963 TS3 36 00112 TR3 After these and on all TX engines the weights were secured by two capscrews the later weights and capscrews are not interch...

Page 43: ...NES WORKSHOP MANUAL also the connecting rod bearings d Examine all bearing surfaces for scoring and wear e Renew the split thrust washers if they are damaged or worn Reﬁtting the Crankshaft 1 If necessary ﬁt new bearing shells to the main bearing housing centre bearing housing s and the gear end crankcase main bearing The grooved bearing shell must be to the top and the oil holes must be lined up ...

Page 44: ...ft Main Bearings Main Bearing Tool 393235 T SERIES ENGINES WORKSHOP MANUAL 48 Notes On current engines 0 127 and 0 254mm 0 005 and 0 010in aluminium shims control the endﬂoat and are assembled as given in 02 43 Main Bearing Housing Early TS and TR engines may have paper and 0 076mm 0 003in metal shims assembled dry or with Wellseal 5 After the bearing housing has been replaced the housing bolts ar...

Page 45: ... nut 2 onto the screw 1 3 Hold the nut ﬁrmly across its ﬂats in a vice 4 Place both dollies 5 6 onto the screw with the tapered ends outwards and the large dolly 6 next to the nut 2 5 Fit the bearing housing on the screw with the thrust face uppermost 6 Fit the bridge 8 followed by the thrust nut 9 onto the screw 1 7 Using the correct size of spanner tighten the thrust nut 9 until the main bearing...

Page 46: ...in the main 2 With the ﬂywheel locked re torque the ﬂywheel retainer to 474 5Nm 350 0lbf ft Crankshaft Extension Spanner 317 50060 The tool is used when it is not possible to torque direct at the gear end with the ﬂywheel locked Figure 2 48 1 Extension Spanner 317 50060 1 Fit the open ended section behind the pinion or onto the shaft 2 Place the bolt through the boss and into the crankcase 3 With ...

Page 47: ...ain plug taking care not to overtighten it 6 Fill the sump to the correct level with the correct grade and type of lubricating oil 7 Start the engine and run it for a few minutes to circulate the oil and check the drain plug does not leak 8 Stop the engine and allow time for the oil to settle and re check the level on the dipstick 9 Add more oil if necessary Oil Sump Capacity litres pints US qts T...

Page 48: ...emblytakecaretoreplacethedistancepieceunderthetopplateandensure that the anti surge plate on the strainer is parallel to the crankcase web Oil Pump The camshaft operated oil pumps are the self regulating plunger type and they are not interchangeable across the ranges Removing the Oil Pump 1 Drain the oil 2 Remove the dipstick and sump 3 Lift out the oil pump 4 Using long nosed pliers remove the oi...

Page 49: ... three components of the rotary seal are a A rotating impeller which is an interference fit on the crankshaft and has an oil sealing thread machined on the outside diameter b A felt ring held in place by a stationary retaining cap which acts as a dust seal c A retaining cap which is an interference fit in the bearing housing Special tools are required to assemble the seal to achieve the correct sp...

Page 50: ... heavy duty gasoline engines Oils designed for this service provide protection from high temperature deposits and bearing corrosion in diesel engines and also from rust corrosion and low temperature deposits in gasoline engines These oils were introduced in 1961 API Service Category CD Service typical of certain naturally aspirated turbocharged or supercharged diesel engines where highly effective...

Page 51: ...0 05 weight sulphur fuel and off highway less than 0 5 weight sulphur fuel applications CG 4 oils provide effective control over high temperature piston deposits wear corrosion foaming oxidation stability and soot accumulation These oils are especially effective in engines designed to meet 1994 exhaust emission standards and may also be used in engines requiring API Service Categories CD CE and CF...

Page 52: ...t although the engines may operate on fuels outside the above specifications such operation may well result in excessive wear and damage CAPTION The fuel injection equipment is manufactured to very accurate limits and the smallest particle of dirt will destroy its efficiency Fuel free from water and contaminants is of the utmost importance Low Temperature Fuels Special winter fuels are often avail...

Page 53: ...n 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 handle which has been designed for the engine Ensure there are no burrs on that part of the handle which fits onto the engine Ensure the handle grip is clean dry and free to turn on its shaft Clean and lightly oil that part of the h...

Page 54: ...ng Aid TS TR 5a If using a non limited kick back handle Insert the correct handle refer to A in Figure 4 1 1 into the starting housing 59 Figure 4 1 3 Cold Start 3 Replace the plunger and inject the oil just before starting the engine CAUTION The device must not be used more than three times in succession during the same attempt to start the engine 4 2 HAND STARTING Before attempting to start the ...

Page 55: ...e it immediately Figure 4 3 2 The Engine Control 3 If a variable speed control lever is fitted move it to the fast position 4 Iftheambienttemperatureisbelow 10 C 14 F refertoitems 2 and 3 in Cold Starting Aid TS TR 5a If a start key is being used Turn the start key clockwise and hold it at position 3 until the engine fires and then release it immediately 60 8 If a variable speed control is ﬁtted r...

Page 56: ...t any maintenance work on an engine it is advisable to remove the battery The battery and alternator must be disconnected before commencinganyelectricweldingwhenapolestrapisdirectly or indirectly connected to the engine It is essential to ensure that nuts and bolts are tightened to the torques specified in this Workshop Manual When re assembling an engine lubricate all moving parts with engine oil...

Page 57: ...urs 5 3 Spanner Torque Settings The tolerance for all spanner torque settings is 5 0 and for practical purposes the figures have been rounded Location Nm lbf ft Governor link adjusting screw 3 0 2 0 Polypropylene flywheel fan TS1 4 0 3 0 Injector stud nut TX Injector leak off banjo screw Nylon side shield retainer TS TR1 6 0 4 5 Cold start oil cup taper thread 8 0 14 5 6 0 10 5 Polypropylene flywh...

Page 58: ...of it Take care not to block the bore of the pipe Crankshaft Bucket Plug Coat the plug periphery with Loctite 572 or Three Bond 1110B End Cover Bush TS TR Coat the outside diameter of the bush before assembly with Loctite 601 or Three Bond 1303 Speeder Spring Anchor Pin Coat the threads with Loctite 222 or Three Bond 1344 before assembling the anchor pin to the speed control spindle End Cover Asse...

Page 59: ...nd Compression Ring Groove Width 2 456 2 482 0 076 0 127 0 23 Oil Ring Width 4 763 4 737 0 050 0 102 0 15 Oil Ring Groove Width 4 813 4 839 TS Builds 60 65 Cylinder Bore 95 275 95 300 0 128 0 063 0 22 Piston Diameter bottom of skirt across thrust face 95 212 95 172 Firing Ring Gap 0 30 0 50 0 36 0 66 0 85 Compression Ring Gap 0 20 0 45 0 28 0 61 0 90 Conformable Oil Ring Gap 0 25 0 45 0 33 0 61 0 ...

Page 60: ...ds Small End Bearing Diameter 33 3807 33 3934 0 0432 0 610 0 09 Gudgeon Pin Diameter 33 3375 33 3324 Big Enf Bore in rod 67 2080 67 2210 0 0376 0 0814 0 14 Bearing Shell Thickness 0 8352 1 8263 Crankpin Diameter 63 5000 63 4870 Main Bearing Housing Bore 67 196 67 221 0 0386 0 0934 0 16 Bearing Shell Thickness 1 8352 1 8263 Crankshaft Journal Diameter 63 4870 63 4750 Thrust Bearing Thickness TS TR1...

Page 61: ...iameter 25 4440 25 4360 Backlash Between Gears 0 13 max 0 20 TX Wearing Parts Component TS TR Initial Dimension mm Initial Clearance mm Max Clearance mm TX All Builds Cylinder Bore 100 000 100 025 0 164 0 121 0 25 Piston Diameter bottom of skirt across thrust face 99 879 99 861 Firing Ring Gap 0 40 0 65 0 40 0 73 1 05 Compression Ring Gap 0 40 0 65 0 40 0 73 1 02 Conformable Oil Ring Gap 0 25 0 55...

Page 62: ...er flywheel end 39 952 39 9390 Fuel Pump Tappet Diameter 24 987 24 962 0 013 0 068 0 10 Fuel Pump Tappet Guide Bore 25 000 25 030 Oil Pump Tappet Diameter 15 850 15 830 0 025 0 070 0 12 Oil Pump Tappet Crankcase Bore 15 875 15 900 Oil Pump Plunger Diameter Tx2 29 960 29 935 0 040 0 098 0 13 Oil Pump Cylinder Diameter Tx2 30 000 30 033 Oil Pump Plunger Diameter Tx3 32 960 32 935 0 040 0 098 0 13 Oi...

Page 63: ... from the sump ThecrankshaftshouldNOTbeturneduntiltheengineisagain required for service The inhibition fluid should be left in the fuel system e Seal all openings on the engine with tape f Remove the batteries and store them fully charged after coating the terminals with petroleum jelly g Grease all external bright metal parts and the speed control linkage h Tie labels on the engine clearly statin...

Page 64: ...p all cylinder related items together This will ensure they are refitted in the original orientation 4 When electrical troubleshooting always start at the battery first 6 3 Troubleshooting Tables Problem Method of Correction Difficult Starting or Failure to Start Incorrect starting procedure Refer to the correct procedure Unsuitable lubricating oil too heavy Use oil of the correct viscosity and sp...

Page 65: ...l system Prime the fuel filter Water in the fuel system Drain flush refill and prime the fuel filter Choked fuel filter Replace the filter Choked air filter Dismantle and clean the cap and element Overload Reduce the load Overheating See the Overheating section Loss of compression Check the piston rings and the valves Loss of electrical supply to the fuel solenoid Check the electrical feed Automat...

Page 66: ...ings Test or replace Overcharging Faulty alternator or charge windings Test or replace Battery Requires Excessive Amounts of Water Battery case leaking Clean surrounding area and replace the battery Deffective battery Test or replace the battery Battery charging rate is too high Check the alternator output or battery charging system Battery will not Charge Loose or corroded connections Clean and t...

Page 67: ...emove the thrust washer and shim from the camshaft 23 Remove all fuel pump inspection doors 24 Disconnect the governor link from all fuel pump racks 25 Remove the two fulcrum pins from the governor lever assembly pivot supports taking care to retain the spring and shims 26 Using long nosed pliers remove the speeder spring from its control 27 Remove the governor lever assembly complete 28 emove the...

Page 68: ...he slot on the face is towards the top of the crankcase 11 Remove the centre bearing dowel 12 Replace the oil seal to the bearing housing 13 Replace the centre bearing dowel and the dowel retaining bolt 14 Replace the flywheel key 15 Heat the crankshaft pinion gear and ensure the 0 timing mark will be facing outwards when the gear is refitted to the crankshaft 16 Replace the sump with four bolts o...

Page 69: ...ction doors 81 Replace the cylinder head covers 82 Replace the lifting eye 83 Refit air filter silencer and fuel tank reconnect all services and replenish the fuel and oil supplies TX Dismantle and Rebuild These notes are of a general nature and are included as an aide memoir and in no way are they intended as instructions Dismantling Before beginning any work on the engine drain all of the fuel a...

Page 70: ...able piece of wood to support it 2 With the sump removed grease the steel backs of the split thrust washers and refit them into the gear end of the crankcase and the main bearing housing 3 Replace the crankshaft taking care to ensure the bearing locating dowel is in line with the hole in the crankcase before the dowel enters the housing If on the final assembly the holes are not in line use a bras...

Page 71: ...ning tube from No 1 cylinder 51 Replace the cylinder head and diagonally torque the bolts 52 Check the cylinder head clearance 53 With the cylinder head removed replace the push rods and tubes a very small mount of grease added to the tube sealing rubbers will ease the fitting of the heads 54 Replace the cylinder head making sure it is fully seated and then replace the bolts hand tight 55 Repeat t...

Page 72: ...regulator and the battery during periods of running the indicator light will remain unlit unless there is a fault in the charging system The battery charge indicator light will always be lit to indicate a charging fault The light will also be switched on with a fully serviceable system under the following circumstances a Ifthechargeratedropsbelow2Ampsatnormalenginespeed and the battery is fully ch...

Page 73: ...TS TR TX engines workshop manual 73 Syncro Fault Finding Flow Charts T SERIES ENGINES WORKSHOP MANUAL 83 Syncro Fault Finding Flow Charts cro au t Fin ing Flow Charts ...

Page 74: ...TS TR TX engines workshop manual 74 Syncro Fault Finding Flow Charts T SERIES ENGINES WORKSHOP MANUAL 84 Syncro Fault Finding Flow Charts c F t F Flo C ...

Page 75: ... charging fault is known to exist refer directly to the relevant ﬂow chart The following instruments are necessary to carry out the tests 1 0 20A moving coil ammeter 2 0 20V moving coil voltmeter or a DC multimeter 3 0 200V moving iron voltmeter or an AC multimeter 4 0 5 Ohm meter or multimeter Figure 7 3 1 Test Instrument Connection Diagram X Removed B Battery Terminal Stator Winding Resistance a...

Page 76: ...TS TR TX engines workshop manual 76 Nicsa Fault Finding Flow Charts T SERIES ENGINES WORKSHOP MANUAL 86 Nicsa Fault Finding Flow Charts F l l ...

Page 77: ...TS TR TX engines workshop manual 77 Nicsa Fault Finding Flow Charts T SERIES ENGINES WORKSHOP MANUAL 87 Nicsa Fault Finding Flow Charts l i F ...

Page 78: ...TS TR TX engines workshop manual 78 Nicsa Fault Finding Flow Charts T SERIES ENGINES WORKSHOP MANUAL 88 Nicsa Fault Finding Flow Chart ...

Page 79: ...ed boxes shown attached to some cables are cable identification numbers The heater plug 17 is an optional accessory Key to all Diagrams 1 Flywheel alternator stator 2 Control keyswitch 3 Engine temperature switch The air temperature switch must be wired in irradiated PVC cable suitable for temperatures up to 120 C 248 F 4 Fuel control solenoid circuit breaker 5 Fuel control solenoid 6 Impulse tran...

Page 80: ...TS TR TX engines workshop manual 80 T SERIES ENGINES WORKSHOP MANUAL 90 ct ical Wiring i g ...

Page 81: ...TS TR TX engines workshop manual 81 T SERIES ENGINES WORKSHOP MANUAL 91 Elect i al Wiring Diagram ...

Page 82: ...TS TR TX engines workshop manual 82 T SERIES ENGINES WORKSHOP MANUAL 92 ctr ca Wi ing Diagrams ...

Page 83: ...TS TR TX engines workshop manual 83 T SERIES ENGINES WORKSHOP MANUAL 93 Electrical Wiring iagram ...

Page 84: ...TS TR TX engines workshop manual 84 T SERIES ENGINES WORKSHOP MANUAL 94 ect ica Wiring Diagrams ...

Page 85: ...TS TR TX engines workshop manual 85 T SERIES ENGINES WORKSHOP MANUAL 95 ...

Page 86: ... speed at 3000r min m sec 7 41 7 41 7 41 ft min 1458 1458 1458 Lubricating oil pressure mean bar 2 0 2 0 2 0 lbf in2 29 0 29 0 29 0 Lubricating oil sump capacity litre 2 7 4 0 5 5 pt 4 7 7 0 5 8 US qt 2 8 4 2 5 8 Engine mounted fuel tank capacity litre 8 25 13 5 13 5 13 5 pt 14 5 23 7 23 7 23 7 US qt 8 7 14 2 14 2 14 2 Maximum crankshaft end thrust kg 132 132 132 lb 290 290 290 Number of flywheel ...

Page 87: ... at 3000r min m sec 8 47 8 47 8 47 ft min 1667 1667 1667 Lubricating oil pressure mean bar 2 0 2 0 2 0 lbf in2 29 0 29 0 29 0 Lubricating oil sump capacity litre 2 7 4 0 5 5 pt 4 7 7 0 5 8 US qt 2 8 4 2 5 8 Engine mounted fuel tank capacity litre 8 25 13 5 13 5 13 5 pt 14 5 23 7 23 7 23 7 US qt 8 7 14 2 14 2 14 2 Maximum crankshaft end thrust kg 132 132 132 lb 290 290 290 Number of flywheel gear r...

Page 88: ...2000 2000 Lubricating oil pressure minimum at 1000 r min bar 0 7 0 7 lbf in2 10 0 10 0 Lubricating oil pressure minimum at 1500 r min bar 1 25 1 25 lbf in2 18 0 18 0 Lubricating oil sump capacity litre 4 0 6 0 pt 7 0 10 6 US qt 4 2 6 3 Engine mounted fuel tank capacity litre 25 0 25 0 pt 43 9 43 9 US qt 26 3 26 3 Maximum crankshaft end thrust kg 132 132 lb 290 290 Number of flywheel gear ring teet...

Page 89: ...eed 1500 r min with overload high speed flywheel 10 Genset Build I500 r min with overload 11 Genset Build 1800 r min with overload 12 Genset Build 3000 r min with overload 13 Genset Build 3000 r min with overload 14 Dumper Build variable speed up to 2500 r min with overload 15 Dumper Build variable speed up to 2500 r min with overload 16 Variable speed up to 2000 r min with overload sheet metal fa...

Page 90: ... to 2500 r min with overload provision for hydraulic pump 06 Variable speed up to 2500 r min 2000 r min on TR1 with overload provision for hydraulic pump 07 Variable speed up to 2500 r min 2000 r min on TR1 with overload provision for hydraulic pump 08 TR1 Genset Build 1500 r min with overload heavy flywheel TR2 3 Genset Build up to 1800 r min with overload heavy flywheel 09 Fixed speed up to 1500...

Page 91: ...load 04 Variable speed up to 2800 r min with overload 05 Variable speed up to 2500 r min with no overload 06 Variable speed up to 2500 r min with no overload 07 Variable speed up to 3000 r min with no overload 08 Variable speed up to 2800 r min with no overload 09 Fixed speed 1500 r min with no overload 10 Fixed speed up to 1800 r min with overload 11 Fixed speed up to 1800 r min with overload 12 ...

Page 92: ...arity max flywheel speed min flywheel speed mean flywheel speed Power kW r min x torque Nm 9549 bhp r min x torque lb ft 5252 Temperature The temperature unit in most practical use in any countries is the degree Celsius C however the terms Centigrade C and Fahrenheit F arestillinuse TheFahrenheitscaleisnotformally defined but it is generally recognized that the temperature difference of 1 F is equ...

Page 93: ... third column 247 244 in It is not good practice to round up the conversion factors given Length metre m inch in foot ft yard yd 1 metre 39 3701 3 2808 1 0936 1 inch 0 0254 0 0833 0 0278 1 foot 0 3048 12 0000 0 3333 1 yard 0 9144 36 0000 3 0000 1 in 25 4 mm 1 mm 0 03937 in Liquid Capacity litre l UK pint 1 pt UK gallon 2 gal US pint pt 1 litre 1 7598 0 2199 2 1134 1 UK pint 0 5683 0 1250 1 2009 1 ...

Page 94: ...ec litre per second l sec cubic foot per second ft3 sec UK gallon per second gal sec 1 m3 sec 1000 0 35 3147 219 969 1 l sec 0 0010 0 0353 0 2200 1 ft3 sec 0 0263 28 3168 6 2288 1 UK gal sec 4 5460 x 10 3 4 5461 0 1605 1 UK gallon 1 2009 US gallon Pressure Table 1 newton per square millimetre N mm2 kilogram force per square centimetre kgf cm2 pound force per square inch lbf in2 pound force per squ...

Page 95: ... x Acceleration newton N kilogram force kgf pound force lbf poundal pdl 1 newton 0 1019 0 2248 7 2230 1 kilogram force 9 8066 2 2046 70 9316 1 pound force 4 4482 0 4536 32 1740 1 poundal 0 1382 0 0141 0 0311 The kilogram is known as the kilopond kp in Germany 1 kgf m 1 kp m 1 pdl 1 lb ft s 1 N 1 kg m s Energy Table 1 kilowatt hour kWh kilogram force metre kgf m foot pound force ft lbf horsepower h...

Page 96: ...our k cal h British thermal unit Btu 1 watt 0 08598 3 4121 1 k cal h 1 1630 3 9683 1 Btu 0 2930 0 2519 Specific Fuel Consumption pounds per horsepower hour lb hp h pounds per Cherval Vapeur hour lb CV h grams per kilowatt hour g kW h grams per Cheval Vapeur hour g CV h 1 lb hp h 0 9862 608 27 447 33 1 lb CV h 1 0140 616 80 453 59 1 g kW h 1 6440 x 10 3 1 621 x 10 3 0 7354 1 g CV h 2 235 x 10 3 2 2...

Page 97: ...er Head 15 Cylinder Head Clearance 16 Cylinder Head Cover 15 D Decompressor 20 Dimensions of Wearing Parts 58 Dismantling and Rebuilding 12 Drive Belt Tension 15 E Electrical Wiring Diagrams 79 Electric Start 55 End Cover 21 End Cover Oil Seal 22 Engine Control 34 Engine Features 9 Engine Fluids 50 Excess Fuel Device 53 Excess Fuel Trip TX 32 F Fanshroud 40 Flywheel 40 Flywheel Housing 41 Formulae...

Page 98: ...ystem 23 Publications 2 Pump Timing 27 Pump Timing Gauge 28 Pump Timing Tables 28 R Rate of Flow Volume 94 Rocker Stub Shaft 17 Rotary Oil Seal 49 Routine Maintenance 56 S Safety Precautions 6 Safety Precautions and Safe Working Practices 6 Safety Symbols 8 Safe Working Practices 6 Spanner Torque Settings 57 Speed Adjustment 34 Speed Control Lever 35 Starter Battery Precautions 7 Starting 54 Start...

Page 99: ...TS TR TX engines workshop manual 99 ...

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