T SERIES

TS, TR, TX Engines

Workshop Manual

P027-08270 | edition 8 | April 2021

 TS, TR, TX engines workshop manual 2

Associated Publications
Operators Handbook P027-08185
TS, TR Master Parts Manual P027-08030
TX Master Parts Manual P027-08929
Technical Handbook P027-09212

Disclaimer
The information, specifications, illustrations, instructions and
statements contained within this publication are given with
Lister Petter Power Systems' best intentions and are believed
to be correct at the time of going to press.
Our policy is one of continued development and we reserve
the right to amend any technical information with or without
prior notice. Whilst every effort is made to ensure the accuracy
of the particulars contained within 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 of Tender and Sale, is for the assistance of users and
is based upon results obtained from tests carried out at the
place of manufacture. The Company does not guarantee that
the same results will be obtained elsewhere under different
conditions.

© Copyright Lister Petter Limited Power Systems

All rights reserved
 TS, TR, TX engines workshop manual 3

Contents

Introduction
1. General Information
1.1 Safety Precautions and Safe Working Practices 6 2.43 Flywheel Housing - TX 41
1.2 Safety Symbols 8 2.43 Main Bearing Housing 41
1.3 Engine Features 9 2.44 The Crankshaft 42
1.4 Engine Identification 10 2.45 Crankshaft End Float 44
1.5 Battery Details 10 2.46 Checking Bearing Clearance 44
2.47 Crankshaft Main Bearings 44
2.48 Gear End Drives 46
2. Engine Servicing & Adjustments 2.49 The Oil Filter 46
2.50 The Oil Dipstick 47
2.1 Preliminary Instructions 12 2.51 The Oil Sump 47
2.2 The Air Cleaner 12 2.52 The Oil Strainer and Pump 48
2.3 The Cold Start Aid 12 2.53 The Oil Seals 48
2.4 The Manifolds 13
2.5 The Air Cowling 14
2.6 The Cylinder Cooling Fins 14
2.7 The Axial Fan - TX 14
3. Engine Fluids
2.8 Drive Belt Tension 15 3.1 Engine Fluids - Lubricating Oil 50
2.9 Axial Fan Drive Guard - TX 15 3.2 Engine Fluids - Fuel 51
2.10 The Cylinder Head Cover 15
2.11 The Cylinder Head 15
2.12 Cylinder Head Clearance 16 4. Operating Instructions
2.13 The Valve Rocker Stub Shafts - TS/TR 17
2.14 The Valve Rockers - TX 17 4.1 Preliminary Instructions 53
2.15 The Valves 18 4.2 Hand Starting 54
2.16 The Valve Guides 18 4.3 Electric Starting 55
2.17 The Valve Seats 19 4.4 Stopping the Engine 55
2.18 Valve Clearance 20
2.19 The Decompressor 20
2.20 The Crankshaft Pulley - TX 21 5. Routine Maintenance
2.21 The Gear End Cover 21
5.1 Preliminary Instructions 56
2.22 The Fuel Tank 22
5.2 Routine Maintenance - Schedule Hours 56
2.23 The Fuel Filter 22
5.3 Spanner Torque Settings 57
2.24 Priming the Fuel System 23
5.4 Jointing Compounds 58
2.25 The Fuel Lift Pump 23
5.5 Dimensions of Wearing Parts 58
2.26 The Fuel Injector 24
5.5 Long Term Storage 63
2.27 The Fuel Pump 25
2.28 Fuel Pump Timing 27
2.29 Governor Modifications 29
2.30 The Governor 29 6. Troubleshooting
2.31 Setting the Governor 30 6.1 Preliminary Information 64
2.32 Governor 'G' Setting and Timing Tables 33 6.2 Method of Troubleshooting 64
2.33 Speed Adjustment 34 6.3 Troubleshooting Tables 64
2.34 The Engine Controls 34
2.35 The Fuel Pump Tappet 35
2.36 The Camshaft 35
2.37 The Camshaft Gearwheel 36 7. Dismantle & Rebuild
2.38 The Camshaft Bushes 37 TS/TR Dismantle and Rebuild 67
2.39 The Cylinder Barrel 38 TX Dismantle and Rebuild 69
2.40 The Piston and Connecting Rod 39
2.41 The Flywheel 40
2.42 The Fanshroud - TS/TR 40
 TS, TR, TX engines workshop manual 4

8. Flywheel Charge Windings 11. Conversion Factors

8.1 Charge Windings 72 11.1 Formulae 92
8.2 Syncro Charge Windings 72 11.2 Conversion Factors 93
8.3 Nicsa Charge Windings 75

12. Index
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
 TS, TR, TX engines workshop manual 5

Introduction

The purpose of this manual is to give information, operating, If Problems Occur

maintenance and repair procedures for the 'T' Series of
engines. If problems occur with your engine, or any of the Lister Petter
The manual is designed primarily for use by qualified technicians Power Systems approved accessories fitted to it, your local Lister
with electrical and mechanical experience. Petter Power Systems Distributor should be consulted.
This work can only be carried out if the necessary hand and There are Lister Petter Power Systems Distributors in most
service tools are available. When the user has insufficient tools, countries of the world and details for these can be obtained
experience or ability to carry out adjustments, maintenance and from any one of the companies listed on the back cover.
repairs then this work should not be attempted.
Where accurate measurements, or torque values, are required Using this Workshop Manual
they can only be made using calibrated instruments.
Each section title is given at the top of the relevant pages and
Under no circumstances should makeshift tools or equipment
each section has its own ‘Contents’ page.
be used, as their use may adversely affect safe working
A full cross reference 'Index' appears at the back of the
procedures and engine operation.
manual.
The specification details given apply to a range of engines and
It is recommended the individual steps contained in the various
not to any one particular engine. In cases of difficulty the user
maintenance or repair operations are followed in the sequence
should consult the local Lister Petter Power Systems Distributor
in which they appear.
or Dealer for further advice and technical assistance.
At times it may be necessary to refer to other parts of the
The information, specifications, illustrations, instructions and
section, or to a different section, for more specific or detailed
statements contained within this publication are given with
information.
our best intentions and are believed to be correct at the time of
going to press. Our policy is one of continued development
and we reserve the right to amend any technical information Caution and Warning Symbols
with or without prior notice. When an engine is operating or being overhauled there are a
Whilst every effort is made to ensure the accuracy of the number of associated practices which may lead to personal
information contained within this publication, neither the injury or product damage.
Manufacturer, Distributor or Dealer shall in any circumstances be Your attention is drawn to the symbols shown and described
held liable for any inaccuracy or the consequences thereof. below which are applied throughout this manual.
The information given is subject to the Company’s current
Conditions of Tender and Sale, is for the assistance of users and
is based upon results obtained from tests carried out at the
CAUTION
place of manufacture. This Company does not guarantee that This caution symbol draws attention to special
the same results will be obtained elsewhere under different instructions or procedures which, if not correctly
conditions. followed, may result in damage to, or destruction of,
Parts that have not been approved by the Lister Petter Power equipment.
Systems organisation cannot be relied upon for correct material,
dimensions or finish. This Company cannot therefore, be
responsible for any damage arising from the use of such parts WARNING
and the guarantee will be invalidated. This warning symbol draws attention to special
When purchasing parts or giving instructions for repairs users instructions or procedures which, if not strictly observed,
should, in their own interests, always specify Genuine Lister may result in personal injury.
Petter Parts and quote the Description of the Part and the
Engine Serial Number.
WARNING
Training
A WARNING SYMBOL WITH THIS TYPE OF TEXT DRAWS
Comprehensive training in the correct operation, service and ATTENTION TO SPECIAL INSTRUCTIONS OR PROCEDURES
overhaul procedures of engines is available at the Lister Petter WHICH, IF NOT STRICTLY OBSERVED, MAY RESULT IN
Power Systems International Product Training Centre. Please SEVERE PERSONAL INJURY, OR LOSS OF LIFE.
contact Lister Petter Power Systems for details.
Note:
A note is used to draw your attention to additional or important information.
 TS, TR, TX engines workshop manual 6

1. General Information

1.1 Safety Precautions and Safe Handling Fluids Safely

Working Practices a. When working with fuel or batteries do not smoke or work
near to heaters or other fire hazards.
At all times follow the recommended precautions and safe b. Store flammable liquids away from fire hazards.
operating and working practices. The following are of a general c. Do not expose pressurised containers to heat and do not
nature and more specific information appears where it is incinerate or puncture them.
relevant. d. Handle fuel with care and always stop the engine before
refuelling. Do not overfill the fuel tank.
Caution and Warning Symbols 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
CAUTION and clean any spills when they occur.
This caution symbol draws attention to special g. Remove any build-up of grease, oil or debris.
instructions or procedures which, if not correctly h. Batteries contain sulphuric acid - if the acid has been splashed
followed, may result in damage to, or destruction of, on the skin, eyes or clothes flush it away with copious
equipment. amounts of fresh water and seek medical aid.

Personal Safety
WARNING
a. Tie long hair close to your head.
This warning symbol draws attention to special
b. Do not wear a necktie, scarf, loose clothing or necklace when
instructions or procedures which, if not strictly observed,
working close to a running engine.
may result in personal injury.
c. It is advisable to remove rings and other jewellery to prevent
possible entanglement in moving parts.
These items could also cause an electric short circuit if any
WARNING part of the electrical system is being worked on.
A WARNING SYMBOL WITH THIS TYPE OF TEXT DRAWS d. Ensure any lifting equipment to be used has the correct
ATTENTION TO SPECIAL INSTRUCTIONS OR PROCEDURES capacity to lift the engine.
WHICH, IF NOT STRICTLY OBSERVED, MAY RESULT IN e. Lifting equipment must be designed to give two vertical lifts
SEVERE PERSONAL INJURY, OR LOSS OF LIFE. from directly above the engine lifting eyes.
f. The engine lifting eyes fitted to the engine are suitable for
lifting the engine and accessory assemblies originally fitted
Follow All Safety Instructions by Lister Petter. They must not be used to lift the complete
a. Carefully read all safety messages in this manual and the plant.
safety and informative symbols on your engine and plant. g. Do not work under any plant that is only held by overhead
b. Starting any diesel engine can be dangerous in the hands of lifting equipment.
inexperienced people. Engine operators must be instructed
in the correct procedures before attempting to start any Personal Protective Clothing & Equipment
engine.
a. Wear close fitting clothing and personal protective clothing
c. Do not make any unauthorised modifications as these may
and safety equipment appropriate to the work being done.
affect the safe operation of the engine and put the operator
b. Wear suitable ear protection to protect against objectionable
at risk.
or uncomfortable loud noise.
d. Ensure all starting devices are removed, or isolated, before
Prolonged exposure to loud noise can cause impairment, or
commencing any work on the engine or plant.
loss of hearing.
c. The use of music or radio headphones could cause a loss of
Emergency Considerations concentration.
a. Be prepared with suitable equipment, and knowledge, in
case a fire starts. Handling Chemical Products Safely
b. Know where to make calls to the emergency services from.
a. Direct exposure to hazardous chemicals can cause serious
c. Ensure a third party knows where you are working and when
injury.
you leave the working area.
b. Potentially hazardous chemicals include such items as
lubricants, fuel, coolant concentrate, battery acid, paint and
adhesives.
 TS, TR, TX engines workshop manual 7

c. Manufacturers Safety Data Sheets will provide specific details d. Never flash any connection to check the current flow or
of the physical and health hazards, safety and emergency experiment with any adjustments or repairs to the system.
procedures and any necessary personal protection equipment e. The battery and alternator/charge windings must be
required while working with hazardous materials. disconnected before commencing any electric welding
when a pole strap is directly or indirectly connected to the
Rotating Machinery engine.
f. Starting engines that are fitted with charge windings which
a. Entanglement with any rotating equipment can cause serious have been disconnected from the batter will cause irreparable
injury or death. damage unless the stator leads from the rectifier/regulator
b. If unprotected skin comes into contact with rotating have been removed.
equipment severe burns can result.
Starter Battery Precautions
Safe Maintenance Considerations
a. Understand the service procedures before commencing WARNING
any work. Sulphuric acid in battery electrolyte is poisonous, is
b. Ensure the work area is clean, dry, well ventilated and has strong enough to burn skin, eat holes in clothing and
adequate lighting. cause blindness if splashed into the eyes.
c. Isolate the engine starting system before commencing any
work on the plant.
d. All persons using equipment or processes in connection with a. Do not smoke near the batteries and keep sparks and flames
the maintenance of plant and machinery must have received away from them.
adequate and suitable training. b. Batteries contain sulphuric acid - if the acid has been splashed
on the skin, eyes or clothes flush it away with copious amounts
of fresh water and seek immediate medical aid.
High Pressure Fluids c. Keep the top of the battery well ventilated during charging.
a. Never allow any part of the body to come into contact with Switch off the battery charger before connecting or
high pressure hydraulic oil, compressed air or fuel oil, for disconnecting the charger leads.
example when testing fuel injection equipment. d.Disconnect the battery negative (earth) lead first and
b. Both digested and ingested fluids can lead to serious injury, reconnect last.
possibly with fatal results in a very short period of time. e. Never 'flash' connections to check current flow.
f. A damaged or unserviceable battery must never be used.
Electrical System Considerations g. Do not attempt to charge a frozen battery; it may explode;
warm the battery to 16°C (60°F).
a. Ensure that the battery is of sufficient capacity to start the
engine down to its minimum operating temperature taking
into account any drag that may be imposed on the engine
Asbestos Dust
by the type of transmission that is attached to it. a. Avoid breathing dust that may be generated when handling
b. Ensure the battery and all engine wiring cables are of components containing asbestos fibres. Inhaled asbestos
sufficient size to carry the currents required. fibres may cause lung cancer.
c. Check that the engine mounted alternator is of sufficient b. Components that may contain asbestos include brake pads,
output to cope with the total electrical load required by the brake band and lining assemblies, clutch plates and some
machine to which it is fitted. gaskets.
d. Ensure engine wiring cables are: The asbestos in these products is usually found in a resin or
Bound together in a loom and adequately supported. Routed it is sealed.
to avoid any hot surfaces, particularly the exhaust system. Not Normal handling is not hazardous as long as airborne dust
in contact with any rough surfaces or sharp corners so as to containing asbestos is not generated.
avoid any possibility of chaffing taking place.
Oil Seals Containing Viton
Alternator / Charge Windings Precautions Some engines may be fitted with seals or 'O' rings manufactured
a. Never remove any electrical cable while the battery is from 'Viton' or a similar material.
connected in the circuit. When exposed to abnormally high temperatures, in excess of
b. Only disconnect the battery with the engine stopped and all 400°C (752°F), an extremely corrosive acid is produced which
switches in the OFF position. cannot be removed from the skin.
c. Ensure cables are fitted to their correct terminals. A short If signs of decomposition are evident, or if in doubt, always wear
circuit or reversal of polarity will ruin diodes and transistors. disposable heavy duty gloves.
Never connect a battery into the system without checking
that the voltage and polarity are correct.
When exposed to abnormally high temperatures, in conditions. Wash them before and after use and
excess of 400°C (752°F), an extremely corrosive acid wrap them up when not required, or fill the tank
is produced which cannot be removed from the skin. direct from a small mouthed screw capped fuel can.
i.The fuel injection TS, TR, TX engines workshop
equipment manual
is manufactured to 8
If signs of decomposition are evident, or if in doubt,
always wear disposable heavy duty gloves. very accurate limits and the smallest particle of dirt
will destroy its efficiency. Fuel free from water and
Fuel Fuel
System Precautions
System Precautions contaminants is of equipment
i. The fuel injection the utmost importance.to very accurate
is manufactured
a.When priming or checking the limits and the smallest particle of dirt will destroy its efficiency.
a. When priming or checking thefuel
fuelinjection pumptiming,
injection pump Fuel free from waterFilters
and contaminants is of the utmost
timing,carecaremustmust be taken
be taken to wipe
to wipe spilledspilled
fuel fromfuel
the outsidePrecautions
from of importance.
for Oil, and Elements
the outside
the engine.of the engine. a.Used liquid filters and elements contain some
b.Always fit afitnew
b. Always a newjoint whena union
joint when a union has disturbed.
has been been of the filtered liquid and should be handled and
c. Special care must be taken to see that there is no leakage from Precautions for Oil, Filters and Elements
disturbed. disposed of with care.
the joints of the fuel pipe connection to the pump.
c.Special care must be taken to see that there is no b.Aftera. Used handlingliquid filters
new and elements
or used contain some
elements the of the filtered
users
d. When tightening or loosening the fuel injection pump liquid and should be handled and disposed of with care.
leakage fromconnections,
the joints ofuse the fuel pipe connection hands should be thoroughly washed, particularly
delivery two spanners to prevent the un- b. After handling new or used elements the users hands should
to thesealing
pump.of the fuel pump delivery valve holders. beforebeeating.
thoroughly washed, particularly before eating.
d.When tightening or loosening the fuel injection
e. When refitting the fuel pipe from the pump to injector, the c.Fuel c.and
Fuel new or used
and new lubricating
or used lubricating oil oil
may may cause
cause skin
pumpconnection
delivery connections,
to the injector use musttwo spannersbefore
be tightened to theskin irritation.
irritation.
prevent connection to the fuelof
the un-sealing pump.
the fuel pump delivery Contact
Contact withwithused
usedlubricating
lubricating oiloilcan
can cause
cause cancer,
cancer, birth defects
This
valve holders. procedure will ensure that there is no leakage frombirth or other
defects reproductive
or other harm.
reproductive harm.
these joints.
e.When refitting the fuel pipe from the pump to d.Thed. materials
f. It is most important that all fuel joints are tight and leak
The materials used usedin the
in manufacture
the manufactureand treatmentandof some
filters and elements may cause irritation or discomfort if they
injector,
proof.the connection to the injector must be treatment of some filters and elements may cause
come into contact with the eyes or mouth and they may give
tightened
g. Always before
fill thethe
fuelconnection
tank through atofine thestrainer, preferably atirritation
fuel pump. or discomfort
off toxic gasses if theyifare
they
burnt. come into contact
This procedure
the end of the willengine
ensure workthat there is no leakage
period. with e. Extreme care must be taken to may
the eyes or mouth and they ensuregive
thatoff toxic
waste oil, filter
from these joints. is stirred up during the process this has timegasses
If any sediment if they are
elements, burnt.
solvents or other toxic wastes are disposed
to settle
f.It is most before the
important thatengine is used
all fuel jointsagain,
are this
tightwill
andminimise
e.Extreme of in care must with
accordance be taken to ensure to
local regulations that
prevent
the risk of condensation contaminating the fuel. If cans arewastecontamination. oil, filter elements, solvents or other toxic
leak proof.
used, avoid tipping out the last few drops. f. As a direct result of combustion the lubricating oil may contain
g.Always fill the
h. Funnels arefuel tank through
very difficult a fine
to keep clean strainer,
in dusty conditions.
wastes are disposed of in accordance with local
harmful acids and therefore it should not be left in the sump
preferably
Wash themat the endand
before of the
afterengine workthem
use and wrap up when notregulations
period. to prevent contamination.
if it is known that the engine will not be used for extended
If anyrequired,
sediment is stirred up during the process
or fill the tank direct from a small mouthed screw f.As a direct
periods. result of combustion the lubricating oil
this hascappedtimefuel tocan.
settle before the engine is used may contain harmful acids and therefore it should
again, this will minimise the risk of condensation not be left in the sump if it is known that the engine
will not be used for extended periods.
1.2 Safety Symbols
1.2 SAFETY SYMBOLS
This section identifies the ISO 8999 symbols currently used by Lister Petter Power Systems.
This section identifies the ISO 8999 symbols currently used by Lister Petter Power Systems.

8
 TS, TR, TX engines workshop manual 9

T SERIES ENGINES WORKSHOP MANUAL

1.3 Engine Features

1.3 ENGINE FEATURES

TS/TR1 TS/TR2

TS/TR3 TX2

TX3

9
 with a minimum voltage at the end of the cranking
Nomenclature period of 8.4 volts (16.8 volts on a 24 volt system).
TS and TR - one, two and three cylinder, direct
injection, naturally aspirated flywheel fan air cooled Preparing a Battery for Use
TS, TR, TX engines workshop manual 10
diesel engines. The following procedure should be used to prepare a
TX - two and three cylinder, direct injection, naturally battery with factory sealed charge.
aspirated, axial fan air cooled diesel engines. 1.Where necessary remove the flash seal in each
vent plugahole.
1.4 Engine Identification
Engine Serial Number
Preparing Battery for Use
2.Fill with battery grade sulphuric acid of specific
The following procedure should
for be used to prepare a- battery
Nomenclature
The engine serial number is stamped on a plate gravity 1.260
withNote).
factoryThesealed
(1.200
charge.
tropical climates see
attached to the engine. temperature of this acid should not be
TS and TR - one, two and three cylinder, direct injection, naturally 1. Where necessary removebefore
the flash seal in each vent plug hole.
It is necessary to identify the type and build of above 30°C (90°F) filling. The correct level
aspirated flywheel fan air cooled diesel engines. 2. Fill with battery grade sulphuric acid of specific gravity 1.260
each engine to enable the correct maintenance is 6mm (0.25in) above the separator guards.
TX - two and three cylinder, direct injection, naturally aspirated, (1.200 for tropical climates - see Note). The temperature of this
procedures, as described later in this publication, 3.Stand the filled battery for one hour and adjust
axial fan air cooled diesel engines. acid should not be above 30°C (90°F) before filling. The correct
to be carried out. the acid to the correct level by adding more acid
level is 6mm (0.25in) above the separator guards.
An example number is shown below. where thenecessary.
Engine Serial Number 3. Stand
4.Charge
filled battery for one hour and adjust the acid to
the battery at more
6-12 acid
amps for anecessary.
minimum
03 001234 TS3 A 01 the correct level by adding where
The engine serial number is stamped on a plate attached to period of 4 hours.
4. Charge the battery at 6-12 amps for a minimum period of
03........................................ Year code (03 = 2003)
the engine. 45.At the end of this charge period the specific gravity
hours.
001234...............................
It is necessary to identify the type and build Unique engine
of each number
engine to of the
5. At the end acid in any
of this cellperiod
charge should thenot be less
specific thanof1.260
gravity the acid
TS3
enable the ...................................................Engine
correct maintenance procedures, as described later series (1.200 for tropical climates).
in any cell should not be less than 1.260 (1.200 for tropical
A .........................................
in this publication, to be carried out. Anti clockwise rotation If the specific gravity readings are uneven or the
climates).
01...................................................... Build number specific
If the gravity
specific gravitylow, continue
readings charging
are uneven or until two
the specific
An example number is shown below. consecutive
gravity half hourly
low, continue readings
charging of specific
until two gravityhalf
consecutive
1.5 BATTERY
03 001234 TS3 A 01 DETAILS and charge
hourly readingsvoltage aregravity
of specific approximately
and charge thevoltage
same.are
approximately
Discontinuethe same. and allow the battery to cool
charging
WARNING
03........................................Year code (03 = 2003) Discontinue charging and
if the temperature risesallow
above the40°C
battery to cool if the
(110°F).
001234...............................
Battery posts, terminals Unique engine number
and related accessories temperature rises above 40°C (110°F).
contain lead and lead compounds, chemicals Note:
TS3 ...................................................Engine series
A ......................................... Anti clockwise rotation
known to the State of California to cause cancer Note: Tropical climates apply to those countries or
01...................................................... Build number Tropical climates apply to those countries or areas where the average temperature of
and reproductive harm. Wash hands after areas where the average temperature of any
anymonth
month of theofyear
theexceeds
year27°Cexceeds
(80°F). 27°C (80°F).
handling.
1.5 Battery Details
WARNING Connecting
ConnectingBatteries
Batteries
Sulphuric acid in battery electrolyte is poisonous, It is
WARNING It most
is most important
important to ensure
to ensure that
that the the battery,
starter starter or
is strong enough to burn skin, eat holes in batteries, battery,are
or batteries,
properly are properly
connected andconnected
all and allare
connections
Battery posts, terminals and related accessories contain
clothing and cause blindness if splashed into tight. connections are tight.
lead and lead compounds, chemicals known to the State
the eyes.
of California to cause cancer and reproductive harm.
Wash hands after handling.
Battery Polarity
All electric start engines have a 12 or 24 Volt
negative earth system and a 12 Volt flywheel
WARNING
mounted charging system is available for some TS
Sulphuric acid in battery electrolyte is poisonous, is
and TR engine builds.
strong enough to burn skin, eat holes in clothing and
cause blindness if splashed into the eyes. Figure 1.5.1
Recommended Battery Type Figure 1.5.1Battery Connections
Battery Connections
A - 12 volt system using four 6 volt batteriesbatteries
A - 12 volt system using four 6 volt connected connected in
in series-parallel;
Heavy Duty Batteries to BS3911:982 or IEC95-1 are series-parallel; B -using
B - 12 volt system 12 volt
twosystem using connected
6 volt batteries two 6 voltinbatteries
series.
Battery Polarity for all engine applications.
recommended connected in series.
Forstart
temperatures below
a 12-18°C
or 24(0°F), high discharge,
All electric
low
engines have
resistance Arctic or
Volt negative
Alkaline batteries
earth Connecting a Slave Battery
mustis be Connecting a Slave Battery
system and a 12 Volt flywheel mounted charging system
availableused.
for some TS and TR engine builds. A slave, or booster
A slave, battery can
or booster be connected
battery can be in parallel withinthe
connected
Lister Petter Power Systems recommend that a parallel with the existing battery to aid conditions.
existing battery to aid starting in cold weather starting in
battery should provide a minimum cranking period cold weather conditions.
Recommended Battery Type
WARNING
Heavy Duty Batteries to BS3911:982 or IEC95-1 are recommended
Heavy duty jumper leads must always be used and no
for all engine
10 applications. attempt must be made to use any others.
For temperatures below -18°C (0°F), high discharge, low
resistance Arctic or Alkaline batteries must be used.
Lister Petter Power Systems recommend that a battery should
provide a minimum cranking period of 60 seconds from a WARNING
70% charged 12 volt battery, with a minimum voltage at the Do not allow the jumper lead free ends to directly, or
end of the cranking period of 8.4 volts (16.8 volts on a 24 volt indirectly touch the engine at any time.
system).
 TS, TR, TX engines workshop manual 11

1. Connect one end of the jumper lead to the positive (+) post The battery electrolyte level should be checked every 500 hours
of the slave battery. and distilled water added, if necessary, to bring the level to the
2. Connect the other end of the jumper lead to the positive (+) bottom of each filler neck.
post of the battery connected to the starter motor. Keep the battery clean by wiping it with a damp cloth. If the
3. Connect one end of the jumper lead to the negative (-) post terminals or battery posts are corroded wash them with a
of the slave battery. solution of 1 part baking soda to 4 parts of water.
4. Make the final connection of the negative (-) cable to a good To help reduce corrosion coat the battery terminals or posts
earth on the engine frame and away from all the batteries. with petroleum jelly and baking soda.

Disconnecting a Slave Battery Battery Cold Cranking Performance

1. Start the engine. The cold cranking battery performance rating figures given
2. Disconnect the slave battery negative (-) jumper lead first. relate to the cranking current required from a starter battery
3. Disconnect the remaining jumper leads. when tested at -18°C (0°F) and not the current available from the
battery at the engine operating ambient temperature stated.
Servicing a Battery This is in accordance with BS3911 Part 2 and lEC95-1.
To use the table:
In freezing weather conditions, run the engine for at least 30 1. Select the system voltage and ambient temperature range.
minutes to ensure thorough mixing after adding distilled water 2. Read off the value in Amps.
to the battery. 3. Refer to a battery catalogue for the battery required.

Ambient Temperature Range

Model
Volts Above 27°C (80°F) 26° to 1°C (79°-34°F) 0° to -8°C (32°-18°F) -9° to -18°C (16°-0°F)
12 120A 135A 180A 285A
TS1
24 65A 75A 115A 185A
12 122A 157A 220A 365A
TS2
24 122A 150A 205A 320A
12 142A 187A 265A 445A
TS3
24 135A 165A 238A 385A
12 120A 135A 180A 300A
TR1
24 68A 82A 120A 195A
12 135A 165A 238A 385A
TR2
24 125A 155A 210A 335A
12 150A 187A 265A 485A
TR3
24 140A 172A 238A 400A
TX2 12 102A 150A 228A 420A
12 142A 187A 295A 540A
TX3
24 108A 127A 170A 315A

Notes: Battery Charging

The recommendations made assume that the engine is filled with the recommended
type and grade of lubricating oil and is not required to start against high inertia loads Battery charging is by means of the alternator, flywheel
such as concrete mixers, tar boilers, hydraulic pumps, screw pumps and similar. In mounted charge windings or a remote mounted charger.
these applications, wherever possible, means should be provided to overcome such Before attempting to charge the starter battery, on engines
loads by the inclusion of clutches and unloading valves, etc. Heavy Duty Batteries fitted with charge windings or an alternator, the regulator/
are recommended for all applications and for temperatures below -18°C (0°F). high rectifier, or alternator, must be disconnected from the starter
discharge, low resistance Arctic or Alkaline batteries must be used. battery.
Failure to do this will result in discharge of the starter battery
and/or damage to the regulator/rectifier.
Too little charging can be indicated by the specific gravity being
frequently below 1230.
Too much charging is indicated by the specific gravity of the
acid being generally at the fully charged value of 1270 to 1290
and by unusually frequent topping-up being necessary.
 T SERIES ENGINES WORKSHOP MANUAL

TS, TR, TX engines workshop manual 12

2. ENGINE SERVICING & ADJUSTMENTS
2.1 PRELIMINARY INSTRUCTIONS the flexible element.
Care must be taken to ensure all joints are kept air
2. Engine Servicing & Adjustments
WARNING tight.
Maintenance must be performed by qualified The standard air cleaner is fitted to the air manifold
persons who are conversant with the hazards adaptor by a jubilee clip. Access to the paper
of fuels, electricity and machinery.
2.1 Preliminary Instructions The
element
Care must beistaken
standard
gained
air centre
by undoing
to ensure
cleaner of
theare
all joints
is fitted
cruciform
to thebody
headed
kept air tight.
air manifold adaptor
screw in the the main of the the filter by
WARNING a jubilee
casing.clip.
If Access to the paper
the element element
is found to beis dirty
gained by undoing
it must be
WARNING
BEFORE COMMENCING ANY WORK ON THE thereplaced.
cruciform headed screw in the centre of the main body of
ENGINE,
Maintenance must PARTICULARLY WHEN
be performed by qualified WORKING
persons the the filter casing. If the element is found to be dirty it must
who areWITH ENGINE
conversant FLUIDS,
with the READ
hazards of 1.1 SAFETY
fuels, electricity be replaced.
The Cyclonic Air Cleaner
and machinery.
PRECAUTIONS AND SAFE WORKING The air cleaner can be engine or remote mounted. It
PRACTICES. The Cyclonic
should Air Cleaner
be cleaned daily under very dusty operating
Theconditions andbeas
air cleaner can enginespecified
or remotein mounted.
"5.4 Routine
It should
WARNING
Dismantling and Rebuilding beMaintenance - schedule
cleaned daily under hours".
very dusty operating conditions and as
beforeWhen the engine
commencing anyiswork
beingondismantled
the engine, all items specified
The airincleaner mounting
"5.4 Routine bracket- schedule
Maintenance bolts arehours".
torqued
must be when
particularly identified and retained
working in theirfluids,
with engine respective Thetoair21.0Nm (15.5lbf ft).
cleaner mounting bracket bolts are torqued to 21.0 Nm
cylinder
read 1.1 safetyorientation andand
precautions all safe
related components (15.5lbf
working 1.Release
ft). the cover clips and remove the end
must be treated similarly.
practices. cap. the cover clips and remove the end cap.
1. Release
The instructions given deal with individual
components and it may be necessary to remove
Dismantling and Rebuilding
others before the relevant instructions can be
When the carried
engineout.is being dismantled all items must be
identified and retained inortheir
a.Disconnect respective
isolate any cylinder orientation
non-electric starting
and all related components must be treated similarly.
systems.
The instructions
b.Disconnectgiven deal
and with individual
remove components and
the battery.
it may bec.Drain the diesel fuel and lubricatingthe
necessary to remove others before oil.relevant
instructions can be carried out.
d.Disconnect all services.
a. Disconnect
e.Removeor isolate
anyanyaccessories
non-electric starting systems. that
or components
b. Disconnect and remove the battery.
may be susceptible to damage when the engine
c. Drain the diesel fuel and lubricating oil.
is turned out of its normal plane.
d. Disconnect all services.
Because of the various engine configurations, and Figure 2.2.1
e. Remove any accessories or components that may be Figure 2.2.1Cyclonic Type
Cyclonic Type AirAir Cleaner
Cleaner
installations in which the engine can be fitted, it is
susceptible to damage when the engine is turned out of its
normalnot possible to give detailed instruction for each
plane. 2.Remove
2. Remove the outer
the outer elementelement (A) or
(A) and clean and clean
replace it or
one.
Because of the various engine configurations, and installations as replace it as necessary.
necessary.
in whichWhen assembling
the engine the engine,
can be fitted, it is notuse the same
possible type
to give 3.Replace
3. Replace the element.
the element.
of lubricating oil as
detailed instruction for each one. used in the engine to spray all 4.Replace
4. Replace the with
the cover cover with
the inlet thedownwards.
facing inlet facing
moving parts during assembly. All
When assembling the engine, use the same type of lubricatingbearings and downwards.
bushes
oil as used in themust be well
engine lubricated
to spray during
all moving assembly.
parts during Note:
assembly.Renew all joints,
All bearings andgaskets, connecting
bushes must be well rod nuts and
lubricated AfterNote:
the outer element (A) has been cleaned three times the inner element (B) must
bolts and the cylinder head bolts.
during assembly. After No
be replaced. the outer
attempt mustelement (A)thehas
be made to clean innerbeen
element.cleaned
Renew all joints, gaskets, connecting rod nuts and bolts and three times the inner element (B) must be
the cylinder head bolts.
2.2 THE AIR CLEANER replaced.
2.3 No attempt
The Cold Startmust
Aid be made to clean
the inner element.
Inlet Manifold Loading
2.2 The Air Cleaner
A conventional air cleaner may be mounted direct
TS and TR Engines
on the manifold,
Inlet Manifold Loading
2.3 THE COLD START AID
or on a light extension which must The cold starting aid may be fitted to the combustion air intake
be no more than 152mm (6ins) long. ports
TSandandis TR
usedEngines
when the ambient temperature is below
A conventional
Heavy airair cleaners
cleaner may be be
must mounted direct
remotely on the or -10°C (14°F).
mounted, The cold starting aid may be fitted to the combustion
manifold,mounted
or on a light
on extension which mustabespecial
no morebracket,
than 1. air
Withintake
the fuel turned
the engine using ports and on, turn the
is used engine
when the for up to 20
ambient
152mm (6ins) long.
and connected by means of flexible pipe or hose, revolutions to prime the fuel and lubrication systems.
temperature is below -10°C (14°F).
Heavy airwith
cleaners mustextensions
no solid be remotelybetween
mounted,the
or mounted
manifoldonand 2. Withdraw the plunger (A) and fill one third of the cup (B) with
the engine using a special bracket, and connected by means 1.With the fuel turned on, turn the engine for up to
the same type of lubricating oil as used in the engine.
of flexible pipe or hose, with no solid extensions between the
manifold and the flexible element.
13
 20 revolutions to prime the fuel and lubrication Heavy exhaust silencers and air cleaners must
systems.
20 revolutions to prime the fuel and lubrication be
Heavyremotely mounted,
exhaust or mounted
silencers on the engine
and air cleaners must
2.Withdraw
systems. the plunger (A) and fill one third of the using a special
be remotely bracket,orand
mounted, connected
mounted on by engine
the means
TS, TR, TX engines workshop manual 13
cup (B) with
2.Withdraw thethe same(A)
plunger type
andoffilllubricating oil the
one third of as of flexible
using pipe bracket,
a special or hose, and
withconnected
no solid extensions
by means
used in the
cup (B) withengine.
the same type of lubricating oil as between
of flexiblethe manifold
pipe andwith
or hose, the flexible
no solidelement.
extensions
used in the engine. All joints must
between be gas tight.
the manifold and the flexible element.
All joints must be gas tight.
WARNING
WARNING
EXHWARNING
A U S T GASSES
EXHAUST G A S SCONTAIN
E S C O CARBON
N TA I N MONOXIDE
C A R B O NWHICH
MONOXIDE
EXH A U S T GWHICH
A S S E S IS
C OAN COLOURLESS,
TA I N C A R B O NGAS
IS A COLOURLESS, ODOURLESS AND POISONOUS
ODOURLESS
MONOXIDE AND
WHICH
THAT CAN CAUSE POISONOUS GAS THAT
IS A COLOURLESS,
UNCONSCIOUSNESS CAN
AND DEATH.
CAUSE UNCONSCIOUSNESS
ODOURLESS AND POISONOUS AND
GASDEATH.
THAT CAN
CAUSE UNCONSCIOUSNESS AND DEATH.
CAUTION
CAPTION
CAUTION
Detrimental damage to the engine, or loss of
Detrimental
performance,
Detrimental damage
may
damage be toto the
theengine,
caused or loss
if exhaust
engine, of of
gasses
or loss
are performance,
sucked in may may
by the be caused if exhaust gasses are
performance, beair cleaner
caused or the fan.
if exhaust gasses
sucked in by the air cleaner or the fan.
Figure 2.3.1 Cold Start are
The sucked
exhaustin by the is
manifold airmade
cleaner or the
of cast ironfan.
and the
Figure
Figure2.3.1 ColdStart
Start inlet
TheThe manifoldmanifold
exhaust of light alloy, bothofare secured to the
exhaust manifold isismademade cast
ironiron and
2.3.1 Cold
3.Replace the plunger and inject the oil just before inlet of cast and the inlet manifold
cylinder
of lighthead
manifoldalloy,on
of studs
light
both are and
alloy, nuts
both
secured which
are
to the are
secured
cylindertorque
to theon studs
head
starting
3.Replace
3. Replace thethe
the engine.
plunger
plunger and and
injectinject thejust
the oil oil before
just before
starting loaded.
cylinder head on studs and nuts which are torque
and nuts which are torque loaded.
starting
the engine.the engine. Bolted to to
thetheside
CAUTION loaded.
Bolted sideofofthe
the exhaust manifold isisthe
exhaust manifold thestandard
standard
Bolted to exhaust
the side silencer
of the which
exhaust has provision
manifold is forpipe or a
the
The CAUTION
device must not be used more than three fitting exhaust silencer which has provision for fitting a tail
CAPTION
times in succession
The device must notduring
be used the more
same thanattempt
standard a tail
lightweight pipe
exhaust or
extension;a
silencerlightweight
whichofhas
the outlet
to outlet of the silencer tail pipe must face away from
three
extension;
theprovision the
silencer tailfor
pipe must
The device must not be used more than three times into fitting
face a tail
away pipe
from or
the a lightweight
engine. extension; the
start
times the engine.
in succession during the same attempt
succession during the same attempt to start the engine. the outletengine.
of the silencer tail pipe must face away from
start the engine. theRemoving
engine.
TX Engines the Manifolds - TS/TR
Removing the Manifolds - TS/TR
TXThe
Engines
TX Engines
TX inlet manifold may have a cold weather 1. Remove the air cleaner and exhaust silencer.
Removing
1.Remove thethe
air Manifolds - TS/TRsilencer.
cleaner and exhaust
glowplug fittedmanifold
The TX inlet and caremay
must be taken
have a coldtoweather
ensure 2. Remove the nuts, spring washers and distance pieces.
2.Remove the the air
nuts, spring washers
The TX inlet manifold may have a cold weather glowplug fitted 1.Remove cleaner and exhaustand distance
silencer.
the battery is and
glowplug isolated and the taken
cable toremoved 3. Unscrew and remove the cold start pots, if fitted.
and care mustfitted care
be taken to must
ensure thebebattery ensureand
is isolated pieces. the nuts, spring washers and distance
2.Remove
before
the attempting
battery is to remove
isolated and the
the manifold
cable from
removedthe 4. Remove the manifolds.
the cable removed before attempting to remove the manifold 3.Unscrew
pieces. and remove the cold start pots, if fitted.
engine.
before attempting to remove the manifold from the 4Remove
from the engine. 3.Unscrewthe andmanifolds.
remove the cold start pots, if fitted.
The
engine.glowplug is energised during the starting
The glowplug is energised during the starting sequence by Refitting the
4Remove the manifolds. Manifolds - TS/TR
thesequence
The key. by theisstart
start glowplug key.
energised during the starting
Refitting
1. Fit newthe Manifolds
gaskets if necessary.- TS/TR
sequence by the start key.
Refitting
2. Refit
1.Fit new thethe Manifolds
manifolds
gaskets - TS/TR
and torque
if necessary. the nuts to:
1.Fit Top
2.Refitnew nuts
the - 21.0Nm
manifolds
gaskets (15,5lbf
and ft). the nuts to:
torque
if necessary.
2.RefitBottom
the nuts
nuts --9.0Nm
Topmanifolds 21.0Nm
and (6.5lbf ft). theft).
(15,5lbf
torque nuts to:
Bottom
Top nutsnuts - 9.0Nm
- 21.0Nm (6.5lbfft).
(15,5lbf ft).
Removing the -Manifolds
Bottom nuts 9.0Nm (6.5lbf - TXft).
Removing theairManifolds
1. Remove the - TX
cleaner and silencer
Removing
1.Remove thethenuts
air
2. Remove the Manifolds
and spring -washers
cleaner and TX retaining the exhaust
silencer
2.Remove
1.Remove
manifoldtheand
the nuts
air itand
cleaner
lift off. spring washers retaining
and silencer
the
2.Remove exhaust
3. Remove the manifold
thenuts
axial andfanand lift it washers
airspring
cowling. off. retaining
3.Remove
the the manifold
4. Ifexhaust axial
a glowpiug fan and
is fitted air cowling.
removelift itthe
off.cable.
4.If5.a Remove
3.Remove glowpiug is nuts
thethe
axialfitted
fan remove
airspring
and cowling.the cable.retaining the inlet
washers
Figure 5.Remove
4.If amanifold theand
glowpiug nuts
is lift itand
fitted off. springthe
remove washers
cable. retaining
Figure2.3.2 TXGlowplug
2.3.2 TX Glowplug
Figure 2.3.2 TX Glowplug
the inlet manifold and lift it off.
5.Remove the nuts and spring washers retaining
Refitting
the the Manifolds
inlet manifold and lift it off. - TX
2.4The
2.4 THE MANIFOLDS
Manifolds Refitting
2.4 THE MANIFOLDS 1. Fit newtheinletManifolds - TX gaskets.
and exhaust manifold
Manifold Loading Refitting
1.Fit new the
inlet Manifolds
and exhaust - TX gaskets.
manifold
2. Refit the inlet and exhaust manifolds and torque the nuts to:
Manifold
Manifold
A Loading
Loading
small, light exhaust silencer may be mounted 2.Refit the-inlet
1.Fit Inlet
new inletand
and exhaust
exhaust manifolds and torque
13.5Nm (10.0lbf ft). manifold gaskets.
direct
A on
small, the manifold,
light exhaust or on a light
silencer extension
may be which
mounted theExhaust
A small, light exhaust silencer may be mounted direct on the 2.Refit nuts
the to:
inlet and exhaust
- 21.0Nm manifolds and torque
(15.5lbf ft).
must
directbe
manifold, or no
on theamore
on light than
manifold, 152mm
or onwhich
extension (6ins)
a light
must long.
extension which
be no more than the Inlet
nuts
3. Replace - 13.5Nm
to:the glowpiug (10.0lbf
cable. ft).
must (6ins)
152mm be nolong.
more than 152mm (6ins) long. Exhaust
Inlet the
4. Replace - 21.0Nm
- 13.5Nm
axial (15.5lbf
fan(10.0lbf ft). ft).
air cowling.
Heavy exhaust silencers and air cleaners must be remotely Exhaust - 21.0Nm (15.5lbf ft).
14
mounted, or mounted on the engine using a special bracket,
14
and connected by means of flexible pipe or hose, with no solid
extensions between the manifold and the flexible element.
All joints must be gas tight.
 T SERIES ENGINES WORKSHOP MANUAL

3.Replace the glowpiug cable. TS, TR, TX engines workshop manual 14

4.Replace the axial fan air cowling. T SERIES ENGINES WORKSHOP MANUAL

2.5 THE AIR COWLING

2.5 The
Three AirofCowling
3.Replace
sides
the glowpiug cable.
the engine are encased in an air
4.Replace the axial fan air cowling.
cowlsides
Three andoftwo
thesides
engineshields, whichintogether
are encased an air cowl with thetwo
and
airshields,
sides baffle(s) direct
which cooling
together withair
thefrom the flywheel
air baffle(s) fan
direct cooling
from 2.5
airaroundthethe THE
flywheel AIR
fan
cylinders. COWLING
around the cylinders.
Three sides of the engine are encased in an air
Removing
Removingcowl and the two
the Air Air Cowling
sides shields,
Cowling - TS/TR
which
- TS/TR together with the
1.Removeair baffle(s)
the cold direct
start cooling
pots if air from the flywheel fan
fitted.
1. Remove the cold start pots if fitted.
2.Drain around the cylinders.
2. Drain thethe fuelfueland and remove remove the engine
the engine mounted mounted
fuel tank,
fuel tank, if fitted.
if fitted. 6.Remove the gear end air shield; it may be
3.Remove
3. Remove Removing
the thegeargearendthe end
air Air
air Cowling
shield shield
by removing - TS/TR
by removing the
the setscrews, necessary to slacken the axial fan before the
spring 1.Remove
setscrews,
washersspring and the cold
washers
plain start and
washers pots if fitted.
plain
in the topwashers
plate and in air shield can be removed.
the 2.Drain
cowling. top platethe and fuelair and remove the engine mounted
cowling. 6. Remove the gear end air shield; it may be necessary to slacken
fuel tank, if fitted. The the 6.Remove
AiraxialBaffles the gear end air shield; it may be
fan before the shield can be removed.
3.Remove the gear end air shield by removing the necessary
The air baffles are to slacken
fitted betweenthe axial thefancylinder
before the
setscrews, spring washers and plain washers barrels in shield can be removed.
the top plate and air cowling. Theand Air extreme
Baffles care must be taken to ensure
they do not totally block the air flow when they are
The
refitted. The Air Baffles
air baffles are fitted between the cylinder barrels and
Theextreme
The air
baffles care must
canbaffles be are
be removed takenfitted
to ensure
for they
between
cylinder findo not totally
the
cleaningcylinder block
by the air flowand
barrels
removing when they pin;
the extreme
split arecare
refitted.
it ismust
not be taken to to
necessary ensure
The
remove baffles
they the can
notbe
docylinder removed
totally block
heads. for cylinder
the air flowfin cleaning
when by theyremoving
are
therefitted.
split pin; it is not necessary to remove the cylinder heads.

2.06The THE baffles can be removed for cylinder fin cleaning

CYLINDER COOLING FINS
2.6 by The
The cylinder
removing Cylinder
barrel,
the split Cooling
head,heads.
pin; it is notFins
crankcase and
necessary to
cooling
remove the cylinder
fanThe finscylinder
must barrel,
be kept head,reasonably
crankcase and clean otherwise
cooling fan fins must be
Figure 2.5.1 Air Cowling - TS/TR seizure
kept of various
reasonably components
clean otherwise can occur
seizure of because
various components
Figure 2.5.1 Air Cowling - TS/TR
can2.06occurTHE
of overheating. because CYLINDER
of overheating. COOLING FINS
4.Remove Cleaning The frequency
Cleaning cylinder
frequency barrel,
will head,
willdepend
depend crankcase
ononthethe
nature and
and
nature cooling
concentration
and
4. Remove the the manifolds.
manifolds. of fan
the finssubstances contained in the cooling air; fluff hair,
concentration must
of thebe kept reasonably
substances containedclean inotherwise
the
5. 5.Remove
Remove thethe air air
cowl cowl
by by removing
removing the the setscrew
setscrew in the vegetable
in the fanshroud
fanshroud Figure
and setscrews, and2.5.1
setscrews,
springAir and
Cowling spring
plain and plain
- TS/TR
washers in the cooling air; fluff hair, vegetable fibre and other suchclogging
seizure fibre
of and
various other such
components items have
can a greater
occur because
effect
of
items have than a dry
overheating. dust. clogging effect than dry dust.
greater
washers in the cowl.
cowl. The cooling
Cleaning fins should always
frequency always be
will dependbecleanedon the when the engine
nature and
6.If
6. If a4.Remove
a fuelfuel
filterfilter isthe
is fitted manifolds.
fitted
to theto flywheel
the flywheel isolate or Theis cooling
end shield,
end shield, decarbonised
fins should
and as necessary.
cleaned
With the
when
engine stopped,
5.Remove
isolate
drain the fuelor drain the
beforethe air cowl
fuel beforethe
disconnecting by removing
disconnecting the
fuel feed to thesetscrew
thefuel the concentration
engine is of
decarbonisedthe substances
and as contained
necessary. in the
and immobilised,
cooling air; fluff the
hair, contaminants
vegetable fibrecanandbe other
raked such off the
in the
fuel feed
pumps and tofanshroud
removethe fuel andand
pumps
the nuts setscrews,
andspringremove spring
washersthesecuring
nuts With the engine stopped, and immobilised,
and plain fins by using a suitable hooked piece of wire or low pressure the
theand washers
fuelspring
filter. in the securing
washers cowl. the fuel filter. items have
contaminants can a greater
be raked clogging
off theeffect
fins by thanusing
dry dust.
compressed air.
7. 7.Remove
Remove 6.Ifthea the
fuel filter isspring
setscrews,
setscrews, fitted to the
washers
spring flywheel
washers andend
and plain a
shield,
washers
plain The
suitable cooling
hooked finspieceshould
of always
wire or be
low cleaned
pressure when
securing
washers thesecuring
isolate flywheel
or drain end
thethe shield
fuel to
flywheel the
endcylinder
before head
to thetopthe
disconnecting
shield the
compressed air. engine is decarbonised and as necessary.
plate. fuel feed
cylinder head top plate. to the fuel pumps and remove the nuts WithWARNING
the engine stopped, and immobilised, the
A setscrew
A setscrew is fitted
and is infitted
spring the middle
washers in the of the
securing filterthe
middle mounting
offuel block.
thefilter.
filter WARNING
Ifcontaminants
compressed aircan is usedbe extreme
raked off care the
mustfinsbebytaken usingto
8. Remove the
7.Remove
mounting shield.
block. the setscrews, spring washers and plain If compressed
a suitable
prevent personal air
hooked is
injuryused
piece
by extreme
theofjetwire
or care
or
debris.low must
pressure
8.Remove washersthe shield.securing the flywheel end shield to the be taken to prevent
compressed air. personal injury by the jet
Removing the head
cylinder Air Cowling
top plate. - TX or debris.
A setscrew
2.7 The WARNING Axial Fan - TX
Removing
1. Remove the airthe cleaner Airiffitted
is Cowling in the
necessary. - TXmiddle of the filter
If compressed air is
1.Remove
2. Remove mounting
the the airblock.
flywheel cleaner if necessary.
end air shield. 2.07 THE
A single AXIAL
stage axial flow FAN fan,used
belt extreme
- TXdriven fromcare
the gearmust end
8.Remove the shield. be
forces taken
cooling to
air prevent
to the personal
cylinder heads, injury
barrel by
and the jet
crankcase
2.Remove
3. Remove the the
axialflywheel
fan cowling. end air shield. A single stage axial flow fan, belt driven from the
or debris.
3.Remove
4. Isolate or drain thethe axial fuelfan cowling.
before disconnecting the fuel pipes gear external
end forcescoolingcooling
fins. air to the cylinder heads,
to andRemoving
4.Isolatefromorthe fuel the
drain thefuel
filter. Airbefore
Cowling - TX
disconnecting the barrel and crankcase external cooling fins.
fuel1.Remove
5. Remove the fuel
pipes thefrom
filter.
to and air cleaner
the fuelif filter.
necessary. 2.07WARNINGTHE AXIAL FAN - TX
2.Remove
5.Remove the fuel filter. the flywheel end air shield. WARNING
A single
The axial fan stage axial be
belt must flow fan, belt
changed every driven
2000from
hours,the
3.Remove the axial fan cowling. Theirrespective
axial
gear fan end belt of itsmust
forces be changed
cooling
condition. air to theevery 2000
cylinder heads,
4.Isolate or drain the fuel before disconnecting the hours, irrespective
barrel and crankcase of its condition.
external cooling fins.
fuel pipes to and from the fuel filter.
Removing WARNING the Fan 15
5.Remove the fuel filter.
The axial
1. Remove thefandrivebelt must be changed every 2000
guards.
2. hours,
Slackenirrespective
the alternator ofmounting
its condition. bolts and move the
alternator as far as it will go towards the crankcase.
15
 T SERIES ENGINES WORKSHOP MANUAL

TS, TR, TX engines workshop manual 15

Removing the Fan 2.10 THE CYLINDER HEAD COVER
1.Remove the drive guards. The light alloy cylinder head cover, which is bolted
2.Slacken the alternator mounting bolts and move the to the top of the cylinder head, gives access to the
3. Remove the drive belt.
alternator as far as it will go towards the crankcase.
4. Remove the fan from the mounting bracket; it will be
2.10 The
breather Cylinder Head
box, decompressors, injectorCover
and valve
3.Remove the drive belt. gear.
The light alloy cylinder head cover, which is bolted to the
necessary to slacken the fan cowling.
4.Remove the fan from the mounting bracket; it will ThetopTS/TR
of theengine mounted
cylinder fuel access
head, gives tank istosecured to
the breather box,
be necessary to slacken the fan cowling. thedecompressors,
side of the cylinder
injectorhead covergear.
and valve at the gear end
Refitting the Fan
by The TS/TR
three engine mounted
setscrews (two onfuel tankengines)
early is secured and
to theby
side of the
Refitting the Fan cylinder head cover at the gear
two setscrews in the side shield. end by three setscrews (two on
CAPTION early engines) and by two setscrews in the side shield.
CAUTION
The drive belt must not be levered or wound on and care
The drive belt must not be levered or onto
wound The Crankcase Breather
must be taken to ensure it is correctly fitted the on OnThe Crankcase
the majority Breather
of TS and TR engines a plate locates
and care
pulley must be taken to ensure it is correctly
grooves.
fitted onto the pulley grooves. overOnthe thebreather
majority of tube andTRforms
TS and enginesanaoil separator
plate locates over the
The above removal procedure is reversed when the fan is boxbreather
in the cylinder
tube andhead
formscover
an oilwhich connects
separator box inwiththe cylinder
The above removal procedure is reversed when thehead
inlet cover
manifold
which port via a copper
connects with thepipe
inletbrazed
manifold to port via
replaced and after the drive belt has been fitted it must be
the fan is replaced and after the drive belt has been theaplate.
copperThe pipebreather
brazed toplate has aThe
the plate. metal contact
breather plate has a
correctly tensioned.
fitted it must be correctly tensioned. withmetal
the contact
cylinderwithhead thecover andhead
cylinder is secured
cover and with
is secured
three self tapping screws. A felt washer is fitted around
with three self tapping screws. A felt washer is fitted
2.8 Drive
2.08 BeltBELT
DRIVE Tension
TENSION around
the top theof top of the
the tube tube between
between thehead
the cylinder cylinder
and breather
It isItimportant
is importthat
ant the
thatension
t the teof
nsthe
iondrive belt
of th e disrichecked head and breather plate and care must be takenis refitted
ve belt after
is
plate and care must be taken to ensure the washer
thechecked
first 50 hours, after an overhaul, after a new belt
after the first 50 hours, after an overhaul, to on
has been re-assembly.
ensure the washer is refitted on re-assembly.
fitted and The breathertube
The breather tubeforms
formsan an interference
interference fitfit in
in the
thecylinder
after a as
newspecified
belt hasin "Maintenance
been fitted and Schedule".
as specified in
The"Maintenance
measurementsSchedule".
shown in the table are taken in the centre head.
cylinder head.
of the
Thelongest span after the
measurements belt has
shown inbeen
the turned
table arethrough 360º
taken
to equalise the tension.
in the centre of the longest span after the belt has Removing Removing thethe Cylinder
Cylinder HeadHead Cover
Cover
After adjustment turn the belt through 360º and recheck the 1.Remove the lifting eye and fuel tank securing
been turned through 360º to equalise the tension. 1.Remove the lifting eye and fuel tank securing bolts if
deflection. bolts if necessary.
After adjustment turn the belt through 360º and re- necessary.
check the deflection. 2.Remove
2. Remove the
thefour
fourbolts
boltssecuring thecover.
securing the cover.
Belt tension force Deflection 3.Lift off off
3. Lift thethe
cover being
cover beingcareful
carefulnot
nottotodamage
damage the
the joint or
Belt Tension Force Deflection joint or leak-off
leak-off pipe. pipe.
N lbf mm in
N lbf mm in
New belt 31.0-33.0 7.0-7.5 Refitting thethe
Refitting Cylinder Head
Cylinder Cover
Head Cover
New Belt 31.0 - 33.0 7.0 - 7.5 3.5 0.14
3.5 0.14 1.On TS/TR engines ensure the breather plate
Used Belt 22.0-24.0
Usedbelt 22.0 - 24.0 5.0-5.4
5.0 - 5.4 1. On TS/TR engines ensure the breather plate is securely
is securely retained in position and that the felt
retained in position and that the felt washer is fitted round
washer is fittedtube.
the breather round the breather tube.
2.Clean
2. Clean the coverand
the cover andcylinder headjoint
cylinder head jointarea.
area.
3.Place the joint on the cylinder
3. Place the joint on the cylinder head. head.
4.Move
4. Move thethedecompressor
decompressorlever, lever, ifif fitted,
fitted, into the vertical
into the
vertical position.
position.
5.Replace
5. Replacethe the cylinder head
cylinder head cover
cover ensuring
ensuring the
the decompressor
decompressor
lever, if fitted,lever, if fitted,
is located is located
between the twobetween
stops and the
thefueltwoinjector
stops and the fuel
leak-off pipeinjector
is locatedleak-off
snuglypipe is recess
in the
located snugly in the recess provided.
provided.
6.Fit thethe
6. Fit four bolts
four boltswith
withnew
newwashers.
washers.

2.11
2.11 The
THE Cylinder HEAD
CYLINDER Head
Figure2.8.1
Figure 2.8.1 Belt
BeltTension
Tension OnOnandandafter
afterthe
theTX
TXengine serialnumbers
engine serial numbers shown,
shown, two spring
twodisc
spring disc
washers washers
were were
fitted under eachfitted under
cylinder bolteach
head instead
2.92.09Axial
AXIAL FanFAN Drive DRIVEGuard GUARD - TX - TX cylinder of onebolt
plainhead instead of one plain washer.
washer.
A polypropylene replaces the earlier, 38 38 00138
00138 TX2 TX2
A polypropylene replaces the earlier, weldedwelded steelIf a
steel guards.
guards. If a later guard is being fitted in place 38 00206
38 00206 TX3 TX3
later guard is being fitted in place of a metal type the end cover
of be
must a modified.
metal type the end cover must be modified.
Drawing
Drawing SK2204/91
SK2204/91 is available
is available fromfrom Lister
Lister Petter
Petter Power Removal of a Cylinder Head
PowerforSystems
Systems for this purpose.
this purpose. 1. Remove the cylinder head cover.
16 2. Remove the valve rocker lubricating oil feed pipe by removing
the oil swivel plugs from the cylinder head and crankcase.
3. Remove the fuel pump to injector pipe.
 their position for re-assembly. cylinder head.
With the cylinder head in position the air baffle/s
may be removed by removing the split pin. 2.12 CYLINDER HEAD CLEARANCE
9.Remove the push rods and tubes and place TS, TR, TX engines workshop manual 16
them with their respective cylinder head if further TS and TR Engines
dismantling is anticipated. 1.With the head removed smear a very small
10.To prevent movement of the barrel if the amount of high melting point grease in the recess
4. Slacken the injector clamp.
crankshaft is turned place a suitable length of tube
5. If more than one head is being removed mark each one with
2.12 Cylinder
on the head where Head Clearance
the shims seat and also the
over one holding down stud of the cylinder secured side of the recess.
chalk to identify their respective cylinders.
by fitting a cylinder head nut finger tight. TS2.Lightly
and TRgrease Engines both sides of each shim in turn
6. Remove the cylinder head securing nuts diagonally and lift and place them in the recess.
off the head. 1. With the head removed smear a very small amount of high
7. EnsureRefitting
the TS/TRacylinder
Cylinder headHeadclearance shims and gaskets melting point grease ininthethe
3.Place the gasket recess
recess on the onhead
top where
of thethe
shims.
from each cylinder are placed withhead
The TS and TR cylinder nuts, top threads
their respective cylinder of shims seat and also the side of the recess.
4.Fromgrease
two 50mm x 1.6mm (2.00
the studs and the
heads for correct re-assembly. area of the top plate in contact with 2. Lightly both sides of each shimx in
0.063in)
turn and diameter
place them
the nuts should be lightly coated with Wellseal.
8. Remove the air baffle/s taking careful note of their position in pieces
the recess. of lead wire or soft, but not multicore,
All cylinder head nuts should be fitted with the solder
3. Place form two
the gasket in the'U' shaped
recess on top symmetrical
of the shims. loops.
for re-assembly.
machined
With the cylinder grade
head insymbol
position facing
the airupwards to ensure
baffle/s may be 4. 5.Twist
From twothe openx 1.6mm
50mm tails of(2.00
eachx 0.063in)
loop to form
diameterfourpieces
or
removeda good seal between
by removing the splitthepin.nut and the head. of five
leadcoils.
wire or soft, but not multicore, solder form two 'U'
9. Remove It isthe
strongly recommended
push rods and tubes that and cylinder
place them headwithnuts 6.Refersymmetrical
shaped to 'Figure loops.
2.12.1' and using a very small
and push cylinder
their respective rod seals areifreplaced
head at every major
further dismantling is amount of grease each
5. Twist the open tails of placeloopthe to
two pieces
form of five
four or wirecoils.
on
anticipated.
overhaul. the piston crown.
6. Refer to 'Figure 2.12.1' and using a very small amount of
10. To prevent movement of thethe barrel if the grease place the two pieces of wire on the
The wires must be at each side of the gudgeon pin piston crown.
1.Renew or replace push rodcrankshaft
seals in isthe
turnedcylinder
place a suitable length of tube over one holding The wires
axis and must
90°betoatthe
each side ofline
centre the and
gudgeon pin axis and
just touching
head and crankcase. 90°the
to the centre line and just touching the cylinder bore.
down2.Lightly
stud of thecoat
cylinder
bothsecured
ends by offitting
the apush
cylinder
rodhead
tubes cylinder bore.
nut finger tight. Care must be taken to ensure the wires
Care must be taken to ensure the wires are not are not placed over
with Hellerine rubber lubricant and replace them any markings on the piston crown.
taking care to ensure they are centralised in their placed over any markings on the piston crown.
Refitting a Cylinder
rubber seals. Head
3.Replace
The TS and TR cylinder thehead
push rods
nuts, topinthreads
their original positions.
of the studs and
4.Replace the cylinder head.
the area of the top plate in contact with the nuts should be
Greatwith
lightly coated careWellseal.
must be taken not to trap the TS or TR
All cylinder head nuts the
shims on cylinder
should barrel
be fitted spigot.
with the machined grade
5.Replace
symbol facing thetohead
upwards ensure nuts finger
a good sealtight only. the nut
between
and the head.The inlet and exhaust flanges of all cylinder
heads
It is strongly must be lined
recommended up withhead
that cylinder a straight
nuts and edge
pushand
rod seals areany gap along
replaced the major
at every straight edge must not exceed
overhaul.
1. Renew or 0.2mm (0.008in).
replace the push rod seals in the cylinder head
and crankcase.
Alternatively fit a manifold before tightening down
2. Lightly coat both endsheads.
the cylinder of the push rod tubes with Hellerine
rubber lubricant and replace them taking care to ensure they Figure
Figure 2.12.1Cylinder
2.12.1 Cylinder Head
HeadClearance
Clearance
are centralised in their rubber seals.
3. Replace the push rods in their original positions. 7. Replace the cylinder head. 17
4. Replace the cylinder head. 8.Replace and torque the cylinder head nuts to 68.0Nm
Great care must be taken not to trap the TS or TR shims on (50.0lbf ft).
the cylinder barrel spigot. 9. Turn the piston twice past TDC.
5. Replace the head nuts finger tight only. 10. Remove the cylinder head and measure the thickness of
The inlet and exhaust flanges of all cylinder heads must be the lead, this should be:
lined up with a straight edge and any gap along the straight TS - 0.813-0.889mm (0.032-0.035in)
edge must not exceed 0.2mm (0.008in). TR - 0.889-0.965mm (0.035-0.038in)
Alternatively fit a manifold before tightening down the If this measurement is not correct it can be adjusted by
cylinder heads. adding or removing 0.07mm or 0.25mm (0.003 or 0.010in)
6. Tighten down the cylinder head nuts diagonally and evenly thick shims placed between the cylinder head and the
to a final torque of: gasket.
TS/TR - 68.ONm (50.0lbf ft) 11. Replace the cylinder head.
TX - 61.ONm (45.0lbf ft) 12. Re-check the head clearance.
7. On TX engines ensure the valve stem caps are in position.
8. Replace the injector and the injector clamp.
TX Engines
9. Check and adjust the valve rocker clearances.
10. Check and adjust the decompressor, if fitted. The cylinder head clearance is maintained by 0.07mm, 0.13mm
11. Replace the cylinder head cover and lifting eye. or 0.38mm (0.003in, 0.005in, 0.015in) metal shims placed
12. Replace the baffle between the cylinder barrels with the between the cylinder barrel and crankcase.
spring clip on the manifold side 1. From two 50mm x 1.6mm (2.00 x 0.063in) diameter pieces
13. Replace the air cowling and manifolds. of lead wire or soft, but not multicore, solder form two 'U'
14. Replace the valve rocker lubricating oil feed pipe, fitting a shaped symmetrical loops.
new union and two washers to the cylinder head. 2. Twist the open tails of each loop to form four or five coils.
 TS, TR, TX engines workshop manual 17

3. Refer to 'Figure 2.12.1' and using a very small amount of Refitting the Stub Shaft
grease place the two pieces of wire on the piston crown.
The wires must be at each side of the gudgeon pin axis and Before fitting check the oil holes are clear, fit a new 'O' ring
90° to the centre line and just touching the cylinder bore. to the recess on the inside face of the stub shaft and coat the
Care must be taken to ensure the wires are not placed over sealing groove nearest to the bolt hole with Wellseal or Hylomar
any markings on the piston crown. PL32/M.
4. Replace the cylinder head. When refitting, the mark 'TOP' on the outside face of the stub
5. Replace and torque the cylinder head bolts to 61.0Nm shaft must be positioned towards the top of the cylinder
(45.0lbf ft). head.
6. Turn the piston twice past T.D.C.
7. Remove the cylinder head and measure the thickness of the WARNING
lead, this should be: Care must be taken to ensure that any part of the hand
0.81-0.95mm (0.032-0.037in) is not likely to become trapped between the two parts of
8. If it is necessary to change the shims: the tool while it is being used.
a. Remove the cylinder barrel.
b. Place the necessary shims, dry, onto the crankcase end of
the cylinder barrel.
9. Replace the cylinder barrel and head.
CAPTION
When refitting the stub shafts using the slide hammer,
great care must be taken not to dislodge the 'O' ring on
2.13 The Valve Rocker Stub Shafts - the inside face recess of the shaft.
TS/TR 1. Fit the small end of the adapter (A) into the screw thread of
The removal of the stub shafts is necessary when it is required the stub shaft and tighten.
to examine or change the valves, valve seats, rocker arms or Ensure 'TOP' is correctly positioned.
AL rocker arm bushes. 2. Place the cylinder on its side on a bench and place the rocker
arm into position for refitting the stub shaft.
Removing Stub Shafts 3. Fit the slide hammer tool on to adaptor.
4. Align the stub shaft with the stub shaft hole.
Removing Stub Shafts 5. Grasp the slide hammer with one hand while positioning the
nuts to WARNING rocker arm with the other and refit the stub shaft by striking
WARNING
Care must be taken to ensure that any part of the hand the end of the tool nearest the cylinder head with the slide
isCare must
not likely tobe takentrapped
become to ensure that any
between the part of theof
two parts hammer.
ure the hand
the toolis not
while likely
it is to
beingbecome
used. trapped between the If the rocker lever bush is not correctly lined up and is
two parts of the tool while it is being used. preventing the stub shaft being refitted gently strike either
). 1.Screw
1. Screw the small
the small end ofend of the adapter
the adapter (A)screw
(A) into the into thread
the end of the tool with the slide hammer while repositioning
). screw
of thread
the stub shaftofand
thetighten.
stub shaft and tighten. the rocker arm.
can be
mm or Note:
placed 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
ned by arms or rocker arm bushes.
.005in,
ylinder
Removing an Individual Rocker Arm
ameter Figure 2.13.1
Figure 2.13.1 Stub Shaft
Stub Shaft Tool
Tool
Individual rocker arms can be removed without removing the
lticore, rocker assembly.
loops. 2. Preferably
2.Preferablyplaceplace the cylinder
the cylinder head head
into a into
vice,aand
vice, andthe
screw 1. Remove the rocker cover.
four or slide screw the slide
hammer hammer
tool onto tool onto the adapter.
the adapter. 2. With the piston at TDC on the firing stroke screw the rocker
3.Grip
3. Grip the hammer
the slide slide hammer
in one handin one handthe
and strike and strike
sleeve in the adjusting screw (A) anti-clockwise until the valve spring is
y small required
the sleeve in the
direction required
until the stubdirection until removed.
shaft has been the stub not tensioned.
wire on 4. Liftshaft hasrocker
out the beenarm.removed.
4.Lift out the rocker arm.
eon pin
uching Refitting the Stub Shaft
Before fitting check the oil holes are clear, fit a new
are not 'O' ring to the recess on the inside face of the stub
own. shaft and coat the sealing groove nearest to the
 Figure 2.15.1 Valve Spring Compressor
Individual rocker arms can be removed without
removing the rocker assembly. 6.Fit the tool (B) into the two plate indentations.
1.Remove the rocker cover. 7.Push down on the tool until the collets can be
2.With the piston at TDC on the firing stroke screw TS, TR, TX engines workshop manual 18
removed.
the rocker adjusting screw (A) anti-clockwise 8.Gently release the tool and remove the carrier,
until the valve spring is not tensioned. valve cap, valve spring and the valve stem
shields.
Refitting the Valves
TS/TR1 engines are not fitted with an exhaust
1. Assemble
valve the valves in the reverse order ensuring the collets
stem shield.
are securely
9.Turn the cylinder in position
head with overtheirandtops slightly the
remove sunk in the
valve
valve. spring carrier.
2. Fit the valve stem caps
3. Replace the TS/TR valve rocker and stub shaft.
Refitting
4. Replace thetheValves
TX oil restrictor plate and the valve rocker
1.Assemble
assembly. valves in the reverse order ensuring
the
the collets the
5. Replace arecylinder
securely headin position
and set the with their
valve tops
clearance.
slightly sunk in the valve
6. Replace the valve rocker cover. spring carrier.
2.Fit the valve stem caps
3.Replace the TS/TR valve rocker and stub shaft.
2.16 The
4.Replace the TX Valve Guides
oil restrictor plate and the valve
Figure
Figure2.14.1 ValveRocker
2.14.1 Valve Rocker
rocker T assembly.
SERIES ENGINES
It is recommended that valve WORKSHOP
guides are removed MANUAL and refitted
3.Using suitable circlip 5.Replace
with the the
aid of cylinder
the Service head
Tool toand
ensure setthe the valve
correct protrusion
3. Using suitable circlip plierspliers
removeremove the circlip
the circlip (B) and(B)
slide
theand slide
rocker theoffrocker
lever the stub lever off the stub shaft.
shaft. clearance.
is obtained.
4.With
4. With the the
piston piston
at TDC atonTDC on the
the firing firing
stroke andstroke and 6.Replace the valve rocker cover.
the adjusting Remo
screwthe turned
adjusting screw turnedslide
fully anti-clockwise fullytheanti-clockwise
rocker lever onto 1.Rem
theslide
stub the
shaft.rocker lever onto the stub shaft. 2.16 THE VALVE GUIDES 2.Rem
5. Using
5.Using suitable
suitablecirclip plierspliers
circlip replace the circlip
replace theand check
circlip andthat It is recommended that valve guides are removed 3.Rem
T SERIES
it ischeck
fully that itinisENGINES
seated the
fullygroove.
seatedWORKSHOP
in the groove. MANUAL 4.Prefe
and refitted with the aid of the Service Tool to
6. Check
6.Check andandresetreset
the valve clearance.
the valve clearance. a sof
ensure the correct protrusion is obtained.
7. Replace
7.Replace the valve
the valverockerrocker
cover. cover. 5.Screw
2.15 THE VALVES 6.Place
e. 2.15RemovingThe Valves the Valves 19
7.Fit th
d while and l
1.Remove the
Removing thecylinder
Valveshead.
er and nece
2.Remove the TS/TR valve rockers.
he tool 1. Remove the cylinder 8.Loca
3.Remove the TX head. valve rocker assembly and oil Figure 2.16.1
2.16.1 Valve Guide Tool
ammer. 2. Remove the TS/TR
Figure Valve Guide Tool 9.Screw
restrictor plate.valve rockers.
ned up 3. 4.Lay
Remove thecylinder
TX valvehead rocker assembly mand
the upright on and oil restrictor
a bench and Valve
Valve Guides
Guides - - TS/TR
TS/TR
refitted plate. 10.Hold
place a circular block of wood under the head of The guides are marked 'IN TOP' and 'EX TOP'
e slide 4. Lay the cylinder head upright on a bench and place a circular The guides rotati
m.
the valve.
block of wood under the head of the valve. (inlet or are marked
exhaust 'IN TOP'
valve andtop
guide, 'EX position)
TOP' (inletand or exhaust
are until t
5.Place the adapter (A) onto the valve spring carrier valve guide, top position) and are a press
a press fit into the two halves of the cylinder head fit into the two halves
5. Place the adapter (A) onto the valve spring carrier with the of the cylinder head assembly. A rubber ring and a retaining If it is
with the two indentations facing outwards. assembly. A rubber ring and a retaining plate are
two indentations facing outwards. plate are located around the top of the inlet guide on early sharp
e and located around the top of the inlet guide on early the s
engines; later engines have sealing caps on both valves.
will be engines; later engines have sealing caps on both
The rubber sealing ring must be inserted in the top plate recess
econd valves.
before pressing in the inlet valve guide to prevent damage to
theThering rubber
as there sealing ring musttobe
is no lead-chamfer the inserted
recess. in the
topcoating
After plate rethe cesoutside
s beforof e pthe
resvalve
sing iguides
n the iwith
nlet vWellseal
alve
guide to prevent damage to the ring positions
as there withis nothe
X they should
lead-chamfer
be pressed
to theand
into their
recess.
correct
markings uppermost pointing towards the opposite
mbly is AfterThe
guide. coating
projectionsthe outside
of the valve of the valve
guides aboveguides
the top with
plate
change Wellseal
surface are: they should be pressed into their correct
er arm positions with the markings
Exhaust: 17.40-17.90mm uppermost and pointing
(0.685-0.704in).
towards the opposite
Inlet: 12.40-1 guide. The projections of the
2.90mm (0.488-0.507in).
valve
These guides above
projections will bethe top ifplate
correct surface
the Service are:
Tool is used.
m Figure 2.15.1
After assembly a gauge 8.707mm (0.343in)
Exhaust: 17.40-17.90mm (0.685-0.704in). diameter must pass
Figure 2.15.1Valve SpringCompressor
Valve Spring Compressor
through theInlet: exhaust valve guide. If the gauge does not pass
without 12.40-1 2.90mm (0.488-0.507in).
through, the guide must be reamed square
These projections will be correct if the Service Tool to 8.707-8.727mm
6.Fit
6. Fit thethe
tooltool (B) into
(B) into the twothe plate
two plate indentations.
indentations. (0.343-0.3436in)
is used. diameter.
7.Push
7. Push down downon the ontooltheuntil
tooltheuntil thecan
collets collets can be
be removed. These fitted with Refitti
screw removed.
8. Gently release the tool and remove the carrier, valve cap, After assembly also
measurements a apply
gaugeto cylinder
8.707mm heads (0.343in)
ckwise pre-finished valve guides that have
diameter must pass through the exhaust valve been obtained from Lister 1.Fit th
8.Gently
valve spring release
and thethe valvetool
stemand remove the carrier,
shields. Petter Power Systems. from
valveengines
TS/TR1 cap, are valve spring
not fitted withand the valve
an exhaust valve stem
stem guide. If the gauge does not pass through, the
2.Place
shields.
shield. guide must be reamed square to 8.707-8.727mm
plate
9. Turn the cylinder head over and remove
TS/TR1 engines are not fitted with an exhaust the valve. (0.343-0.3436in) diameter.
3.Place
valve stem shield. These measurements also apply to cylinder heads
and s
9.Turn the cylinder head over and remove the fitted with pre-finished valve guides that have been
4.Fit th
valve. obtained from Lister Petter Power Systems.
(E) o
 TS, TR, TX engines workshop manual 19 T

pressing in the inserts, at ambient temperature the

2.17 W
Valve Guides - TX headThe
shouldValve Seats
be heated to 100°-150°C (212°-302°F) The va
After the outside of the valve guides have been coated with Theforvalve
a minimum
seats areofcast
45 iron
minutes and
inserts the insert
which chilled
are pressed into is adju
Wellseal they are pressed into the cylinder head. to -65° to -75°C (-85° to -103°F) for
position to ensure they bed on the bottom of the recess a minimum of in guide
The projection of the valve guide above the top plate surface the30 minutes.
cylinder head. Before pressing in the inserts, at ambient even,
must be 12.45-12.95mm (0.489-0.509in). The widththe
temperature of the
headTS/TR
shouldseatings
be heatedmust be:
to 100°-150°C (212°- when u
After fitting the internal measurement should be 7.910- 302°F) for aInlet:
minimum1.65-2.29mm
of 45 minutes (0.065-0.090in).
and the insert chilled to too mu
7.965mm (0.311-0.313in). -65° to -75°C Exhaust: 1.35-1.78mm
(-85° to -103°F) (0.053-0.070in).
for a minimum of 30 minutes.
TheIf width
necessary metalseatings
of the TS/TR must bemust ground
be: or cut from the
Removing Valve Guides top
Inlet:of1.65-2.29mm
the insert (0.065-0.090in).
or recess. The valves are pre- 2.18
Exhaust: 1.35-1.78mm
finished and no lapping (0.053-0.070in).
or further processing is The v
1. Remove the cylinder head. If necessary
required. metal must be ground or cut from the top of the adjuste
2. Remove the valves. insert
3. Remove the valve guide oil seal. All seats are precision ground to allowand
or recess. The valves are pre-finished theno lapping
valves to or that th
further processing is required.
lay below the combustion surface of the head. preven
4. Preferably place the cylinder head on its side in a soft jawed AllUp
seatstoarethe
precision ground to allow the valves to lay below
vice. TS/TR serial numbers shown the new e
themeasurements
combustion surface of
were: the head. overha
5. Screw the correct mandrel (B) into the tool (D). Up to Inlet
the TS/TR serial numbers shown the measurements
6. Place the sleeve (C) onto the tool. valves: 1.02-1.27mm (0.040-0.050in). during
were: that the
7. Fit the bevelled adapter (E) into the sleeve (C) and locate the Exhaust valves: 0.89-1.14mm (0.035-0.045in).
Inlet valves: 1.02-1.27mm (0.040-0.050in).
bevel into the valve seat; it may be necessary to fit the spacer 36 00199 TS1 36 00025 TR1 it is fo
Exhaust valves: 0.89-1.14mm (0.035-0.045in).
(F) into the sleeve. 36 00480 TS2 36 00020 TR2 The pe
36 00199 TS1 36 00025 TR1
8. Locate the mandrel through the guide. 36 00307 TS3 36 00043 TR3 increas
36 00480 TS2 36 00020 TR2
9. Screw the small threaded sleeve (A) onto the mandrel. On
36 00307 TS3 36 00043 TR3the measurements are:
later TS/TR engines
10. Holding the sliding handle firmly to prevent rotation, On laterInlet
TS/TRvalves:
engines 0.63-0.94mm
the measurements (0.025-0.037in).
are: Adjus
turn the double handled lever clockwise until the guide is Exhaust valves: 0.51-0.82mm
Inlet valves: 0.63-0.94mm (0.025-0.037in). (0.020-0.032in).
T SERIESthrough
withdrawn ENGINES WORKSHOP MANUAL
the head. On TX engines the measurement for both valves is
Exhaust valves: 0.51-0.82mm (0.020-0.032in).
If it is found difficult to start moving the guides a sharp tap On1.020-1.550mm (0.040-0.061in).
TX engines the measurement for both valves is 1.020-
with a copper hammer should break the seal. 1.550mm (0.040-0.061in). TS/T
Removing Valve Guides
Valve Recess and Seat Cutting
Valve
1.Remove1.Fit Recess
the cylinder
correctandadjustable
Seat Cutting
head. mandrel (A) into the
TX
2.Remove valvetheguide
valves. and turn the adjuster until the flutes
1. Fit the correct adjustable mandrel (A) into the valve guide and
3.Remove just the
bindvalve
onto guide oil seal.
the guide.
turn the adjuster until the flutes just bind onto the guide.
4.Preferably
2.Selectplace the the cylinder head
necessary cuttingon its
toolside(B)
in and
2. Select the necessary cutting tool (B) and assemble it to the 1.Ensu
a softassemble
jawed vice. it to the handle (C). valve
handle (C).
5.Screw the correct mandrel (B) into the tool (D). 2.With
6.Place the sleeve (C) onto the tool. engin
7.Fit the bevelled adapter (E) into the sleeve (C) posit
and locate the bevel into the valve seat; it may be close
necessary to fit the spacer (F) into the sleeve. 3.Hold
8.Locate the mandrel through the guide. and s
Figure 2.16.1
Figure 2.16.2 Valve Guide
Valve Guide Tool
Tool 9.Screw the small threaded sleeve (A) onto the Turn
mandrel. been
Valve Guides
Refitting - TS/TR
Valve Guides 10.Holding the sliding handle firmly to prevent
The guides are marked 'IN TOP' and 'EX TOP' rotation, turn the double handled lever clockwise
1. Fit theor
(inlet correct
exhaustmandrel
valveinto the valve
guide, guide hole
top position) and from
arethe until the guide is withdrawn through the head.
valve rocker
a press end. the two halves of the cylinder head
fit into
2. Place the valve guide over the mandrel in the top plate. If it is found difficult to start moving the guides a
assembly. A rubber ring and a retaining plate are
3. Place the correct depth stop (G) over the mandrel and screw sharp tapFigure with a copper hammer should break
2.17.1 Recess andSeat
Seat Cutting
located around the top of the inlet guide on early the seal. Figure 2.17.1 Recess and Cutting Tool Tool
on the threaded sleeve (A).
engines; later engines have sealing caps on both
4. Fit the tool complete with the bevelled adapter (E) onto the
valves.
mandrel. 3. 3.Place
Place thethe cutter
cutter overover
thethe mandrel
mandrel andand adjust
adjust the the
three
The rubber sealing ring must be inserted in the three individual
individual blades by blades
using byAllen
the usingKeythe(E).
Allen Key (E).
5. Hold the sliding handle firmly, to prevent it rotating, and
top the
platdouble
e recehandled
ss beforlever
e prclockwise
essing inuntilthe the
inledepth
t valvstop
e 4.Rotate
4. Rotate the the
tooltool in a clockwise
in a clockwise directiondirection
until theuntil the
valve seat
turn
guide toany
prevents prevent
furtherdamage
movement. to the ring as there is no or valve
recess seat
finish or
is recess finish
satisfactory. is satisfactory.
lead-chamfer to the recess.
At this point the guide will protrude the correct distance
After the
above coating thehead.
cylinder outside of the valve guides with
Wellseal they should be pressed into their correct
6. Fit a new valve guide oil seal.
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). Figure 2.16.2 Valve Guide Tool
These projections will be correct if the Service Tool
 T SERIES ENGINES WORKSHOP MANUAL 5.Re-check to ensure the clearance is correct. trave
6.Repeat the procedure for both valves in all 5.Tight
cylinders. screw
ure the WARNING TS, TR, TX engines workshop manual 20 TX Eng
302°F) The valve guide will be damaged if the mandrel
2.19 THE DECOMPRESSOR 6.Place
chilled The decompressor is fitted to the exhaust valve on positi
is adjusted too much when it is located in the
mum of guide and care must be taken to ensure an some engines. When the cylinder head cover is 7.Slack
WARNING
even, gentle downward pressure is applied 2.19beingThe Decompressor
replaced care must be taken to ensure the the p
lever is vertical between the two stops. 8.Turn
when using the cutter to prevent the removal of The decompressor is fitted to the exhaust valve on some lockn
The valve guide will be damaged if the mandrel is The decompressor lever is cover
springis loaded towards
too much
adjusted too metal.
much when it is located in the guide and engines. When the cylinder head being replaced care
0in). the cylinder head and is located by
must be taken to ensure the lever is vertical between the two All Eng
a plain
om the care must be taken to ensure an even, gentle downward washer and a split pin or circlip fitted through the 9.Repla
2.18 VALVE
re pre- pressure is applied whenCLEARANCE
using the cutter to prevent the stops.
removal of too much metal. The decompressor shaft.is spring
decompressor lever A seal,loaded
fittedtowards
on thethe cylinder the d
outside
sing is The valve clearance must be measured and headof and
the iscylinder
located head, prevents
by a plain oil seepage
washer and a split pin along
or circlip
adjusted when the engine is cold. It is important the through
fitted spindle.theOn engine builds
decompressor shaft.not fitted
A seal, with
fitted on athe 2.20 T
alves to that the clearances are maintained correct to
ad.
2.18 Valve Clearance
prevent serious damage to the valve gear. With
decompressor
outside the head,
of the cylinder
plugged
spindle.
drillingprevents
with a dowel.
On engine
in theoilcylinder
seepageheadalongisthe
builds not fitted with a decompressor the
The pu
wn the Thenew valveengines,
clearance or mustengines whichand
be measured have just when
adjusted beenthe thread
drilling in the cylinder head is plugged with a dowel.
engine is cold. It isthe
overhauled, important
valvethat the clearances
gear beds down are maintained
rapidly Removing the Decompressor
n). correct
during to prevent
the firstserious
500 hoursdamage to theand
running valve gear.
it is With new
essential Remo
Removing the
Remove the Decompressor
cylinder head cover.
1.Slack
045in). engines,
that theor engines
clearancewhich is have just been
checked everyoverhauled,
25 hoursthe valve
until Remove the split pin or circlip, washer, spring and
gear it beds downthat
is found rapidly
theduring the first 500
clearances hoursconstant.
remain running and Remove the cylinder head cover. the a
adjusting screw.
Remove the split pin or circlip, washer, spring and adjusting crank
it isThe
essential that the
periods clearance
between is checked every
adjustments may25then hoursbe until
it isincreased
found thattothe clearances remain constant. The periods Withdraw the decompressor lever from the cylinder
screw.
1000 hours. 2Remo
between adjustments may then be increased to 1000 hours. head. the decompressor lever from the cylinder head.
Withdraw
are: 3.Fit th
n). Adjusting the Valve Clearance in the
Decompressor
Decompressor Adjustment
Adjustment
032in). Adjusting the Valve Clearance This adjustment should only be made when the
will n
alves is GO NOT GO This adjustment should If the
GO NOT GO valve clearance is only be made
correctly when the valve clearance
adjusted. the c
mm 0.15 0.20 is correctly adjusted.
After the decompressor has been set on TX
TS/TR After the decompressor has beenliftsetmust
on TX preve
inmm 0.006
0.15
0.008
0.20 engines the maximum valve notengines
exceedthe The
TS/TR maximum valve lift
0.76mm (0.030in). must not exceed 0.76mm (0.030in).
nto the mmin 0.100.006 0.008
0.15 1. Remove the cylinder head cover. hand
TX 1.Remove the cylinder head cover.
e flutes inmm 0.0040.10 0.006 2. Turn the engine until the piston is at TDC. firing stroke, for
0.15 2.Turn the engine until the piston is at TDC. firing
TX the cylinder being worked on.
stroke, for the cylinder being worked on.
B) and in 0.004 0.006
1.Ensure the decompressor is clear of the exhaust
valve rocker. TSTSand
andTR
TR Engines
Engines
1. 2.With
Ensure the
the decompressor
cylinder head iscoverclearremoved,
of the exhaust valve
turn the
rocker.
engine until the relevant piston is at the TDC
2. With the cylinder head cover removed, turn the engine until
position on the firing stroke - both valves will be
the relevant piston is at the TDC position on the firing stroke
closed.
- both valves will be closed.
3.Hold
3. Hold thethe adjusting
adjusting screwscrew (A)
(A) with with a screwdriver
a screwdriver and slacken
and slacken
the locknut (B). the locknut (B).
Turn
Turn thethe screw
screw untiluntil
thethe correct
correct clearance
clearance hashas
been
been
obtained. obtained.
4.Rem
clock
5.Pull o
6.Rem
FigureFigure
2.19.1
2.19.1Decompressor
Decompressor LeverLever
l Refitti
3.Slacken
3. Slacken the locknut
the locknut (A) and(A) andtheadjust
adjust screw the it just 1.Fit th
screw
(B) until
ust the in the
(B) until it just touches the exhaust valve rocker
touches the exhaust valve rocker when the lever is vertical.
Key (E).
4. Turn the screw half a turn clockwise so that it travels towards
ntil the
the rocker.
22
5. Tighten the locknut whilst restraining the adjusting screw.

Figure 2.18.1
TX Engines
Figure 2.18.1 Valve Clearance
Valve Clearance
6. Place the decompressor lever in the vertical position.
4. Torque the locknut, while continuing to hold the adjusting 7. Slacken the decompressor pin locknut and adjust the pin to
21 take up the valve clearance.
screw, to 21.0Nm (15.5lbf ft).
5. Re-check to ensure the clearance is correct. 8. Turn the pin a further half a turn and tighten the locknut.
6. Repeat the procedure for both valves in all cylinders.
over is
the pin to take up the valve clearance. The Service Tool 317-50063 (TS/TR) or 317-50065 3.Inser
ure the
8.Turn the pin a further half a turn and tighten the (TX), is used to protect the oil seal when the end the s
locknut. cover is either removed or replaced and it can also 4.Rem
owards
be used TS,toTR, TX engines
remove andworkshop manual
replace the seal in the end 21 5.Rem
plain All Engines
cover. 6.Clean
ugh the 9.Replace the rocker cover taking care to ensure
On TX engines a bracket supporting the axial fan and c
outside the decompressor lever is vertical.
7.If nec
along All Engines Onand alternator
TX engines is fitted
a bracket to the cover.
supporting the axial fan and alternator seal
with a 2.20 THE CRANKSHAFT PULLEY - TX is fitted to the cover.
head is 9. Replace the rocker cover taking care to ensure the Removing the End Cover - TS/TR
The pulley is lever
decompressor secured by a torque loaded left hand
is vertical. 1.Remove the
the End
plastic dustcap in the end cover Refitt
thread nut. Removing Cover - TS/TR 1.With
boss.
clean
2.20 The Crankshaft
Removing the Pulley Pulley - TX
1. Remove
On early
On a.Turn
the plastic
engines:
early engines:
dustcap in the end cover boss.
2.Fit th
the crankshaft until the spring pin (A) of the
1.Slacken
The the alternator
pulley is secured mounting
by a torque bolts
loaded left and
hand move
thread nut. a. Turn the crankshaft
starting handle until
catchthe
pinspring pinthe
(B), in (A)camshaft
of the starting
is seal.
ng and
the alternator as far as it will go towards the handle catch pin (B), in the camshaft is visible
visible through the hole in the cover boss. through the 3.Repla
Removing
crankcase. the Pulley hole in the cover boss.
b.Tap out the pin (A) with a suitable punch. the n
ylinder
2Remove the drive belt. b. Tap out the pin (A) with a suitable punch.
c.Turn the engine through 90° and drift out the corre
1. Slacken the alternator mounting bolts and move the c. Turn the engine through 90° and drift out the starting handle
3.Fit the flywheel locking tool into the tapped hole starting handle catch pin (B). TS/TR E
alternator as far as it will go towards the crankcase. catch pin (B).
in the flywheel housing - check that the flywheel 4.Repla
2. Remove the drive belt.
will not turn.
3. Fit the flywheel locking tool into the tapped hole in the screw
en the If the housing
flywheel- locking tool
flywheel check that theisflywheel
not available
will notwedge
turn. TX Eng
the crankshaft with a suitable piece
If the flywheel locking tool is not available of wood
wedgetothe
on TX 5.Repla
prevent itwith
crankshaft turning.
a suitable piece of wood to prevent it
exceed 6.Repla
The
turning. pulley is secured by a torque loaded left
hand thread nut.by a torque loaded left hand thread nut. All Eng
The pulley is secured
7.Chec
C. firing
The E
The ca
bush fi
Figure 2.21.1 Starting Handle
Figure 2.21.1 Starting Handle Pin Pin to supp
A - Early Engines
A - Early Engines; B - Later Engines The S
B - Later Engines 50065
On later engines: end co
On laterthe
d. Remove engines:
grub screw (A) from the end of the camshaft. also be
Figure 2.20.1
d.Remove
e. Drift out the pinthe(B).
grub screw (A) from the end of the end co
Figure 2.20.1Flywheel Locking
Flywheel Locking Tool
Tool
camshaft.
2. Insert the oil seal tool into the end cover to protect the seal. 1.Place
4.Remove the pulley retaining nut byit clockwise.
turning it e.Driftthe
3. Remove outretaining
the pin bolts.
(B). cove
4. Remove the pulley retaining nut by turning
On hydraulic pump build engines a retaining bolt is fitted
clockwise.
5. Pull off the crankshaft pulley.
behind the pump mounting flange and it must be removed
5.Pull off
6. Remove the
the crankshaft
locking tool. pulley.
before attempting to remove the end cover.
6.Remove the locking tool.
4. Remove the end cover.
Refitting the Pulley 5. Clean all traces of the old joint from the crankcase and cover.
Refitting the Pulley 6. If necessary push out the oil seal by using the oil seal tool, or
1. Fit the flywheel locking tool into the tapped hole in the
1.Fit the flywheel locking tool into the tapped hole
screw flywheel a suitable plug press.
housing - check that the flywheel will not turn.
in thethe
rocker 2. Replace flywheel housing
crankshaft pulley.- check that the flywheel
3. Replace the pulley retaining nut and torque it anti-clockwise Removing the End Cover - TX
to 197.0Nm (145.0lbf ft).
1. Remove the drive belt and crankshaft pulley.
4. Remove the flywheel locking tool.
2. If necessary remove the alternator and axial fan.
5. Replace the drive belt and tension it following the instructions
3. Insert the oil seal tool into the end cover to protect the seal.
given in "02.20 Drive Belt Tension".
4. Remove the seven end cover bolts.
5. Remove the end cover.
2.21 The Gear End Cover 6. Clean all traces of the joint from the crankcase and cover.
7. If necessary push out the oil seal by using the oil seal tool or
The light alloy end cover is located on two dowels and is a suitable plug press.
secured to the crankcase by seven setscrews and washers.
The end cover contains an oil filler neck and filler cap, and a
bucket plug is secured in position with Hylomar PL32M over Refitting the End Cover
the crankshaft pinion. A joint is fitted between the end cover 1. With the crankcase and end cover joint faces clean and dry
and the crankcase face. fit a new joint.
The Service Tool 317-50063 (TS/TR) or 317-50065 (TX), is used 2. Fit the oil seal tool into the outside face of the oil seal.
to protect the oil seal when the end cover is either removed 3. Replace the end cover, taking care to ensure the new joint
or replaced and it can also be used to remove and replace the is not damaged and the cover is correctly fitted over the
seal in the end cover. dowels.
 TS, TR, TX engines workshop manual 22

TS/TR Engines 5. Remove the bolts securing the top of the tank to the cylinder
head cover and air cowl bracket.
4. Replace the catch pin and spring pin or grub screw.
Replacing the Fuel Tank - TS/TR
TX Engines
1. Support the tank and replace the bolts securing the top of
5. Replace the crankshaft pulley and drive belt. the tank to the cylinder head cover and air cowl bracket.
6. Replace the alternator and axial fan. 2. Replace the two nuts securing the base of the tank to the air
shield and end cover bracket.
T SERIES ENGINES WORKSHOP MANUAL
All Engines 3. Reconnect the fuel pipe at either the fuel pumps or fuel tank.
4. Push the leak-off pipe into the top of the tank.
7. Check the camshaft end float.
shoulder of the seal boss. 4.Remove the four nuts securing the tank flexible
The End Cover
2.Using theOil Sealtool press the seal into position Removing
oil seal
the Fuel Tank - TX
mountings to the mounting plate.
within theisoil seal 1. Drain
5.Lift the
off fuel
the into
tank.a clean receptacle.
The camshaft oil seal of the liphousing'
variety andboss until
a plain bush it fitted
is flush
with the inside face of the boss. 2. Disconnect the fuel pipe from tank.
to the outside of the end cover sleeve is to support the starting
3. Pull off the leak-off pipe from the top of the tank.
In in
anuse.
emergency, if the tool is not available a Replacing the Fuel Tank the- tank
TX flexible mountings
handle when
4. Remove the four nuts securing
The Servicesuitable plug, preferably
Tool, 317-50063 hard wood,
(TS/TR) or 317-50065 (TX), iscanused be 1.Support the tank and replace the four flexible
to the mounting plate.
to protect used.
the oil seal when the end cover is either removed mounting studs into the mounting plate and
5. Lift off the tank.
or replaced and it can also be used to remove and replace the replace the washers and nuts.
seal in the end cover.
2.22 THE FUEL TANK
1. Place a new seal into the outside neck of the end cover, lip
2.Reconnect the fuel pipe to the tank.
Replacing the Fuel Tank - TX
Various sizes itofsquarely
engineonmounted fuelof tanks 3.Push the leak-off pipe onto the union at the top
side first, and position the shoulder the sealare 1. Support
available as shown in the table below. of thethe tank and replace the four flexible mounting studs
tank.
boss. into the mounting plateprime
and replace the washers
4.Refill the tank and the fuel system if itand nuts.
is not
2. Using TS/TR tanks
the oil seal toolare fitted
press theto theinto
seal gear end ofwithin
position the engine
the 2. Reconnect the fuel pipe to the tank.
oil sealand TX are
housing' bossfited at itthe
until flywheel
is flush with end.
the inside face of
self-priming.
3. Push the leak-off pipe onto the union at the top of the tank.
the boss. 4. Refill the tank and prime the fuel system if it is not self-
In an emergency, if the tool litresis not available
pints a suitable USplug,
qts 2.23 THE FUEL FILTER
priming.
preferably hard wood, can8.2 be used. 14.5 8.7 One of three types of filter will be fitted and a
TS/TR1
13.5 23.7 14.2 combined filter and agglomerator is available when
2.22 The Fuel Tank
TS/TR/TX2 13.5 23.7 14.2
2.23 The Fuel Filter
no tank is fitted.
One The filter is
of three an essential
types of filter willpart of a diesel
be fitted engine and
and a combined filter
TS/TR/TX3
Various sizes 25.0 fuel tanks
of engine mounted 43.9 are available
26.3as
and agglomerator
the engine must is available
never be when
runnowithout
tank is fitted.
a fuel filter
shown in the table below. The filter is anThe
essential part ofshould
a dieselbe engine and the engine
element. element renewed every
TS/TR tanks
Tankare fitted to the gear end of the engine and TX are
Maintenance must500never
hours,be or
runmore
without a fuel filter
frequently element.
if for The element
any reason the
fited at the flywheel end.
1.Drain the tank. should be renewed every 500 hours, or more frequently if for
fuel is known to be dirty.
2Remove any sediment. any reason the fuel is known to be dirty.
litres pints US qts
3. Flush the tank with clean kerosene and allow it The Fuel Tank Filter
TS/TR1to drain dry.
8.2 14.5 8.7 TheTheFuelfuelTank filter isFilter
an essential part of the engine
13.5 and prime23.7
4.Refill the tank the fuel system 14.2if it is not
Theand
fuelitfilter
mustis annever
essentialbepartrunofwithout
the engine a filter
and itand
mustthe
never
self-priming.
TS/TR/TX2 13.5 23.7 14.2
beelement
run without should beand
a filter renewed everyshould
the element 500 hours, or
be renewed
TS/TR/TX3 more
every 500 frequently
hours, or if
morefor any reason
frequently if the
for fuel
any is
reasonknown
the fuel
Removing25.0 the Fuel Tank43.9
- TS/TR26.3 to be dirty.
is known to be dirty.
1.Drain the fuel tank into a clean receptacle. 1.Remove
1. Remove the the retaining
retaining plug plug
(A). (A).
Tank Maintenance
2.Disconnect the fuel pipe at either the fuel pumps 2. Remove 2.Remove the the old element
old element (B) and(B)the
and the(C).
joints joints (C).
or fuel
1. Drain the tank. tank.
2. Remove 3.Pull out the leak-off pipe from top of the tank.
any sediment.
3. Flush the tank withthe
4.Remove nuts
clean securing
kerosene andthe base
allow it toofdrain
the tank
dry. to
the air shield and end cover bracket.
4. Refill the tank and prime the fuel system if it is not self-
5.Remove the bolts securing the top of the tank to
priming.
the cylinder head cover and air cowl bracket.
Removing the Fuel Tank - TS/TR
Replacing the Fuel Tank - TS/TR
1. Drain the fuel tankthe
1.Support intotank
a clean
andreceptacle.
replace the bolts securing
2. Disconnect the fuel pipe at either the fuel pumps or fuel tank.
the top of the tank to the cylinder head cover and
3. Pull out the leak-off pipe from top of the tank.
air cowl bracket.
4. Remove the nuts securing the base of the tank to the air shield
2.Replace the two nuts securing the base of the
and end cover bracket.
tank to the air shield and end cover bracket. Figure 2.23.1
Figure 2.23.1Fuel TankInternal
Fuel Tank Internal Filter
Filter
3.Reconnect the fuel pipe at either the fuel pumps
or fuel tank. 3.Fit a new element and new joints.
4.Push the leak-off pipe into the top of the tank. 4.Replace and tighten the retaining plug (A).
 T SERIES ENGINES WORKSHOP MANUAL
TS, TR, TX engines workshop manual 23
T SERIES ENGINES WORKSHOP MANUAL

The Fuel Filter - TS/TR2, 3 2.24 PRIMING THE FUEL SYSTEM

1.Unscrew andnewremove
joints.the retaining bolt (A) from If the fuel system is self venting it should not be
3. Fit
The a new
4. Replace
Fuelelement
the
and
Filter
element
and tighten
- bowl.
TS/TR2,
the retaining
3
plug (A).bolt (A) from
2.242.24 Priming
PRIMING THEtheFUEL Fuel SYSTEM System
1.Unscrew and remove the retaining Tnecessary
SERIES ENGINESto manually prime it. MANUAL
WORKSHOP
If the fuel
If the system
fuelthe
system isself
selfventing
venting it should notnecessary
be
5. Prime the fuel system.
the element bowl. 1.Fill tank iswith fuel. it should not be to
necessary
manuallyto manually
prime it. prime it.
2.Vent the fuel filter through the bleed screw (A)
The Fuel Filter - TS/TR2, 3 3 1.Fill thethe
1. Fill tank
tankwith
withfuel.fuel.
until a full air free flow of fuel is obtained.
The Fuel Filter - TS/TR2, 2.24
2.Vent PRIMING
2. Ventthethefuel filterTHE
fuelfilter through
through FUELthebleed
the SYSTEM
bleed screw
screw (A) a full air
(A) until
1.Unscrew
1. Unscrew andand remove
remove the retaining
the retaining bolt (A)
bolt (A) from from If the
the element 3.Vent the fuel at each pump in turn through the
free
untilfuel flow of
a fullsystem fuel
air freeisflowis obtained.
selfof fuel is obtained.
venting it should not be
the element bowl.
bowl. bleed
3. Vent the screws
fuel at each (B) starting
pump in with
turn the pump
through nearest
the bleed
3.Vent
necessary the fuel
to at
manually eachprime pump it. in turn through the screws
(B)to the fuel tank.
bleed
1.Fill thestarting
screws
tank with with
(B)fuel.the pumpwith
starting nearestthe to the fuel
pump tank.
nearest
to thethe
2.Vent fuelfuel
tank. filter through the bleed screw (A)
until a full air free flow of fuel is obtained.
3.Vent the fuel at each pump in turn through the
bleed screws (B) starting with the pump nearest
Figure 2.23.2 Fuel Filter to the fuel tank.

Figure 2.23.2 Fuel Filter

2.Remove the element (B) and discard it.
3.Discard the three joints (C).
2.Remove the element (B) and discard it.
4.Fit a new joint to the element adapter, the retaining
3.Discard the three joints (C).
bolt and the filter head.
4.Fit a new jointFigure to the2.23.2element Fueladapter,
Filter thethe retaining
5.Place the Figure new element
2.23.2 Fuel onto
Filter adapter.
bolt and the filter head.
6.Replace the element bowl and retaining bolt.
5.Placethe
2.Remove
2. Remove thethe new
element element
element (B) and (B) onto
and
discard the adapter.
discard
it.the it. system.
7.Fill the fuel tank and prime fuel
6.Replace
3.Discard
3. Discard thethe the
three element
threejointsjoints bowl
(C). (C). and retaining bolt.
7.Fill
4.Fit
4. Fit athe
a new new fuel
joint totank
joint to the
the and prime
element
element the fuel
adapter,
adapter, system.
the retaining
the retaining bolt and
The Cartridge Agglomerator
boltfilter
the andhead. the filter head.
Several types of filter/agglomerator have been
The the
5.Place
5. Place Cartridge
the
newnew element Agglomerator
element onto onto the adapter.
the adapter.
used but the following instructions are valid for all
Figure 2.24.1
Figure 2.24.1Priming theFuel
Priming the Fuel System
System
6.Replace
6. Replace the the
elementelement bowl
Several types of filter/agglomerator have beenbowl
and and
retaining retaining
bolt. bolt.
types. Figure 2.24.1 Priming the Fuel System
7. Fill thethe
7.Fill
used fuelfuel
but tanktank
the and and
following prime the fuel
prime thesystem.
instructions
The cartridge agglomerator is an essential part 2.25
fuelare system.
valid for all 2.25The THEFuel FUEL LiftLIFT Pump PUMP
types. A THE
PienneFUEL (B) fuelLIFT lift pump was first fitted from the
of the engine and should be renewed every 500
The TheCartridge is an essential part 2.25 PUMP
The hours, or Agglomerator
Cartridge Agglomerator
cartridge agglomerator A Pienne (B) fuel lift pump was first fitted from the engines
more frequently if for any reason the engines below and differs from the older AC Delco
of the engine
Several types and
of should be renewedhave
filter/agglomerator everybeen 500 A Pienne below and (B)differs
fuel lift
frompump was first
the older fitted(A)
AC Delco from
type.the
Several typesfuel isof known to be dirty.have
filter/agglomerator Water beenisused drained
but thefrom (A) Figure type. 2.24.1 Priming the Fuel System
hours,
used the but or more
the following frequently if
instructions for any reason
are the
valid the
for all engines 38 02253
below TS1
and differs from the older AC Delco
following agglomerator
instructions are valid by forunscrewing
all types. drain tap (C) 38 00287
38TS202253 TS1
fuel
types. is known to be dirty. Water is drained from (A) type.
The cartridge
sufficientlyagglomerator to allowisthe an essential
water topart of the engine
drain. 38TS300287 TS2
and the
The agglomerator
cartridge
should be renewed byevery
agglomerator unscrewing
500 is
hours,antheor drain
essential
more tap (C) 2.25 38
part
frequently
THE
3800262 FUEL
02253
38
TS1LIFT PUMP
00262 TS3
A strap wrench is required to remove the 38 00754 TR1
sufficiently
of
if for theagglomerator
any engine
reason tothe
allow
and the
fuelshould water
is known be torenewed
bedrain.
toengine dirty. every
Water 500
is drained A Pienne 38(B)00287 TS2
fuel00754
lift pump was first fitted from the
from the but it must not be 383800003 38 TR2TS3 TR1
A the strap wrenchfrequently isbyrequired to remove the(C) engines 00262
below and
fromhours, or more
agglomerator
used to fit a replacement. if
unscrewing for any thereason
drain the
tap
383800094 38TR300003 TR2from the older AC Delco
differs
agglomerator
fuel
sufficiently to allowfrom
is1.Using
known tothe be the
water engine
dirty.to Water
drain. butisitdrained
must not frombe (A) type. 00754 TR1
a suitable strap wrench unscrew the 383800244 38TX200094 TR3
used to fit
the agglomerator a replacement.
byfromunscrewing 38 00003
02253 TR2
TS1
A strap wrench is
cartridge (A) required to the headthe
remove the (B).drain tap (C)
agglomerator from
38 00242 38TX300244 TX2
1.Using a to suitable strap wrench unscrew the 38 00094 TR3
thesufficiently
engine 2.Screw allow
but it a newthe
must not be water onto
used
cartridge to drain.
fit a the head and hand With 38
replacement. 00287 TS2
38 00242
the introduction TX3
of the Pienne pump a new fuel control
cartridge
1. Using
A strap a suitable (A)
wrench from
strap the
wrench headunscrew(B).
is required to remove the the cartridge (A) from 38 00244
38 the
00262 TX2
TS3
tighten it. With
solenoid introduction
arrangement and aofnewthespeed
Pienne pump
control cablea new
anchor
2.Screw
the head (B).
agglomerator a newfrom cartridge
the engine onto the but head
it must andnot hand be 38(366-07912)
38 00242 TR1
00754 TX3were introduced.
fuel
bracket control solenoid arrangement and a new
2. Screw
tighten
used a new
to fitit.acartridge
replacement. onto the head and hand tighten it. With the 38introduction
00003 TR2 of thebeen
Pienne pump a new (C) lift
Thespeed
Pienne control
pump cable
has since anchorreplaced
bracketby(366-07912)
a Corona
1.Using a suitable strap wrench unscrew the fuelpump. control
38 00094solenoid
were introduced. TR3 arrangement and a new
cartridge (A) from the head (B). speed
The control
38Pienne
pump 00244
push cable
TX2
rod anchor
and bracket
joint since
are (366-07912)
interchangeable for all
The pump has been replaced bytypes
a
2.Screw a new cartridge onto the head and hand were introduced.
38
of Corona 00242 TX3
pump. (C) lift pump.
The Pienne
With pump hasofsince
the introduction the been replaced a by
newa
tighten it. The pump push rod andPienne
joint are pumpinterchangeable
Corona
fuel control(C) lift pump.
solenoid arrangement and a new
for all types of pump.
The pump
speed push
control rod and
cable anchor jointbracket
are interchangeable
(366-07912)
for allintroduced.
were types of pump.
The Pienne pump has since been replaced by a
Corona (C) lift pump.
The pump push rod and joint are interchangeable
Figure 2.23.3 The Cartridge Agglomerator for all types of pump.

Figure 2.23.3
Figure 2.23.3The Cartridge
The Cartridge Agglomerator
Agglomerator
25
25
Figure 2.23.3 The Cartridge Agglomerator
 c.Fit the adaptor nylon bush over the high
T SERIES ENGINES WORKSHOP MANUAL pressure pipe connection.

TS, TR, TX engines workshop manual 24

T SERIES ENGINES WORKSHOP MANUAL
c.Fit the adaptor nylon bush over the high
pressure pipe connection.
c.Fit the adaptor nylon bush over the high
pressure pipe connection.

Figure 2.26.1 Injector Removal Tool with Early Type

Adaptor

6.Use the slide hammer to remove the injector.

Figure 2.25.1 Fuel Lift Pumps
A - AC Delco
WARNING
Figure 2.26.1
Figure 2.26.1 Injector
Injector Removal
Removal ToolEarly
Tool with
Adaptor
with Early
Type Type
Adaptor

B - Pienne
Care must be taken to ensure that any part of
6. Use
the the
hand slide hammer totoremove the injector.
C - Corona Figure
6.Use theis
2.26.1 not likely
Injector
slide Removal
hammer become
Tool with
to remove trapped
Early Typebetween
the injector.
the two parts of Adaptor
the slide hammer while it is
Figure 2.25.1 Fuel Lift Pumps WARNING
being WARNING
used.
2.26 THE FUELA INJECTOR 6.Use the slide
- AC Delco
Care
Care mustmust behammer
taken
be taken to to remove
ensure thatthe
to ensure injector.
anythat
part any
of theparthandof
The fuel injection equipment B - Pienneand all of the pipes
is Note:
not
the likely
hand to
is become
not likely trapped
to become between the
trapped two parts
between of
and unions FigureFigure 2.25.1
between
A - AC
Fuel
2.25.1 Fuel -Lift
CLift
the
Delco
fuelPumps
Corona
Pumps filter and the injector the WARNING
The
theslide
twotool
hammer
parts design while
of the has
it is being
slide changed
used.
hammer and
while now
it is
must beA absolutely
- AC Delco; B - Pienne; C - Corona
clean. A minute particle of dirt
B - Pienne
Careincorporates
must be taken ato larger ensure hole that anywith part a ofnylon
being used.
2.26
can THE
easily block FUEL one INJECTOR
hole
C - Corona in the injector nozzle the
and hand is not likely to become
insert which fits over the high pressure trapped between
2.26 The this
Thewill Fuel
give Injector
rise to equipment
a dirty exhaust and and starting theNote:
and two
Note: parts of the slide hammer while it is is
fuel injection all of the pipes Thepipe connection
tool design has changed and onnow the injector.
incorporates No hole
a larger screwwith a nylon
running problems. being used.
required.
The2.26
fuel and THE unions
injection FUEL between
equipment INJECTOR
andtheallfuel
of the filterpipes andand theunions
injector insertThewhichtool
fits over design
the high pressure has pipechanged
connection on theand
injector.now
No screw
Lucas
must beDizelabsolutelyfuel injectorsclean.must Aareminute currentlyparticle fitted to is required.
of dirt incorporates a larger hole with a nylon
between
The fuel the
the
can
fuel
engines
easily
filter
injectionand and
block
the
equipment injector
theyhole
one must andnot
inone
be
allbe
thehole
absolutely
of mixed
injector
the pipes clean.
with any
nozzle
Note:
A minute
and unionsparticle of dirt
between canthe easily block
fuel filter and in the
the injectorand
injector The Removing
insert
tool design which an fits Injector
has over
changed - the
TX high and pressure
now
earlier
thisthis
will types
give on to
rise an engine.
aa dirty
dirty exhaust It and
isand recommended
starting and Removing
1.Remove the cylinder head cover.
nozzle and
must that will
be absolutely give rise to
clean. A exhaust
minute particle starting
of and
dirt pipe connection an Injector
incorporates a larger hole with a nylon on the - TXinjector. No screw is
running running injectors
problems. problems. are changed as a set rather than 2.Remove the fuel pipe between the fuel pump and
can easily block one hole in the injector nozzle and required.
Lucas Dizel individually.
Lucas DizelFor
fuel injectors arefurther
fuel injectors
currently information theplease
aretocurrently
fitted engines and insert
contact
fitted which
to 1. Remove the fits over
cylinder head the
cover.
injector; hold the fuel pump delivery valve holder
high pressure
this will
any give risePetter
Lister to a dirty Power exhaustSystems and distributor.
starting and pipe connection the fuelon the injector. No pumpscrewand is injector;
they must thenot engines
be mixed andwith they
any must
earlier not
types beonmixedan engine.with Itany 2. Remove
with a spanner
Removing
pipe
antoInjector
between
prevent it-turning.
the fuel
TX
running problems. required.
hold the fuel pump delivery valve holder with a spanner to
earlier types
is recommended that injectorson anareengine. changedItasis a setrecommended
rather than 3.Remove
1.Remove the
the leak-off
cylinder pipe headfrom the injector.
cover.
Lucas Dizel fuel injectors are currently fitted to prevent it turning.
Removing
individually.
thatFor furtheran
injectors areInjector
information
changed - TS/TR
please as contact
a set any rather Lister
than 4.Remove the fueltwo pipeclamp retaining
2.Remove thenuts
fueland lift and
the
the Power
Petter engines
1.Remove
and they
Systems the
must not be mixed with any Removing
cylinder
distributor. head
individually. For further information please contact clampcover. 3. Remove anthe
the
off.
leak-off
Injector pipe-from between
TX the injector. pump
earlier types on an engine. It is recommended 1.Remove injector;the hold twothe fuelretaining
pump delivery valve holderoff.
2.Remove
any Lister Petter the fuelPower pipe between
Systemsthe fuel pump and 4. Remove
distributor. 5.Fit the adapter
cylinder clamp head cover. nuts and lift the clamp
that injectors are changed as a set rather than 2.Remove 5. Fit theathe
with spanner
adapter (A) tointo(A)adapter
prevent into itadapter
turning. (B) and
between the fuel pump andonto the
(B) and screw them screw
Removing an
injector; Injector
hold the fuel - TS/TRpump delivery valve holder them onto
individually. For further information please contact injector; injector.
the fuel the pipe
injector.
3.Remove the leak-off pipe from the injector.
with a spanner
Removing an to prevent-itTS/TR
Injector turning. hold the fuel pump delivery valve holder
any Lister Petter Power Systems distributor.
1. Remove the cylinder head cover. 4.Remove the two clamp retaining nuts and lift the
3.Remove
1.Remove the leak-off
the between
cylinder the pipe
head and union from with
the a spanner to prevent it turning.
2. Remove the fuel pipe fuelcover.
pump and injector; clamp off.
injector.
2.Remove pumptoand 5.Fit the adapter pipe
3.Remove the leak-off from the injector.
hold the
Removing fuel pump
4.Unscrew anthe the
fuel pipe
delivery
Injector
Allen
valve between
- TS/TR
screw
holder with
and
the afuel
remove
spanner
the 4.Remove
injector the two clamp
(A) into adapter (B) and screw
retaining nuts and lift the
prevent injector;
it turning. hold the fuel pump delivery valve holder them onto the injector.
1.Remove clamp; the the cylinder clamp head
is cover. in position by a hole
located clamp off.
3. Remove with
the the a spanner
leak-off pipe to
and prevent
union from it turning.
the injector.
2.Remove inthe
theAllen fuelof
side pipe
the between
cylinder the fuel
head pump and 5.Fit the adapter (A) into adapter (B) and screw
4. Unscrew 3.Remove thescrew leak-off
and pipe
remove theassembly.
and union clamp;
injector from the
injector; hold the fuel pump delivery valve holder
the clamp is located in position by a hole in the side of the them onto the injector.
Either:
injector.
with aa.Screw
spannerthe to prevent
adaptor it(A)
turning.
into remove
the slide
cylinder 4.Unscrew
head assembly. the Allen screw and thehammer
injector
3.Remove the
and tighten leak-off pipe and union from the
Either: clamp; the clamp is located in position by aleak-
the screw (C) into the injector hole
a.injector. off
Screwinthe thehole;
sidesee
adaptor of(A)
theNote.
into the slide
cylinder hammer
head and tighten
assembly.
4.Unscrew Or:
the screw the Allen
(C) into thescrew
injector andleakoffremove hole;the seeinjector
Note.
Either:
Or:clamp; the clamp
b.Screw the is located
adaptor (A)
a.Screw the adaptor (A) into the slide hammer
ininto
position
the by ahammer.
slide hole
b.inScrew
the side
the of the cylinder
adaptor (A) into head
the slide
and tighten the screw (C) into the injector leak-
assembly.
hammer. Figure 2.26.2
2.26.2Injector Removal ToolTool
c.Either:
Fit the off
adaptor nylon
hole; see Note. bush over the high pressure pipe Figure Injector Removal
a.Screw
connection. the adaptor (A) into the slide hammer
26Or: 6. Fit the slide hammer to the adapter and remove the injector.
and tighten the screw (C) into the injector leak-
b.Screw the adaptor (A) into the slide hammer.
off hole; see Note.
Or: WARNING Figure 2.26.2 Injector Removal Tool
b.Screw the adaptor (A) into the slide hammer. Care must be taken to ensure that any part of the hand
26 is not likely
Figureto2.26.2 become trapped
Injector Removal between
Tool the two parts of
the slide hammer while it is being used.
26
 section.
Care must be taken to ensure that any part of
the hand is not likely to become trapped between WARNING
the two parts of the slide hammer while it is Under no circumstances allow unprotected skin
being used. TS, TR, TX engines workshop manual 25
to come into contact with the spray as the fuel
may enter the blood stream with fatal results.
Cleaning an Injector
• A thoroughly cleaned container holding a supply Injector Backan
Pressure
Cleaning an Injector Replacing Injector
of clean, fresh fuel oil should be available for The leak-off rate is 6-27 seconds between 172-
A thoroughly cleaned
washing containerparts.
dismantled holding a supply • of clean, fresh If the injector sealing washer has been used more than
142bars (170-140atmos) on an injector tester using
fuel
• oil The
should be available for
components of washing dismantledinjector
each individual parts. once it will become compressed and may adversely affect
Calibration C fluid, at a temperature of 15.5°C
The components
should beofkepteachtogether
individual
at injector
all times.• should be kept combustion. Care should be taken to ensure two washers
together at all times. (60°F).
are not fitted.
• Never use paraffin or woven cloths; it is
Never usepermissibleor
paraffin towoven cloths; it ispaper
use non-fluffing • permissible
during to
theuse 1. Examine the oil seal ring for damage or cuts, replace if
non-fluffing paper during the cleaning process. Replacing
necessary.an Injector
cleaning process.
Components should be assembled wet.• If the injector
2. Ensure thesealing washerwasher
injector sealing has been used
has been more and the
removed
• Components should be assembled wet.
than seating
once itin the will cylinder
become compressed and
head is clean and smooth. may
Setting the adversely
3. Lightly affect
smear combustion.
a very smallCare amount should be taken
of high melting point
Setting theInjector
Injector to ensure
greasetwo washers
to one side of aarenew not fitted.sealing washer and place
injector
To To ascertain
ascertain if theif injector
the injector is in good
is in good condition,
condition, it is
it is removed 1.Examine
it over the theinjector
oil seal ringgreased
nozzle, for damage or cuts,
side first.
removed
from from
the engine andthe engine to
connected and connected
a fuel torig,
injector test a fuel
similar 4. Replace
replace the leak-off pipe to the injector.
if necessary.
to injector test rig, similar to the one shown.
the one shown. 5. Fit thethe
2.Ensure injector into the
injector cylinder
sealing head. has been
washer
removed and the seating in the cylinder head is
TS/TR
clean andEngines
smooth.
3.Lightly smear a very small amount of high melting
6. Replace the clamp and leave the Alien screw finger tight.
point
7. Replace thetofuel
grease one sideto
pump ofinjector
a new pipe injector
- dosealing
not tighten.
washer
8. Replace the leak-off pipe into the fuel tank.nozzle,
and place it over the injector
greased
9. Torqueside first. screw to 21.0Nm(15.5lbf ft).
the clamp
4.Replace
10. Torque all fuel pipepipe
the leak-off nuts toto 28.5Nm
the injector.
(21.0lbf ft) and the leak-
5.Fit the off pipe swivel union to 4.0Nmhead.
injector into the cylinder (3.0lbf ft).
TS/TR Engines:
11. Replace the cylinder head covers.
6.Replace
12. After the the initial
clamp runand leave an
following the Alien replacement
injector screw re-
finger tight.the injector clamp screw.
torque
7.Replace the fuel pump to injector pipe - do not
Figure 2.26.3
2.26.3Typical Injector Test
Rig Rig
Figure Typical Injector Test tighten.
TX Engines
8.Replace the leak-off pipe into the fuel tank.
If aIf rig
a isrignotisavailable
not available it becomes
it becomes necessary necessary
to replacetothe 13. Replace
9.Torque the clamp
the clamp screwandto leave the nuts fingerft).
21.0Nm(15.5lbf tight.
complete injector by a new or serviced one whichserviced
replace the complete injector by a new or has a clean 14. Replace the fuel pump to injector pipe - do not tighten.
10.Torque all fuel pipe nuts to 28.5Nm (21.0lbf
one and
nozzle which has correctly
has been a cleanset.nozzle and has been 15. Push the leak-off pipe onto the injector.
ft) and the leak-off pipe swivel union to 4.0Nm
Allcorrectly
sprays shouldset. have the same appearance and the same 16. Torque the clamp screw to 8.0Nm (6.0Ibf ft).
(3.0lbf ft).
All sprays
length should have
of penetration in thethe air.same
If oneappearance and or
spray is shorter 17. Torque all fuel pipe nuts to 28.5Nm (21.0lbf ft).
11.Replace
18. Replace the
thecylinder
leak-off head
pipe intocovers.
the fuel tank.
the same
weaker than thelength
others of this
penetration
means that in the
thecorresponding
air. If one 12.After the initial run following an injector
hole is partially
spray blocked
is shorter orand best results
weaker than will
thenot be obtained.
others this replacement re-torque the injector clamp screw.
TX2.27 The Fuel Pump
If one
means hole isthat
totally
theblocked or the nozzle
corresponding dribbles
hole it must be
is partially Engines:
replaced.
blocked and best results will not be obtained. If one
When 13.Replace
The individual the fuel
clamppumps and areleave
locatedthe nuts
at the sidefinger
of the engine
holea new nozzle
is totally is fitted or
blocked thethe
injector
nozzle must be resetit on
dribbles a test
must tight.
rig.beAfter testing and resetting the injector top plug must be between the push rods and are secured to the crankcase by two
replaced. 14.Replace
torque loaded to 27.1 Nm (20.0lbf ft). bolts. Earlythe fuel pump
TS engines were to injector
fitted with apipe - do not
long headed bolt fitted
When a new nozzle is fitted the injector must be tighten.
to the inside hole in the pump mounting flange.
reset on a test rig. After testing and resetting the 15.Push the leak-off pipe onto the injector.
Note:
injector top plug must be torque loaded to 27.1 Nm 16.Torque the clamp screwPumpsto 8.0Nm (6.0Ibf ft).
Injector setting pressures can be found in 'Technical Data" in the relevant engine
(20.0lbf ft). Removing the Fuel
section. 17.Torque all fuel pipe nuts to 28.5Nm (21.0lbf ft).
1. Drain the
18.Replace fuel
the tank orpipe
leak-off isolateintothethe
fuelfuel
supply.
tank.
2. Disconnect the fuel feed pipes at the pumps.
WARNING 3. Remove the fuel pipes from the pumps to injectors taking care
to hold the fuel pump delivery valve holder with27 a spanner
Under no circumstances allow unprotected skin to come
to prevent it turning.
into contact with the spray as the fuel may enter the
4. Remove the fuel pump inspection doors.
blood stream with fatal results.
5. Release the spring tension of the speeder spring by
unscrewing the speed adjusting screws on the side of the
Injector Back Pressure crankcase.
6. Using long nose pliers disconnect the speeder spring from
The leak-off rate is 6-27 seconds between 172-142bars (170- its spigot.
140atmos) on an injector tester using Calibration C fluid, at a It may be necessary to turn the spigot until the hole axis is
temperature of 15.5°C (60°F). parallel to the camshaft before removing the spring.
7. Disconnect the governor and pump interconnecting linkage
at the pumps.
 6.Using long nose pliers disconnect the speeder
spring from its spigot.
It may be necessary to turn the spigot until
the hole axis is parallel to the camshaft before
TS, TR, TX engines workshop manual 26
removing the spring.
7.Disconnect the governor and pump interconnecting
linkage at the pumps. T SERIES ENGINES WORKSHOP MANUAL
The 'ring' typeFigure 2.27.2 Timing
are available Shims
in 0.127, 0.762, 1.016 and 1.276mm
sizes and were first fitted on:
2.27
The 'ring' THE
type
40 00213 are 40
TS1 FUEL
available PUMP
00113 TR1in 0.127, 0.762, 1.016 Fuel P
and 1.276mm
40 00297 sizes
TS2 40and were
00135 TR2first fitted on: It is re
The individual fuel pumps are located at the side of
4040 00213
00223 TS2TS1 40 00039 TR3 40 00113 TR1 fuel pu
the engine between the push rods and are secured
In all instances
40 00297 it isTS2
recommended 40that the thickest
00135 TR2 shim is fitted Depots
to to
next the crankcase by two bolts. EarlyfitTS engines
40the crankcase
00223 TS2 and it is 40 advisable
00039to TR3 the minimum own m
were of fitted with a long headed bolt fitted to the
In number
all instancesthinner itshims as possible.
is recommended that the the rele
inside hole in the pump mounting flange.
thickest shim is fitted next to the crankcase and it
Refittingtothe
is advisable fit theFuel Pumpsnumber of thinner
minimum Timin
shims Removing
as possible the Fuel Pumps
1. If1.Drain
'ring' type theshims
fuel tankare being fitted place
or isolate the fuelthem onto the fuel
supply. To imp
pump
2.Disconnect the fuel feed pipes at the pumps.ring.
taking care not to damage the pump sealing 'sickle'
Refitting
2. Place
3.Remove
the
the Fuel
pumps into
the fuel
Pumps
the crankcase
pipes from the and fit the to
pumps retaining bolts
injectors form 'ri
1.If finger
'ring' type
tight shims are being fitted place them
only. not be
Figure 2.27.1 taking care to hold the fuel pump delivery valve
2.27.1Fuel Pump Linkage onto
3. If the fuel pump
'sickle' taking care not to place
damage the the The 'ri
holdertype withshims are being fitted pumps into
Figure Fuel Pump Linkage
A - BEarly
A - Early TS/TR; - LaterTS/TR
TS/TR and all TX a spanner to prevent it turning.
pump the sealing
crankcasering. and fit the retaining bolts finger tight only: the remove
B - Later TS/TR and all TX 4.Remove the fuel pump inspection doors.
2.Placepumps theshould
pumpsbeinto theabove
slightly crankcase
the faceand fit crankcase.
of the the
8. Move the rack operating lever on the pump to the central 5.Release the spring tension of the speeder spring
Replacebolts
retaining the shims
fingerbetween the pump and crankcase taking
tight only.
8.Move the rack operating lever on the pump to the
position. by unscrewing the same
speedthickness
adjusting screws on the
care to ensure
3.If 'sickle' type shims that theare being fittedofplace shims theare on each
centralthe
9. Remove position.
fuel pump holding down bolts. side
side ofinto of the
the thepump.crankcase.
pumps crankcase and fit the retaining
10.9.Remove the the
Gently lift out fuelpump
pumptakingholding caredown bolts.
to retain the timing 4. 6.Using
Evenly long nose
tighten the pliers disconnect
retaining bolts toshould the speeder
a torque
bolts finger tight only: the pumps beof 9.0Nm
10.Gently
shims which liftare
outbetween
the pump thetaking care toand
pump flange retain the
crankcase. spring
(6.6lbf ft). from its spigot.
slightly above the face of the crankcase.
timing shims which are between the pump flange It may
5. Connect thebe necessary
governor andtotheturn the spigot until
Replace the shims link between fuel pump
the pumpinterconnecting
and
CAUTION
and crankcase. the hole
linkage astaking
crankcase
axis is parallel to the
shown.care to ensure that the same camshaft before
AL Whenremoving
re-fitting the thespring.
new type of linkage to the fuel pumps it
If more than one pump is being removed care must be
CAUTION
taken to retain the timing shims with their respective
thickness of shims are on each side of the
7.Disconnect
is important to the
ensuregovernor and
that the pump interconnecting
radiused shackles follow the
If more than one pump is being removed care pump.
pump. pumplinkage
radius. at the pumps.
must Pump
Fuel be taken to retain the timing shims with 4.Evenly tighten the retaining bolts to a torque of
Maintenance
their respective pump. 9.0Nm (6.6lbf ft).
side of It is recommended that the work of servicing the 5.Connect the governor link and the fuel pump
FuelfuelPump
pump Maintenance
is carried out by accredited Service The 'rin
ecured interconnecting linkage as shown.
It isDepots
recommendedFor operators
that the work wishing to carry
of servicing out pump
the fuel their is and 1.2
ngines
to the own out
carried maintenance,
by accredited reference
Service Depots should be made
For operators to
wishing
28
to the
carryrelevant
out theirMaster Parts Manual.
own maintenance, reference should be made
to the relevant Master Parts Manual.
Timing Shims In all
Timing Shims
To improve the accuracy of fuel pump timing the thickes
ly. is advis
ps. To'sickle'
improvetype shims (A)
the accuracy have
of fuel been
pump replaced
timing by full
the 'sickle' type shims a
jectors form 'ring' types (B). The two types of shim should
shims (A) have been replaced by full form 'ring' types (B). The
y valve not
two be mixed
types of shimon the same
should not bepump.
mixed on the same pump.
The 'ring' type can only be fittedbe
The 'ring' type can only fitted
with with removed
the pump the pump from Refitti
.
removed
the engine. from the engine. 1.If 'ri
Figure 2.27.1
Figure 2.27.3Fuel Pump
Fuel Pump Linkage
Linkage onto
spring A - BEarly
A - Early TS/TR; - LaterTS/TR
TS/TR and all TX pump
on the B - Later TS/TR and all TX
2.Place
6. Re-connect the speeder spring to the spigot.
retain
peeder If8.Move thewas
the spigot rackturned
operating
whenlever on thewere
the pumps pump to the it
removed
3.If 'sic
mustcentral position.
be turned until the hole axis is at 90° to the camshaft
pump
ot until 9.Remove
before thethe
refitting fuelspring
pumpwhen
holding down bolts.
the speeder spring spigot
is10.Gently
upright. lift out the pump taking care to retain the
bolts
before
slight
timing shims which are between the pump flange
Repla
necting and crankcase.
crank
Figure 2.27.2 TimingShims
Shims CAUTION thickn
Figure 2.27.2 Timing
If more than one pump is being removed care pump
must be taken to retain the timing shims with 4.Even
The 'ring' type are available in 0.127, 0.762, 1.016 9.0Nm
and 1.276mm sizes and were first fitted on: their respective pump.
5.Conn
40 00213 TS1 40 00113 TR1 interc
40 00297 TS2 40 00135 TR2
40 00223 TS2 40 00039 TR3
In all instances it is recommended that the 28
thickest shim is fitted next to the crankcase and it
 B - Later TS/TR and all TX

6.Re-connect the speeder spring to the spigot.

If the spigot was turned when the pumps were
TS, TR, TX engines workshop manual 27
removed it must be turned until the hole axis is
at 90° to the camshaft before refitting the spring Figure 02.28.1 Fuel Pump Components
when the speeder spring spigot is upright.
5.Carefully lift out the delivery valve (D) taking care
10. Turn the flywheel, in the direction of rotation, until the piston
not to disturb the valve seat.
for the cylinder being timed is at 'FP' on the compression
6.Place these components in a suitable container
stroke.
of clean
At this fuel.
position both the inlet and exhaust valves will be
7.Replaceclosed. the delivery union body (A).
8.Fit
11.a Connect
suitable the spillfuelpipe. supply and bleed the fuel filter and
9.Ensure pump. the fuel pump rack is in the run position
by removing a cylinder
12. Carefully turn the flywheel fuel pump againsthousing
rotationdoor until fuel is
and flowing
manually moving the
from the spill pipe. fuel pump rack towards
the
13.gear
Turn end.the flywheel very slowly in the direction of rotation
10.Turn untilthe theflywheel,
fuel flow in from thethe direction
spill pipeofjust
rotation,
stops dripping
until the
this piston as
is known forthethe'Spill
cylinder
Point'.being timed is at
Figure 2.27.4 'FP'Check
14. on the thecompression
flywheel timing stroke.
mark.
Figure 2.27.4Speed Control
Speed Control Lever
Lever
At this
The position both the
flywheel timing mark inlet and
(FP), exhaust
which can be valves
seen through
will anbe aperture
closed. in the fanshroud, should align with the arrow
7.Check
7. Check the governor
the governor setting; refer setting; refer to
to "2.31 Setting "02.31
the Governor". on the the
11.Connect fanshroud.
fuel supply and bleed the fuel filter
Setting the Governor".
8. Fit new joints to the fuel pump inspection doors and replace 15.
and IfTpump.
SERIES
the flywheel ENGINES
mark is not WORKSHOP
correct, seeMANUAL
'Figure 2.28.2', the
8.Fit
the new joints to the fuel pump inspection doors
doors. shims under the fuel pumpagainstmust berotation
adjusted,untilsee "Timing
and replace
9. Replace the fuel the pipes.doors. 12.Carefully turn the flywheel
Shims".
fuel is flowing from the spill pipe.
10.9.Replace
Prime the fuel thesystem
fuel pipes.
if it is not self-priming.
11.10.Prime
Check andthe adjustfuelthesystem
pumpiftiming.it is not self-priming. 13.Turn the flywheel very slowly in the direction of inject
T SERIES ENGINES WORKSHOP MANUAL rotation until the fuel flow from the spill pipe just 3.Conn
11.Check and adjust the pump timing.
stops dripping this is known as the 'Spill Point'. delive
2.28 Fuel Pump Timing 14.Check the flywheel timing mark. 4.Bleed
he fuel Fuel
2.28
be used
pump
FUELto check
components
PUMP the
aretiming
TIMING withouttothe
manufactured need limits
exacting to The flywheel timing mark (FP), which can be 5.Ensu
diused and Fuel
dismantlepump
care mustthe components
be pump. are manufactured
taken to ensure they are returned to their to seen through an aperture in the fanshroud, by re
exacting
respective limitsif more
pumps and thancareone mustpump beistaken to ensure
dismantled at a time. should align with the arrow on the fanshroud. and m
The they
fuelare
Spill returned
Timing
pump to their317-50518,
timing gauge, respective canpumps
be usedif to
morecheck 15.If the flywheel mark is not correct, see 'Figure the ge
than one
the1.Isolate
timing pump
without is
the
the fuel supply. dismantled
need to at
dismantlea time.
the pump. 2.28.2', the shims under the fuel pump must be 6.Turn
The fuel pump
2.Remove the fuel timingpipe gauge,
from the 317-50518,
pump to can the adjusted, see "Timing Shims". prime
Spill Timing
injector. 7.Turn
3.Unscrew thesupply.
fuel pump delivery union body (A) the fl
1. Isolate the fuel Figure 2.28.2 Marks 29
and remove it. Figure 2.28.2Flywheel Timing
Flywheel Timing Marks arrow
2. Remove the fuel pipe from the pump to the injector.
4.Lift out the delivery valve spring
3. Unscrew the fuel pump delivery union body (A) and remove it. seat (B) and At this
spring (C). If the
If thetiming
timingis:is: will be
4. Lift out the delivery valve spring seat (B) and spring (C).
Advanced
Advanced - Add - Add
Shims Shims 8.Turn
Retarded
Retarded - Remove
- Remove Shims.Shims. (2.00
Approximately
Approximately 1° of1°flywheel
of flywheel movement
movement can becan be 9.Slowl
obtained
obtained
with a 0.127 with a 0.127mm
mm (0.005 in) shim.(0.005in) shim. level
16.16.Re-check
Re-check the timing. the timing. gauge
17.17.When
When the correct the correcttiming has beenhas
timing obtained
been remove the spill 10.Turn
obtained
pipe and delivery
remove the spill union
pipebody. and delivery union body. extre
18.18.Replace
Replace the delivery valve,
the delivery valve, delivery valve spring
delivery valveand spring
spring just
seat.
and spring seat. 11.Che
19.19.Refit
Refit the the delivery unionunion
delivery body and torque
body andit to 35.0/45.0
torque it toNm The
ot. (26.0/33.0 lbf ft).
35.0/45.0Nm (26.0/33.0lbf ft). seen
s were 20. Check that the fuel pump calibration marks are still
20.Check that the fuel pump calibration marks are shou
axis is aligned.
still aligned. 12.If th
spring Figure 02.28.1
02.28.1Fuel PumpComponents
Components 21. Repeat this procedure for the remaining fuel pumps.
Figure Fuel Pump 21.Repeat this procedure for the remaining fuel unde
22. Connect all fuel pipes and torque the pump to injector
pumps.
pipe nuts to: "Tim
5.Carefully lift out the delivery valve
5. Carefully lift out the delivery valve (D) taking care not to(D) taking care
22.Connect all fuel
TS/TR - 29.0 Nm (21.0 lbf ft). pipes and torque the pump to
not tothe
disturb disturb the valve seat.
valve seat.
6.Place
6. Place thesethese components
components in a suitable
in a suitable containercontainer
of clean fuel. TXinjector
- 22.0 Nm pipe
(16.0 nuts to:
lbf ft).
of clean
7. Replace thefuel.
delivery union body (A). 23. Bleed the entire fuel system. ft).
TS/TR - 29.0Nm (21.0lbf
TX - 22.0Nm (16.0lbf ft).
7.Replace
8. Fit a suitablethe spilldelivery
pipe. union body (A).
23.Bleed the entire fuel system.
8.Fit athe
9. Ensure suitable
fuel pump spillrack
pipe. is in the run position by removing
a9.Ensure
cylinder fuel thepump housingrack
fuel pump doorisand in manually moving the
the run position
fuel
bypump rack towards
removing a cylinderthe gear fuelend.
pump housing door Fuel Pump Timing Gauge
and manually moving the fuel pump rack towards 1.Assemble the pipe (A) to the gauge ensuring that
the gear end. the pipe nuts are tight.
10.Turn the flywheel, in the direction of rotation,
until the piston for the cylinder being timed is at
 pumps. "Timing Shims".
22.Connect all fuel pipes and torque the pump to
injector pipe nuts to:
TS/TR - 29.0Nm (21.0lbf ft). TS, TR, TX engines workshop manual 28
TX - 22.0Nm (16.0lbf ft).
23.Bleed the entire fuel system.

Fuel Pump
Fuel Timing
Pump Gauge
Timing Gauge If the timing is:
Advanced - Add Shims
1.Assemble
1. Assemble the the
pipepipe (A)
(A) to togauge
the the gauge ensuring
ensuring that
that the pipe Retarded - Remove Shims.
the pipe nuts
nuts are tight. are tight. Approximately 1 of flywheel movement can be obtained
with a 0.127mm (0.005in) shim.
13. Remove the gauge and replace the pump to injector pipe
and torque the pipe nuts to:
Figure
TS/TR 2.28.3 Flywheel
- 29.0Nm Timing Marks
(21.0lbf ft).
TX - 22.0Nm (16.0lbf ft).
If the timing is:
Advanced
Fuel Pump - Add ShimsTables
Timing
Retarded - Remove Shims.
The values given 1
Approximately in of
theflywheel
first tablemovement
apply to early
canTS/TR
be engines
with serial numbers up to those shown.
obtained with a 0.127mm (0.005in) shim.
36 00489
13.Remove TS1gauge
the and36 03079 TR1the pump to
replace
36 00314 TS2 36 05126 TR2
injector pipe and torque the pipe nuts to:
36 00467 TS2 36 03520 TR3
Figure 2.28.3
Figure Fuel
2.28.3 FuelPump TimingGauge
Pump Timing Gauge - 317-50518
- 317-50518 TS/TR - 29.0Nm (21.0lbf ft).
TX - 22.0Nm (16.0lbf ft).
2.Remove
2. Remove thepipe
the fuel fuelfrom
pipe
thefrom
pumpthe pump
to the to the
injector. Early TS/TR
3. Connect the gauge and pipe to the fuel pump delivery valve
BTDC
union for the cylinder being timed. r/min
4. Bleed
30 the filter and pump. 1500 1800 2500 1 3000 1 3000
5. Ensure the fuel pump rack is in the run position by removing
a cylinder fuel pump housing door and manually moving the TS1 20° 20° - 22° 25°
fuel pump rack towards the gear end.
TS2 20° 20° - 23° 23°
6. Turn the flywheel, in the direction of rotation, to prime the
gauge. TS3 20° 20° - 23° 23°
7. Turn the flywheel, in the direction of rotation, until the
flywheel 'FP' timing mark is in line with the arrow. TR1 20° 20° 23° - 26°
At this position both the inlet and exhaust valves will be
TR2 20° 20° 23° - 26°
closed.
8. Turn the flywheel against rotation for 50.8mm (2.00in). TR3 20° 20° 23° - 26°
9. Slowly release the gauge knob (B) until the fuel level is in line
with the calibration mark on the gauge sight glass. Note:
10. Turn the flywheel in the direction of rotation, extremely The value given is for variable speed engines running at any speed up to the maximum
slowly, until the fuel in the sight glass just moves. shown.
11. Check the flywheel timing mark.
The flywheel timing mark (FP), which can be seen through
an aperture in the fanshroud, should align with the arrow Later Engines - TS/TR and all TX
T SERIES
on ENGINES WORKSHOP MANUAL
the fanshroud. All TX engines and TS and TR engines with serial numbers after
12. If the flywheel mark is not correct, the shims under the fuel those given above have values as given in "02.32 Governor 'G'
pump must be adjusted, see "Timing Shims". Setting and Timing Tables".
injector.
3.Connect the gauge and pipe to the fuel pump
delivery valve union for the cylinder being timed.
4.Bleed the filter and pump.
5.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.
6.Turn the flywheel, in the direction of rotation, to
prime the gauge.
7.Turn the flywheel, in the direction of rotation, until
the flywheel 'FP' timing mark is in line with the
Figure 2.28.2
Figure 2.28.3Flywheel Timing
Flywheel Timing Marks
Marks arrow.
At this position both the inlet and exhaust valves
If the timing is: will be closed.
Advanced - Add Shims 8.Turn the flywheel against rotation for 50.8mm
Retarded - Remove Shims. (2.00in).
Approximately 1° of flywheel movement can be 9.Slowly release the gauge knob (B) until the fuel
obtained with a 0.127mm (0.005in) shim. level is in line with the calibration mark on the
 by unscrewing the speed adjusting screws on the
side of the crankcase.
6.Using long nose pliers disconnect the speeder
springTS,from
TR, TX
itsengines
spigot.workshop manual 29
It may be necessary to turn the spigot until
the hole axis is parallel to the camshaft before
removing the spring.
2.29 Governor Modifications The Governor
7.Disconnect theLinkage
governor and pump interconnecting
There have been alterations to the TS/TR governor assembly linkage
The fuel pump atgovernor
the pumps.
linkage has also been modified.
and the two types are not totally interchangeable.
A one-piece 'Nylatron' sleeve has been introduced to replace
the original sleeve assembly. The 'rin
The new type is interchangeable with the original if the and 1.2
following changes are made:
The governor lever shoes are removed.
The governor weight shoes are removed.
The governor sleeve setting 'A' is set at 9.5mm. In all
Re-designed support blocks and return springs are now fitted thickes
with the springs not being interchangeable; if the pivot blocks is advis
are changed the return springs must also be changed.
shims a
All of the above changes were introduced on the following
engines, and in later text, dealing with the governor, these
changes will be referred to as being applicable to early engines Refitti
or later engines. 1.If 'ri
Figure 2.27.1
Figure 2.29.1Fuel Pump
Fuel Pump Linkage
Linkage onto
35 01614 TS1 36 00001 TR1 A - Early TS/TR
A - Early TS/TR; B - Later TS/TR an all TX pump
35 07495 TS2 36 00011 TR2 B - Later TS/TR and all TX
35 06047 TS3 36 00141 TR3 2.Place
When re-fitting the new type of linkage to the fuel pumps it
retain
8.Move the
is important to rack operating
ensure that the lever on the
radiused pumpfollow
shackles to thethe
3.If 'sic
pump central
radius.position.
pump
9.Remove
If the shackle the fueldoes
radius pump notholding down
follow the bolts.
pump radius the
bolts
10.Gently
shackle lift outwedged
will become the pump taking
against thecare to retain
fuel pump bodytheand
slight
timing will
the pumps shims which arefrom
be prevented between
closingthe pump flange
correctly.
Repla
and crankcase.
crank
2.30 The Governor
CAUTION thickn
Governing Ranges to BS5514 pump
If more than one pump is being removed care
must be taken to retain the timing shims with 4.Even
Build Number r/min ranges to BS5514 9.0Nm
their respective pump.
Full Load Full Load Idling Governor 5.Conn
TS1 TS2 TS3 Outside 10% interc
Class A1 Class A1 Limits Code
01, 02, 03, 04, 06, 07, 01, 02, 03, 04, 05, 06, 01, 02, 03, 04, 05, 06, QW2
2700-3000 2100-3000 1300-2099 1 850-950
14, 15, 17, 40, 60, 61 07, 14, 15, 40, 42, 60, 61 07, 40, 42, 60, 61 28 18W2 2
16 41 41 850-950 LW2
08, 09, 10, 11, 62, 63, LWS4
08, 09, 10, 11, 43, 62, 63 08, 09, 10, 11, 62, 63 1200-2000
64, 65 13WS4 2
1300- LY2
12, 13 12, 13 2050-3000
3000 1 13Y2 2
SY2
12, 13
20Y2 2
Full Load Full Load Idling Governor
TR1 TR2 TR3 Outside 10%
Class A1 Class A1 Limits Code
01, 02, 03, 04, 06, 07, QW2
01, 02, 03, 06, 07, 14, 15 01, 02, 03, 04, 06, 07 2700-3000 2100-3000 1300-2099 1 850-950
14, 15, 16 18W2 2
LWS4
08, 09, 10, 11 08, 09 08, 09 1200-2000 1200-2000
13WS4 2
12, 13 12, 13 LY2

Full Load Full Load Idling Governor

TX2 TX3 Outside 10%
Class A1 Class A1 Limits Code
01, 02, 03, 04, 05, 06, 01, 02, 03, 04, 05, 06,
2700-3000 1800-3000 1500-1799 850-950 SU2
07, 08, 12, 13, 20, 21, 52 07, 08, 12, 13, 14, 52
09, 10, 11 1200-2000 LUS4
 TS, TR, TX engines workshop manual 30

Notes: Changing Governor Weights

The speed ranges given in the table do not necessarily relate to the full load build
speeds due to flywheel limitations. A table of governor weight and spring combinations is given in
1. The minimum full load speed must not be less than 1500r/min. "GoverningT Ranges
SERIES ENGINES WORKSHOP MANUAL
to BS5514". Current engines are fitted with
2. These codes are for earlier TS/TR engines, see "02.29 Governor Modifications - TS/ an improved camshaft gearwheel design, the weights remain
TR", that are fitted with a metal thrust washer assembly and shoes on the governor the same although on current engines they are retained in
Dismantling the Governor which
position locate retaining
by sintered over theplatesweight pins.
with Bothwhich
cast slots typeslocate
lever and weights. 1.Remove the gear end cover. are shown in 'Figure 2.30.2' and they are not2.30.2'
over the weight pins. Both types are shown in 'Figure
2.Remove the fuel pump inspection door/s. T interchangeable.
SERIES ENGINES WORKSHOP MANUAL
and they are not interchangeable.
Governor Combination 3.Disconnect the Codefuel pump and governor linkage 1.Remove the gear end cover.
1. Remove the gear end cover.
at the fuel pump using long nosed pliers. 2.Remove the governor lever and sleeve
First letter or number - weight code. 2. Remove the governor lever and sleeve assemblies.
assemblies.
4.Slacken off the speed control screw and then
Second letter - spring colour code 3. Disconnect the speeder spring spring
from itsBoth
spigot and fit a new
Dismantlingdisconnect the Governor the speeder spring. which locate over
3.Disconnect the speeder
weight pins. from types
its spigot
(W1.Remove
= white, B =the black, U = blue, Y = yellow) spring
are shown if necessary.
and fitin a'Figure
new spring 2.30.2' and they are not
if necessary.
gear endboth
5.Remove cover.fulcrum pins from the pivot support
Letter 'S' - Innerthe speeder
blocks spring,
using ifafitted.
1.5mm door/s.
rod, punch or suitable 4. Turn the engine
4.Turn until until
the engine one of onetheofgovernor weight
the governor retaining
weight
2.Remove fuel pump inspection interchangeable.
End figure - numberpiece of weights.
of stiff wire. plateretaining
bolts is accessible.
plate bolts is accessible.
3.Disconnect the fuel pump and governor linkage 1.Remove 5. Remove
the gear end cover.
the bolt and
Take care not to lose the shims. 2.Remove 5.Remove
the the boltplate.
governor and plate.
lever and sleeve
at the fuel pump using long nosed pliers.
Dismantling the
6.Remove Governorthe governor lever assembly complete
4.Slacken off the speed control screw and then
6. Turn the engine
6.Turn
assemblies.
the engineuntiluntil
thetheadjacent
adjacentretaining
retaining plate
platebolt is
with the speeder spring and fuel pump linkage. accessible. bolt is accessible.
disconnect
1. Remove the gear theend
7.Removespeeder the spring.
cover. governor sleeve assembly
3.Disconnect
7.Remove
7. Remove the
the speeder
the governor
governor spring
weight.weight.from its spigot
2. Remove
5.Remove the both
fuel pumpfulcrum inspection
pins from door/s.
the pivot support and fit a new
8.Repeat spring
items if
4. necessary.
to 7. for
8. Repeat items 4. to 7. for the remainingthe remaining weights.
weights.
3. Disconnect
blocks using the fuel a pump
1.5mm androd, governor
punch linkage
or at the fuel 4.Turn the engine until one of the governor weight
suitable
Assembling the Governor
pump
pieceusing long
of stiff nosed pliers.
wire.
Assemble the governor and fuel pump linkageretaining in plate bolts is accessible.
4. Slacken
Take care off the speed
notthe to lose control
the screw
shims. and then disconnect
reverse order to dismantling, taking care to the 5.Remove the bolt and plate.
speeder spring.
6.Remove the governor lever assembly complete
note the following points: 6.Turn the engine until the adjacent retaining plate
5. Remove both fulcrum
a.The pins
fulcrum from
pins
with the speeder spring and fuel pump linkage. the
are pivot
drilledsupport
at one blocks
end only bolt
and is accessible.
using a 1.5mm rod, punch or must
suitable piece of the
stiffouter
wire. end. 7.Remove the governor weight.
7.Remove the these governor holes sleeve be fitted at
assembly
Take care not to lose the shims.
b.Ensure the governor sleeve is fitted the correct 8.Repeat items 4. to 7. for the remaining weights.
6. Remove the governor way. lever assembly complete with the
Assembling
speeder springc.The
and the fuelGovernor
speed
pump control
linkage.spring is correctly hooked into
7. Remove the governor sleeveand
Assemble the governor
its spigot. fuel pump linkage in
assembly
the reverse d.Theorder small
to dismantling,
return spring, taking
whichcare to fitted to
is only
note the following points:
variable speed engines, must be fitted to the
Assembling the Governor
a.The fulcrum fuel pinspump side end
are drilled of the
at one endlever
onlyassembly
and with
Assemble
thesethe the short
governor
holes must and tail
fuelwound
be fitted at thebackwards
pump linkage andreverse
in the
outer end. held captive
order
b.Ensure undertaking
to dismantling,
the governor the sleeve
pivot
caresupport block.
to fitted
is note the correct
the following
points:
way.
a. The fulcrum
c.The speed pins are drilled
control at one
spring end only and
is correctly hookedtheseinto
holes Figure 2.30.2 Governor Weights - TS/TR
Figure 2.30.2 Governor Weights - TS/TR
must be fitted
its spigot. at the outer end. A - Early
A - Early TS/TR; TS/TR
B - Later TS/TR and TX
b. Ensure the governor sleeve is fitted the correct way. B - Later TS/TR and TX
d.The small return spring, which is only fitted to
c. The speed control spring is correctly hooked into its spigot.
variable speed engines, must be fitted to the 9. Fit the
9.Fitnew
the weights
new weights and retaining
and retainingplate; taketake
plate; carecare
to ensure
d. The small return spring, which is only fitted to variable speed the weight
fuel pump side end of the lever assembly with
engines, must be fitted to the fuel pump side end of the lever to ensure the weight pins are correctly seated in slots.
pins are correctly seated in their respective
the short tail wound backwards and held captive 10. Torque therespective
their retaining plate
slots. bolts to 9.0Nm (6.5lbf ft).
assembly with the short tail wound backwards and held 11. Replace the governor sleeve
underunder
the pivot support block. 10.Torque the retaining plateand governor
bolts to 9.0Nm lever assemblies.
(6.5lbf ft).
captive the pivot support block. 12. Check the governor settings.
11.Replace the governor sleeve and governor lever
13. Replace the fuel pump inspection door and the end cover.
assemblies.
Figure 2.30.2
12.Check theGovernor
governorWeights
settings.- TS/TR
Figure 2.30.1 Variable Speed Return Spring A - fuel
Earlypump
TS/TR
13.Replace the inspection door and the
2.31 Setting the Governor
B - Later TS/TR and TX
end cover.
e.Check that the governor lever assembly is
perfectly free to move. Before setting the governor refer to "Governing Ranges to
9.Fit the new weights and retaining plate; take care
2.31
BS5514" andSETTING THE GOVERNOR
"Governor Modifications - TS/TR".
to adjust
To ensure the weight pins are correctly seated in the fuel
Changing Governor Weights Before setting the governor refer to to
or check the settings, it is necessary remove
"Governing
their Ranges
pump respective
inspection slots.andand
doors
to BS5514" the"Governor
end cover. The engine control
Modifications
A table of governor weight and spring combinations
10.Torque
must be the
in
is given in "Governing Ranges to BS5514". Current - TS/TR".
retaining
the start plate
position bolts
and to
the 9.0Nm
end of (6.5lbf
the ft). gently
camshaft
engines are fitted with an improved camshaft 11.Replace
tappedTo the
towards
adjust governor
the
or check sleeve
flywheel
the to and
take
settings, governor
up
it any
is end lever
play.
necessary to
gearwheel design, the weights remain the same assemblies.
remove the fuel pump inspection doors and the
although on current engines they are retained 12.Check endthe
in CAUTION governor
cover. settings.
The engine control must be in the start
Figure 2.30.1
2.30.1Variable Speed Return Spring
Figure
position Variable Speed
by sintered Return Spring
retaining slots position
plates with cast13.Replace theand
fuelthe end of
pump the camshaft
inspection doorgently
and tapped
the
Extreme carethe
towards must be taken
flywheel to ensure
to take up anythat
end the
play.governor
end cover.
e.Check
e. Check that that the governor
the governor lever isassembly
lever assembly is to
perfectly free is correctly set for the engine type and build.
perfectly
move. free to move. 33
2.31 SETTING THE GOVERNOR
Changing Governor Weights Before setting the governor refer to "Governing
A table of governor weight and spring combinations Ranges to BS5514" and "Governor Modifications
- TS/TR".
 Extreme care must be taken to ensure that the
governor is correctly set for the engine type
and CAUTION
build.
T SERIES ENGINES WORKSHOP
Extreme care must be taken to ensureMANUAL
that the TS, TR, TX engines workshop manual 31
governor T SERIES ENGINES
is correctly setWORKSHOP
for the engineMANUALtype
Governor 'E' Setting
and build.
Adjustment 'E', as shown below, should be checked
CAUTION
and if necessary shims added or removed to obtain
Governor
Governor 'E' Setting
'E'
CAUTION
Extreme Setting
care must be(0.005-0.010in).
a clearance of 0.12-0.25mm taken to ensure that the
Adjustment
Extreme'E',
governor as
is
careshown
must below,
correctly
be
Adjustment 'E', as shown below, shouldsetshould
taken for
be be
tothe checked
engine
ensure
checked thattype
and ifthe
and if
necessary necessary
and build.
governor
shims added shims added
is correctly or
or removedset removed
for the
to obtain to obtain
engine type
a clearance of
a clearance
0.12-0.25mm of 0.12-0.25mm (0.005-0.010in).
and build.
(0.005-0.010in). Figure 2.31.3 Governor 'Q' Setting
Governor 'E' Setting
Governor 'E',
Adjustment 'E'as
Setting
shown below, should be checked
2.Adjust the two locknuts on the speeder spring
and if necessary
Adjustment 'E', asshims
shown added
below, orshould
removed be to obtainlink until Figure
checked the ends 2.31.3 Governor 'Q' Setting
of both links are flush.
a
andclearance
if necessary of 0.12-0.25mm
shims added(0.005-0.010in).
or removed to obtain
2.Adjust the two locknuts on the speeder spring
a clearance of 0.12-0.25mm (0.005-0.010in). Governor 'A' Setting
link until the ends of both links are flush.
1.Set the distance 'A', between the end of the thrust
sleeve and the shoulder
Figure on the camshaft
2.31.3 Governor 'Q' Setting gear
Governor
hub, to 5.0mmFigure'A' Setting
(0.197in) 2.31.3 on early 'Q'
Governor TS/TR
'Q' Settingengines
Figure 2.31.3 Governor Setting
1.Set the
and2.Adjust
9.5mm distance the 'A',
(0.374in)twobetween on laterthe
locknuts on
TS/TRend theofand the all
speeder thrustTXspring
Figure 2.31.1 Governor 'E' Setting sleeve2.Adjust
engines
2. Adjust and
link by until the
the
themarking
two shoulder
thelocknuts
twoends a of
locknuts on
both
scribed
on the
theon links camshaft
linethe
speeder are flush.
thespeeder
required
spring gear
linkspring
until the
hub,
distance
endsto
link5.0mm
ofuntil
boththe
from (0.197in)
the
links ends
shoulder ofon
are flush. both early
and links TS/TR
then are engines
flush.
moving the
The pivot pins (B) can be withdrawn with a 1.5mm and
thrust 9.5mm
sleeve(0.374in)
Governor 'A' Setting
forward onthis
to later TS/TRmark.
scribed and all TX
Figure
punch or stiff Figure 2.31.1
wire,2.31.1 Governor
theyGovernor
are drilled 'E' Setting
at one end only engines by marking a scribed line the required
'E' Setting With Governor
Governor
care,the
1.Set 'A'
andistance 'A'
Setting
engineers Setting
'A',screwdriver
between thecan end beoffitted
the thrust
therefore care must be taken on re-assembly to distance
behind the
sleeve from thethe
governor
and shoulder
sleeve
shoulder and
to hold
onthen ittheinmoving
the correct
camshaft the gear
1.Set the distance 'A', between the end of the thrust
The The pivot
pivot pins pins
(B) (B)
can can
be be withdrawn
withdrawn
ensure they are fitted with the holes facing outwards. with a with
1.5mm a 1.5mm
punch or thrust
1. Set sleeve
the distanceforward 'A' , to
betweenthis scribed
the end of mark.
the thrust sleeve and
position hub,
sleeve while
to and the the
5.0mm next stages on
(0.197in)
shoulder are
onearlycarried
the TS/TR out. engines
camshaft gear
stiffpunch or stiff
wire,care
Take they to wire,
are drilledthey
retain are
at one
the drilled
end
endfloat only at one
therefore
shims and end only
care
check the
must With care, shoulder
and
on
an engineers the camshaft gear
screwdriver hub, to 5.0mm
can be and fittedall TXon
(0.197in)
hub, 9.5mmto 5.0mm (0.374in)
(0.197in) on on later early TS/TR TS/TR engines
betherefore
takenthe
that care must
on re-assembly
governor to be
lever ensuretakentheyon
assembly areis re-assembly
fitted with thefree
perfectly to
holes earlythe
behind TS/TR enginessleeve
governor and 9.5mm (0.374in)
toscribed
hold it inline theoncorrect
later TS/TR and
Figure 2.31.1 Governor 'E' Setting
all
engines
and
TX 9.5mm
engines
by by
marking
(0.374in)
marking a
ascribed
on later line TS/TR
the
theand
required
required
all TX
distance
ensure
facing they are fitted with the holes facing outwards.
outwards.
to move. position while the next stages areand carried out.
Figure 2.31.1 Governor 'E' Setting distance
engines from
by the
marking shoulder
a scribed
from the shoulder and then moving the thrust sleeve forward then
line moving
the required the
TakeTake
The carecare
small
The toreturn
to retain
pivot retain the can
the endfloat
pinsspring,
(B) endfloat shimsshims
which isand
be withdrawn only and
check
withcheck
that the
fitted a to
1.5mm to thrust distance
this scribedsleeve frommark. forward
the shoulder to thisand scribed thenmark. moving the
governor
that thelever assembly
governor is perfectly
lever assembly free to move.
is the
perfectly free
variablepunch speed or engines,
stiff wire, is
they fitted
are to
drilled
The pivot pins (B) can be withdrawn with a 1.5mm With fuel
at onepumpend only With
thrust
care,care,
sleeve
an an
engineersengineers
forward to
screwdriverscrewdriver
this scribed
can be can
mark.
fitted be fittedthe
behind
The to small
move. return spring, which is only fitted to variable speed
side end
punch of the
therefore or lever
care
stiff assembly
must
wire, theybe are and
taken the
drilledonshort tailend
re-assembly
at one is only
to governorbehind
With care,the
sleeve governor
an toengineers
hold sleeve
it in to
screwdriver
the hold
correct it in
can
positionthe correct
be fittedthe
while
engines,
The is fittedreturn
small to the fuel pump side
spring, which endis of the
only lever assembly
fitted to
and
wound backwards
ensure
therefore
the shortspeed they are
care
tail is wound
and held
fitted
must with
be
backwards
captive
the
taken holes
and
under
on the
facing pivot
outwards.
re-assembly to nextposition
behind
stages while
the
are governor
carriedthe nextsleeve
out. stages to are
hold carried
it in the out.
correct
variable
support Take block.
care engines,
toareretain is fitted to held captive
the fuel pumpunder
theside
pivot ensure
support they
block. fittedthewithendfloat
the holesshims facingand check
outwards. position while the next stages are carried out.
end
that of thethegovernor
lever assembly and the short tail is free
Take care to retainlever assembly
the endfloat is perfectly
shims and check
wound to backwards
move. and held captive under the pivot
that the governor lever assembly is perfectly free
support The block.
small return spring, which is only fitted to
to move.
variable
The small speed return engines,
spring,is which fitted to is the
onlyfuel pump
fitted to
side
variableend speed
of the lever engines,assembly
is fitted and tothetheshort
fuel tail
pumpis Figure 2.31.4 Governor 'A' Setting
wound
side end backwards
of the lever and held captive
assembly and the undershortthetail
pivot
is
support block.
wound backwards and held captive under the pivot 2.Disconnect the fuel pump linkage, for the
support block. Figure 2.31.4 Governor 'A' Setting
remaining fuel pumps from No.1 pump by:
a.Sliding the oval split ring towards the gear
2.Disconnect
end. the fuel pump linkage, for the
remaining
b.Lifting the springfuel pumps tail fromfrom No.1the pump end by:of the
a.Sliding
governorthe link. oval split
Figure 2.31.4
ring towards the gear
Figure 2.31.4Governor
Governor 'A''A' Setting
Setting
Figure 2.31.2 Variable Speed Return Spring end.
c.Removing the governor
Figure 2.31.2 Variable Speed Return Spring Figure 2.31.4 link
Governor from 'A' theSetting
fuel pump
b.Lifting
rack. the spring
2.Disconnect the tail
fuel from pump the linkage,end of the for thefuel
2. Disconnect the fuel pump linkage, for the remaining
Governor 'Q' Setting governor link.
Governor Figure 'Q'2.31.2
Setting Variable Speed Return Spring 3.Check that
remaining
2.Disconnect the
pumps from No.1 pump by:
c.Removing thethe
calibration
fuel the
governor
pumps fuel mark
from
pump
link from
(X)
No.1
the
on No.1
pump
linkage,
fuel pump
fuel
by:for the
1.Gently move the governor plate forward pump is in
a.Sliding
remaining
a. Sliding line
the oval with
fuelsplit ovalthe
pumps mark
split
ring from on
ring
towards No.1 the
towards
thepump centre
gear end. by:of gear
the
1. Gently move theto
sufficiently governor
ensure platetheforward
chamferedsufficiently to ensure
spacers rack.
theb.fuelLiftingpump
end.
a.Sliding body,oval
the
the spring as from
tail shown
splitthe ringbelow,
endtowards of thewhile the gear
the
governor link.
Governor
the chamfered
behind the'Q' Setting
spacers
locknuts behind
on the the speeder
locknuts on the speeder
spring and 3.Check that thethe calibration mark (X)the on No.1 fuel
correct distance
b.Lifting
c. Removing
end. the 'A' is maintained.
spring
governor tail from
link from thefuel end
pump ofrack.
the
1.Gently
spring move
and governor the are governor
linkages are seated.plate forward pump is in line with the mark(X)on
governor linkages seated. 3. Check that
governor
b.Lifting thethe calibration
link. springmark tail from onthe No.1 centre
thefuel end pump of is in line
of the
sufficientlyFigure to ensure
2.31.2 Variablechamfered
the Speed Returnspacers Spring thewithfuel pump
the mark on body, as
the governor shown
centre of the below,
fuel pump while the
c.Removing
governor the
link. link from thebody, fuel aspumpshown
behind the locknuts
Figure 2.31.2on the speeder
Variable Speed Return spring and
Spring correct
below, distance
while the'A' is maintained.
correct distance 'A' from
is maintained.
34governor linkages are seated. rack.
c.Removing the governor link the fuel pump
Governor 'Q' Setting 3.Checkrack. that the calibration mark (X) on No.1 fuel
Governor
1.Gently move 'Q' Settingthe governor plate forward 3.Check pump isthat in thelinecalibration
with the mark mark on (X)the on centre
No.1 fuel of
34 sufficiently
1.Gently move to ensure
the the
governor chamfered plate spacers
forward the
pump fuelis pumpin linebody, with as theshown mark on below,the whilecentrethe of
behind
sufficiently the locknuts
to ensure on the the chamfered
speeder spring and
spacers correct
the fueldistance pump body, 'A' is as maintained.
shown below, while the
governor
behind the linkages
locknuts areon seated.
the speeder spring and correct distance 'A' is maintained.
governor linkages are seated.
34
34
 T SERIES ENGINES WORKSHOP MANUAL
On some engines a tamperproof setscrew is
fitted.
screw (A) and rotate the plate (B) until the fuel
TS, TR, TX engines workshop manual 32
pumpENGINES
T SERIES calibrationWORKSHOP
marks are aligned.
MANUAL
On some engines a tamperproof setscrew is
fitted.
screw (A) and rotate the plate (B) until the fuel
pump calibration marks are aligned.
On some engines a tamperproof setscrew is
Figure 2.31.5 Fuel Pump Calibration Marks
fitted.
4.If the two calibration marks are not in line they
can be adjusted by altering the effective length of
the governor link through the two locknuts on the Figure 2.31.6 Governor 'G' Setting
Figure 2.31.5 Fuel Pump Calibration Marks
outside of the governor lever.
Ensure the chamfered spacer is seated when 4.Tighten the plate retaining screw.
4.If the two
making thiscalibration
adjustment. marks are not in line they
5.Replace the linkage to No.1the
can be adjusted by altering pump. effective length of 5.After all the settings have been carried out,
the governor link through the two locknuts onandthe ensure the fuel pump rack and all moving parts
6.The
Figure
Figure length
2.31.5
2.31.5 Fuel
Fuel ofPump
theCalibration
Pump links from
Calibration Marks No.1
Marks to No.2, move freely. Figure 2.31.6
Figure 2.31.6Governor
Governor 'G' 'G'Setting
Setting
outside of the governor
between No.2 and No.3 pumps are then adjusted lever.
Ensure the by chamfered spacer is seatedlinkagewhen
4.Iftwo
4. If the individually
thecalibration
two calibration
making marks
this
removing
marks
are not inare
adjustment. linethe not
they relevant
incanline they
be adjusted from4. Tighten CAUTION
4.Tighten the plate
the plate retaining
retaining screw.screw.
can be the
by altering the
adjusted pump
effective and
by length rotating
alteringofthe the the link
effective
governor as necessary
length
link throughof until 5.After
Extreme
5. After all
all the care the
settingssettings
musthavebe have
beentaken been
carried when out,carried
inserting
ensure out,
the fuel
5.Replace
the the linkage
calibration marks to No.1
(X) pump.
on all pumps are ensure the fuel pump rack and all moving parts
the governor
the two locknuts onlinkthe through
outside theof twogovernor
the locknuts lever. on the the
pump feeler
rack and gauge
all or
moving rotating
Figure 2.31.6 Governor 'G' Settingparts the
move plate
freely. to ensure
Caution
6.The
in the length
line of the links while
simultaneously from the No.1distanceto No.2,'A', and move freely.
Ensureoutside of
the chamfered
between
governorspacer
No.2 and
lever.
isNo.3
seated pumps whenare making
then this is Extreme
adjusted that the caregovernor
must be takendoeswhen not move
inserting intothethe start
feeler gauge
adjustment. maintained.
Ensure the chamfered spacer is seated when 4.Tighten orposition.
rotating the plate
the plate retaining screw. to ensure that the governor does not
making
5. Replace the
individually
7.Release
this
linkage the
adjustment.
to
bygovernor
No.1
removing
pump. leverthe relevant
assembly linkage
and check from
move CAUTION
into the start position.
5.After all the settings have been carried out,
the pump andofrotating the linkmove as necessary
freely.No.2 until Extreme care must be taken when inserting
6. The length ofthat
5.Replace the
the
all parts
linkage
thecalibration
links from the governor
to No.1
No.1
marks topump.
No.2,
(X) and on betweenall pumps ensureLimited
are the fuel Excesspump rack Fuel
and Trip - TX parts
all moving
6.The the feeler gauge or rotating the plate to ensure
and No.3 length
pumpsin line
of
arethe then links
adjusted
simultaneously
fromindividually
No.1 to No.2,
while thebydistance
and
removing isLimited
'A',move freely.
This device Excess mayFuel Trip
be fitted -
to TX
some TX2 Build 20
between Governor
No.2 and 'G'
No.3 Setting
pumps are rotating
then adjusted that the governor does not move into the start
the relevant linkage
maintained. from the pump and the link as engines.
Thisposition.
checkCAUTION
individually
necessary untilThe 'G' by removing
thesetting
calibration is usedthe
marks relevant
to ensure linkage
(X) onassembly that
all pumps from
the fuel arepumps
in device may be fitted to some TX2 Build 20 engines.
7.Release the governor lever and
line the pump
deliver
simultaneously andthe rotating
correct
while thethe link asof
amount
distance
that all parts of the governor move freely.
necessary
'A', fuel
is as dictated
maintained. until by the Adjusting
Extreme care mustthe beTrip
taken when inserting
the the
calibration
engine marks
build number. (X) on and allcheck pumps arepartsthe feeler Limited
Adjusting Excess
the Trip Fuel Trip - to
TXensure
7. Release governor lever assembly that all Care must be taken tothe
gauge or rotating plate
ensure the governor 'G' and
in line
of the governor simultaneously
The variousmove freely. while the distance
settings are given in "02.32 Governor 'A', is that the'Q' This device
governor may
does be fitted
not move to some
into theTX2 Build 20
startto
Governor 'G' Setting Care mustsettings
be are
taken correct
to ensure before
the attempting
governor 'G' and adjust
'Q' settings
maintained.
'G' Setting and Timing Tables". For intermediate position. engines.
The 'G' setting is used to ensure that the fuel pumps are the trip.
correct before attempting to adjust the trip.
7.Release the governor lever assembly and check
speeds not given in the tables use the setting for 1.Adjust the two locknuts (A) to a nominal position
Governor 'G'nearest
that alldeliver
parts
the
Setting
thethe
of correct
governor
higher amount
speed. move of freely.
fuel as dictated by the1. Adjust Adjusting the twothe locknuts
Trip (A) to a nominal position on the
engine build number. Limited Excess
on
adjusting thescrew Fuel
adjusting(B).
Trip
screw - TX
(B).
The 'G' setting All isTS used and to TR ensureengines that the builtfuelfrom pumps Januarydeliver1999This Care
device
2.Adjust must
may be
the bespeed
takento
fitted to some
ensure
control, ifTX2the Build
governor
necessary, 20 'G'
to the and
ensure
the Governor The
have'G' various settings arefuelgiven in 201-31305
"02.32 Governor 2. Adjust the speed control, ifbefore
necessary, to ensure speeder
correct amount been Setting
of fitted
fuel as with
dictated pump
by the engine build (Mk ll 'Q' settings are correct
engines. the speeder spring (C) is tensioned with the stop attempting to adjust
'G' Setting
Pump).isThese and Timing Tables". For intermediate
as spares the spring (C) is tensioned with
trip. against the overload stop. the stop control against the
The 'G' setting
number. used tocan ensure be fittedthat the individually
fuel pumps control
The deliver speeds
to replace not given
the earlier in the
pumps,tables use
but'G' the
improved setting
engine for overload stop.
1.Adjust the two locknuts (A) to a nominal position
the
various settings correct amount
are given of fuel
in "02.32 as dictated
Governor by the and
Setting
Adjusting the Trip
the
idling nearest higher speeds
characteristics speed. can not only bethegainedtables by on the adjusting screw (B).
Timingengine build
Tables". For number.
intermediate given in
Care must be taken to ensure the governor 'G' and
use The All
changingTSthe and all TRpumps engines in the built
engine fromto January
the new 1999 type. 2.Adjust the speed control, if necessary, to ensure
various
the setting for settings nearest are higher
given in "02.32
speed. Governor 'Q' settings are correct before attempting to adjust
have
This been
fuel pump fitted with January
supersedes fuel pump earlier 201-31305
pumps (Mk ll
although the speeder spring (C) is tensioned with the stop
All TS'G'andSetting
TR and
engines Timing
built Tables".
from For intermediate
1999 have been
the trip.
Pump).
the fuel These
pump can be
element (Mkfitted
remains individually as spares control against the overload stop.
fittedspeeds
with fuel notpumpgiven in the
201-31305 tables use
ll Pump).the unchanged.
setting
These can for be1.Adjust the two locknuts (A) to a nominal position
to replace
1.Turn asthe the
engineearlier pumps,
controlthe but
to earlier
the stop improved position engine
and
fittedthe nearest
individually higher speed.
spares to replace pumps, but
on the adjusting screw (B).
idling
release characteristics
it. characteristics can only onlybe gained by
All TSengine
improved and TR engines
idling built fromcan January be 1999gained2.Adjust the speed control, if necessary, to ensure
changing
2.Gently allinpumps
move theengine in thetoengine
governor assembly to the new
lever type.
have been
by changing all fitted
pumps with fuel
the pump 201-31305
the new (Mk
type. llThisawaythe speeder spring (C) is tensioned with the stop
fuel Pump). Thisfrom fuelthe pumpcamshaft supersedes until theearlier
excess pumpsfuelpump although
device is
These
pump supersedes canearlier
be fittedpumps individually
although as
the spares
fuel control against the overload stop.
the fuel
heard pump
to 'click' elementinto but remains
the run position. unchanged.
to replace
element remains the earlier
unchanged. pumps, improved engine
1.Turn
3.Withcontrol the
a feelerengine gauge control of to
the the stop position and
idling
1. Turn characteristics
the engine can
to the stop only positionbe correctgained
and release thickness
by it. for
changing
2. Gently moverelease
the
allthe build
pumps
it.inserted
governor in theassembly between
engine to theaway
the
lever control
new type.
from lever
the and
2.Gently
thethe lever move stop, the governor
loosen the assembly
control toplate lever intoaway
retaining Figure 2.31.6
2.31.6Excess FuelTripTrip - TX
This fueluntil
camshaft pump supersedes
excess fuel earlier
device ispumps
heard although
'click' Figure Excess Fuel - TX
from the camshaft until the excess fuel device is
thetherunfuel pump element remains unchanged.
position.
heard to 'click' into the run position. 3. Slacken the collar grubscrew sufficiently and screw the35 collar
1.Turn
3. With the engine
a feeler gauge of control
the correctto the thickness
stop position for the and build
3.With a feeler gauge of the correct thickness for along the adjusting screw (B) until it just touches the plate (E).
release
inserted it. the control lever and the lever stop, loosen
between
the build inserted between the control lever and4. Turn the collar back half a turn and tighten the collar
the2.Gently moveretaining
control plate the governor screw assembly
(A) and rotate lever theaway plate (B)
the lever stop, loosen the control plate retaining grubscrew. Figure 2.31.6 Excess Fuel Trip - TX
untilfrom the pump
the fuel camshaft until themarks
calibration excess are fuelaligned. device is
heardengines
On some to 'click' into the runsetscrew
a tamperproof position.is fitted. 5. Move the stop control fully anti-clockwise and release it,
3.With a feeler gauge of the correct thickness for checking that the engine goes freely into the excess 35 fuel
the build inserted between the control lever and position.
6. Gently Figure 2.31.6
move the Excess
governorFuel Trip - TX lever away from the
assembly
the lever stop, loosen the control plate retaining
camshaft until the excess fuel device is heard to 'click' into
the run position. 35
7. Ensure that when the stop control contacts the overload
stop the clearance between the collar (D) and plate (E) is
0.3-0.4mm (0.12-0.16in).
 TS, TR, TX engines workshop manual 33

2.32 Governor 'G' Setting and TR1

Timing Tables Builds
Timing Speed/ Load 'G'
BTDC Class Rating Setting
TS1
01, 02 20° 2500 B1 90/100% 0.040"
Timing Speed/ Load 'G'
Builds 03 23° 3000 B1 90/100% 0.055"
BTDC Class Rating Setting

01, 02 20° 2500 B1 90/100% 0.045" 06, 07 20° 2500 B1 100% 0.040"

03, 04 20° 3000 B1 90/100% 0.055" 08, 09 20° 1500 A1 100% 0.053"

06, 07 20° 2500 B1 100% 0.060" 10, 11 20° 1800 A1 100% 0.053"

08, 09 20° 1500 A1 100% 0.045" 14, 16 20° 2500 B1 100% 0.040"

10 20° 1800 A1 100% 0.045" 78 20° 1500 A1 100% 0.053"

16 20° 2000 B1 90/100% 0.045" 100 20° 2500 B1 90/100% 0.040"

17 20° 2500 B1 90/100% 0.045" 105, 106 20° 2500 B1 90/100% 0.040"

18 20° 2200 A1 90/100% 0.045"

TR2
62 20° 1500 A1 100% 0.045"

101 20° 1500 A1 100% 0.045" Timing Speed/ Load 'G'

Builds
BTDC Class Rating Setting
102, 103 20° 2500 B1 90/100% 0.045"
01, 02 20° 2500 B1 90/100% 0.040"
106 20° 2500 B1 90/100% 0.045"
04 23° 3000 B1 90/100% 0.055"

06, 07 20° 2500 B1 90/100% 0.040"

TS2, 3
1500 A1
Timing Speed/ Load 'G' 08, 09 20° 100% 0.050"
Builds 1800 A1
BTDC Class Rating Setting

01, 02 20° 2500 B1 90/100% 0.045" 1500 A1

101 20° 100% 0.050"
03, 04 23° 3000 B1 90/100% 0.055" 1500 A1

06, 07 20° 2500 B1 100% 0.060"

TR3
08, 09 20° 1500 A1 100% 0.045"

10 20° 1800 A1 100% 0.045" Timing Speed/ Load 'G'

Builds
BTDC Class Rating Setting
16 20° 2000 B1 90/100% 0.045"
01, 02 20° 2500 B1 90/100% 0.040"
17 20° 2500 B1 90/100% 0.045"
03 23° 3000 B1 90/100% 0.055"
18 20° 2200 A1 90/100% 0.045"
1500 A1
62 20° 1500 A1 100% 0.045" 08, 09 20° 100% 0.045"
1800 A1
101 20° 1500 A1 100% 0.045"
78 20° 1500 A1 100% 0.045"
102, 103 20° 2500 B1 90/100% 0.045"

106 20° 2500 B1 90/100% 0.045"

 of the speeder spring which is internally attached 4.Rem
to the speed control which in turn can be operated
either by a cable or rod.
TS, TR,
The idling TX engines
speed must notworkshop
be setmanual
below 850r/min. 34
1.Move the speed control until it is against the
adjusting screw (A).
2.Turn the adjusting screw (A) anti-clockwise until
TX2,3 1. Move the speed control until it is against the adjusting
it has no further effect on reducing the engine
screw (A).
speed.
Timing Speed/ Load 'G' 2. Turn the adjusting screw (A) anti-clockwise until it has no
Builds
BTDC Class Rating Setting
3.Turn (A) clockwise until the no-load speed is
further effect on reducing the engine speed.
850r/min.
3. Turn (A) clockwise until the no-load speed is 850 r/min.
TheThe adjuster can be turned further clockwise
if a higherifidling
a
01 20° 2500 B1 90/100% 0.045"
adjuster can be turned further clockwise
higher idling
speed is required. speed is required.
02 22° 2500 B1 100% 0.069"

03 24° 3000 B1 90/100% 0.043"

5.Rem
04 24° 2800 B1 100% 0.071"
exce
05 22° 2500 B1 100% 0.069" 6.Rem
sprin
09 20° 1500 A1 90/100% 0.042" and p
1800 A1 7.Exam
10 20° 100% 0.056" 8.Repla
1800 A1 lever
9.Repla
13 24° 2900 B1 90/100% 0.043"
(G) th
14 22° 2500 B1 100% 0.069" Figure 2.33.2
Figure 2.33.2Variable Speed
Variable Speed Adjustment
Adjustment

16, 17 22° 2500 B1 90/100% 0.069" T SERIES

4. Tighten the ENGINES
locknut. WORKSHOP MANUAL
52 22° 2000 B1 90/100% 0.045" 5. Move the speed control until it is against the adjusting
screw (B).
If the speed is not correct turn the adjusting screw (B)
2.33 SPEED ADJUSTMENT 4.Tighten the locknut.
2.33 Speed
The speed Adjustment
of the engine is controlled by the tension
clockwise
5.Move the speed
increase
to
it.
reduce the speed
control untiland antiagainst
it is clockwise to
the
adjusting screw (B).
Theofspeed
the speeder spring iswhich
of the engine is internally
controlled by the attached
tension oftothe
If the speed is not correct turn the adjusting
the speed
speeder springcontrol. The control
which is internally hastotwo
attached the adjustable
speed control.
Thescrews
controlwhich areadjustable
has two adjusted screws
and locked
whichtoare
give the
adjusted 2.34(B)
screw The Engine
clockwise Controls
to reduce the speed and
anti-clockwise to increase it.
andrated fulltoon-load
locked give theor variable
rated speedoras
full on-load determined
variable speed as
The Engine Control
by the engine
determined by theBuild.
engine build.
2.34 THE knob,
The control ENGINE CONTROLS
spindle and plate assembly was modified on
Fixed Speed
Fixed Adjustment
Speed Adjustment and after the following TS engines:
The Engine Control
35 01203 TS1
TheThe
twotwo screws
screws are are adjusted
adjusted andand locked
locked against
against the The control knob, spindle and plate assembly was
the speed 35 06483 TS2
speed control lever to give the full on-load speed.
control lever to give the full on-load speed. The right hand modified35on and TS3
after the following TS engines:
05021
The right hand
screwside adjustingthescrew
speed(A) increases
side adjusting (A) increases when it is turned On later TS and allTS1
35 01203 TR and TX engines the knob and spindle are
the speed when it is turned clockwise.
clockwise. 35 06483
one assembly andTS2the location plate is a separate item.
35 05021 TS3
OnNote:
later TS and all TR and TX engines the knob
andThespindle are one
current assembly cannot assembly
be used with anand
early the
type oflocation
unmodified locating
plate
plate.is a separate item.

Note:
Removing the Assembly
The current assembly cannot be used with an
1. Remove
early theunmodified
type of gear end cover.
locating plate.
2. Remove No.1 cylinder fuel pump inspection door.
3. Move the automatic excess fuel lever (B) along the shaft
Removing the Assembly
towards the outside of the crankcase and hold it in this
1.Remove the gear end cover.
position.
2.Remove No.1 cylinder fuel pump inspection
4. Remove the small dowel pin (C).
Figure 2.33.1
Figure 2.33.1Fixed Speed
Fixed Speed Adjustment
Adjustment door.
3.Move the automatic excess fuel lever (B) along
Variable
Variable Speed
Speed Adjustment
Adjustment the shaft towards the outside of the crankcase
The speed of the engine is controlled by the tension and hold it in this position.
Theofspeed of the engine
the speeder springis which
controlled by the tension
is internally of the 4.Remove the small dowel pin (C).
attached
speeder spring which is internally attached to the speed control
to the speed control which in turn can be operated
which in turn can be operated either by a cable or rod.
either by a cable or rod.
The idling speed must not be set below 850 r/min.
The idling speed must not be set below 850r/min.
1.Move the speed control until it is against the
adjusting screw (A).
2.Turn the adjusting screw (A) anti-clockwise until
 1.Remove the gear end cover.
2.Remove No.1 cylinder fuel pump inspection
2.35 THE FUEL PUMP TAPPET 2.Rem
door. Removing a Tappet 3.Rem
3.Move the automatic excess fuel lever (B) along 1.Remove the fuel pump. 4.Rem
the shaft towards the outside of the crankcase 2.With TS,
theTR,fuel
TX engines
pump workshop
removedmanual
use long nosed 35 5.If the
ension and hold it in this position. pliers to remove the tappet insert (A) from the top follow
tached 4.Remove the small dowel pin (C). of the tappet assembly (B). clips
perated 6.Gent
keep
r/min. 7.Rem
nst the
Inspe
se until a.Exam
engine b.Exam
freed
peed is c.Chec
pinio
wise if a d.Ensu
e.Chec
Figure 2.34.1 Engine Control
Figure 2.34.1 Engine Control
Figure 2.35.1 Fuel Pump Tappet
Figure 2.35.1 Fuel Pump Tappet conta
f.Exam
5.Remove
5. Remove the the
springspring (D) its
(D) from from its location
location on the
on the excess fuel 3.Lift
3. Lift outout
thethe
fuel fuel
pump pump
tappet tappet assembly
assembly from thefrom the
guide (C). or we
excess
lever. fuel lever. guidethe
4. Remove (C).guide locating bolt (D) from the fuel pump side
6.Remove
6. Remove the excess
the excess fuel
fuel lever lever assembly
assembly (B) and (B)(E)and
spring while 4.Remove
of the guide locating bolt (D) from the fuel
the crankcase.
T SERIES ENGINES WORKSHOP MANUAL
spring (E) while withdrawing the control
withdrawing the control lever (F) and plate assembly (G). lever (F) 5. Remove the tappet guide.
and plate
7. Examine assembly
and renew (G).
the '0' ring (H) if necessary. 38
7.Examine
8. Replace the camandspring
renew (A),the '0' ring (H)
if removed, if necessary.
to the lever assembly Replacing a Tappet
the excess
8.Replace
(B). thefuel
camlever assembly
spring (A), if(B).
removed, to the pump side of the crankcase.
10.Relocate the lever
spring (D)plate
on assembly
the excess fuel 1. Replacethe
5.Remove thetappet
guide into the crankcase taking extreme care to
guide.
9. Replace
lever the control
assembly (B). (F) and (G) through
lever. ensure the end with the two flats enters first and the locating
the crankcase
9.Replace theinto the spring
control lever (E) (F)and
andthe excess
plate fuel lever
assembly
11.Move the automatic excess holes in the crankcase and guide are correctly aligned.
assembly (B).
(G) through the crankcase intofuel
thelever
spring(B)(E)
along
and Replacing a Tappet
2. Replace the guide locating bolt and a new copper washer.
the shaft towards the outside
10. Relocate the spring (D) on the excess fuel lever. of the crankcase 1.Replace the guide into the crankcase taking
3. Replace the tappet.
11. Moveandthe
hold it in this excess
automatic position. fuel lever (B) along the shaft extreme care to ensure the end with the two flats
4. Replace the tappet insert with the smaller section on the
12.Replace
towards the the dowel
outside the crankcase and hold it in37
of (C). this enters
outside. and the locating holes in the crankcase
first
position.
13.Replace the gear end cover. and guide are correctly aligned.
12.14.Replace
Replace the dowel
No.1 (C).cylinder fuel pump inspection 2.Replace the guide locating bolt and a new copper
13. Replace
door. the gear end cover. washer.CAUTION
14. Replace No.1 cylinder fuel pump inspection door. Failure to
3.Replace thefittappet.
a new washer to the guide locating bolt may
The Speed Control Lever allow the bolt
4.Replace the tappet to touch the
insert tappet
with and prevent
the smaller section
The
To Speed Control
ensure the speedLever
control is correctly re-fitted, it operating.
on the outside.
To care
ensuremust be taken
the speed to ensure
control there-fitted,
is correctly angle iscare
89°-91°
must be
when the speeder spring spigot is upright. CAUTION
taken to ensure the angle is 89°-91° when the speeder spring
When the lever
spigot is upright. is assembled it must be free to Failure 2.36 The Camshaft
to fit a new washer to the guide locating
rotate.
When the lever is assembled it must be free to rotate. bolt
The steelallow
may the isbolt
camshaft to touch
carried in plainthe tappet
bearings and
in the crankcase
prevent it operating.
at both the flywheel end and in the centre web(s). A ball bearing
attached to the camshaft and fitted behind the camshaft gear
provides
2.36 THE theCAMSHAFT
bearing for the gear end. The camshaft gear carries
the governor weights.
TheCams
steel camshaft
on the camshaftisoperate
carried
thein plain
valve bearings
tappets, oil pump, fuel
in the crankcase at both
pumps and the fuel lift pump.the flywheel end and in
the centre web(s). A ball bearing attached to the
camshaft and fitted behind the camshaft gear
Removing the Camshaft
provides the bearing for the gear end. The camshaft
gear1. Remove the sump.
carries the governor weights.
2. Remove the
Cams on the camshaft oil pump.operate the valve tappets,
oil pump, fuel pumpscover.
3. Remove the end and the fuel lift pump.
4. Remove the governor and fuel pumps.
Figure 2.34.2
Figure 2.34.2Speed Control
Speed Control Lever
Lever 5. If the engine is in its normal plane hold the cam followers
Removing the Camshaft
clear of the camshaft using suitable clips or magnets.
1.Remove the sump.
2.352.35The THEFuel FUEL Pump PUMP TappetTAPPET 6. Gently ease the camshaft out of the crankcase keeping it
2.Removesquarethe oiltimes.
at all pump.
Removing a Tappet 3.Remove
7. Remove the camcover.
the end followers.
Removing
1.Remove the a Tappet
fuel pump. 4.Remove the governor and fuel pumps.
2.With the
1. Remove the fuel pump removed use long nosed 5.If the engine is in its normal plane hold the cam
fuelpump.
pliers
2. With to remove
the fuel the tappet
pump removed insert
use long (A) from
nosed pliers the top
to remove followers clear of the camshaft using suitable
theoftappet
the tappet assembly
insert (A) top of the tappet assembly (B). clips or magnets.
from the(B).
6.Gently ease the camshaft out of the crankcase
keeping it square at all times.
7.Remove the cam followers.
 TS, TR, TX engines workshop manual 36

Inspecting the Camshaft 1. Remove T SERIES ENGINES

the setscrew (A) fromWORKSHOP
the end cover.MANUAL
2. Use a suitable rod through the hole to push the camshaft
a. Examine the camshaft bush for scars or wear. gearwheel as far as it will-go towards the flywheel end.
b. Examine the ball race bearing for wear and freedom of 3. Insert a clock
Replacing the Camshaft
movement.
4.Push the gauge extension
camshaft through
gearwheel the holethe
towards untilgear
it rests
against
end the
by gearwheel
inserting aand zero
suitably the gauge.
cranked rod through
c. Check1.Replace
the camshaftthe cam followers
gearwheel and secure
and crankshaft teeth in 4. T
pinion them SERIES ENGINES WORKSHOP MANUAL
Push the
their
for wear. highest positions. the fuelcamshaft gearwheel towards
pump inspection door and thecheck
gear end the by
inserting a suitably cranked rod through the fuel pump
d. Ensure2.Carefully
the cams are replace the camshaft into the crankcase T gauge
not damaged. SERIESreading.
ENGINES WORKSHOP MANUAL
inspection door and check the gauge reading.
keeping
Replacing it square
theforCamshaft at all times; take care to line
scars or damage to the contact face. 4.Push This endfloat should betowards0.08-0.2mm (0.003-
e. Check the tappets Thisthe camshaft
endfloat shouldgearwheel the gear
be 0.08-0.2mm (0.003-0.008n).
f. Examine up
1.Replace the
the oil '0'
theseal
cam timing
in the marks
end cover
followers andon the
for securecrankshaft
damage them
or wear.
in and 0.008n).
end by inserting a suitably cranked rod through
camshaft
Replacing the
their highest gears exactly.
Camshaft
positions. 4.Push
the fuel thepump
camshaft gearwheel
inspection doortowards
and check the gearthe
Replacing
2.Carefullythe
1.Replace the Camshaft
cam
replace followers and secure
the camshaft into the crankcasethem in end
gauge by CAUTION
CAUTION
inserting
reading. a suitably cranked rod through
their highest positions. the
This Excessive
Excessive
fuel pump
endfloat camend
cam should
shaft shaft
inspection befloat end
door float
affects
and
0.08-0.2mm thecheckaffects
governingthe and
(0.003- the
keeping it square
1. Replace the cam followers at all
andtimes;
secure take
them care tohighest
in their line
2.Carefully can
gaugegoverning
cause uneven
reading. and can
firing. cause
Some uneven
early engines firing.
were Some
fitted
up the '0'replace
positions. timing the camshaft
marks on the intocrankshaft
the crankcaseand 0.008n).
keeping itgears square at all times; take care to line This early
with a engines
paper
endfloat gear were fitted
end cover
should be with
joint and
0.08-0.2mm a ifpaper is gear
this(0.003-
replacedend
camshaft
2. Carefully replace theexactly.
camshaft into the crankcase keeping it
up the
square at all'0'times;
timing
takemarks
care toonlinethe crankshaft
up the '0' timingand
marks
CAUTION
cover joint and if this is replaced with a new type
with
0.008n). a new type thicker joint the end float must be
checked
thickerand
Excessive cam adjusted
joint the
shaftendasend
necessary.
floatfloat
mustaffectsbe checked the and
oncamshaft
the crankshaftgears
andexactly.
camshaft gears exactly.
CAUTION
adjusted as necessary.
governing and can cause uneven firing. Some
Excessive
early engines camwere shaft
fittedend withfloat
a paper affects
gear endthe
2.37
cover 2.37
governing The
joint andTHE
Camshaft
ifcanCAMSHAFT
this cause Gearwheel
uneven
is replaced GEARWHEEL
withfiring.
a newSome
type
early
thicker engines
joint the were fitted with
endGearwheel mustabe paper gear and
end
Removing
Removing
cover joint
the thefloatGearwheel checked
adjusted asand if this is replaced with a new type
necessary.
1.Drift
1. Drift pinpin
(A) (A) the
into intocamshaft
the camshaft
(B) be it(B)
untilchecked until
clears the itgearwheel
clears
thicker joint the end float must and
the gearwheel (C).
(C).
adjusted as necessary.
Figure 2.36.1 Gear Timing Marks 2.37 THE CAMSHAFT GEARWHEEL
Removing the Gearwheel
3.Release the cam followers. 2.37 THE CAMSHAFT GEARWHEEL
1.Drift pin (A) into the camshaft (B) until it clears
4.Replace the oil pump, sump, fuel pumps, governor
Removing the(C).
the gearwheel Gearwheel
and Figure
end cover.
2.36.1 Gear Timing Marks 1.Drift pin (A) into the camshaft (B) until it clears
the gearwheel (C).
Camshaft
3.Release the
Figurecam Endfloat
followers.
2.36.1 Gear Timing
Figure 2.36.1 Gear Timing Marks Marks
The end
4.Replace the oilfloat,
pump,maintained
sump, fuel pumps, with a governor
single metal
shim
3.Release
and end
3. Release between
the
cover.
the cam cam the camshaft
followers.
followers. thrust washer and the
4. Replacecamshaft
4.Replace the the gearwheel
oil pump,
oil pump, sump,sump, hub, is 0.08-0.2mm
fuel pumps,
fuel pumps, and(0.003-
governor
governor end
and 0.008in).
end
Camshaft Endfloat
cover. cover.
The In endengines where the camshaft
float, maintained with a single does notmetal extend
Camshaft through
Camshaft
shim between the
the camshaft thrust washer and the be
Endfloat
Endfloat end cover the end float can Figure 2.37.1
Figure 2.37.1Camshaft Gearwheel
Camshaft Gearwheel
measured
The end gearwheel
camshaft through
float, maintained the top
with
hub, aissingle right hand tapped
a single(0.003-
0.08-0.2mm metal hole
The endof float,
the maintained with metal shim between
shim between
0.008in). gear thecover SAE flange.
camshaft thrust washer and the 2. 2.Press
Press off off thethe gearwheel
gearwheel sufficiently
sufficiently to allow
to allow a thin
a thin metal
the camshaft thrust washer and the camshaft gearwheel hub, metal washer to be placed between the bearing
camshaft
In engines gearwheel
where the hub, is 0.08-0.2mm
camshaft does not (0.003-
extend washer to be placed between the bearing (D) and the
is 0.08-0.2mm (0.003-0.008in). (D)Figure
and to the gearwheel toGearwheel
prevent dirt entering the
0.008in). gearwheel prevent dirt entering the bearing.
In through
engines wherethe theendcamshaft
cover does the notendextend
float through
can bethe 2.37.1 Camshaft
In engines
measured where
through the
thebecamshaft
top right handdoes nottheextend
tapped hole bearing.
Continue to press off the bearing.
end cover the end float can measured through top right
through
of the
hand the
gearhole
tapped end
cover
of theSAEcover
gearflange.the end
cover SAE flange. float can be 2.Press off the to
3. Continue
Remove the
Figure pressCamshaft
Woodruff
gearwheel
2.37.1 offkeythe(E).bearing.
sufficiently
Gearwheelto allow a thin
measured through the top right hand tapped hole 4. Drift pin
3.Remove (A) out
the of the
Woodruff
metal washer to be placed between camshaft key (B)
(E).using
theabearing
small drift.
of the gear cover SAE flange. 2.Press4.Drift
off pin
the (A) out
gearwheel of the camshaft
sufficiently
(D) and the gearwheel to prevent dirt entering to (B) using
allow a small
a thin
the
Refitting
drift. the Gearwheel
metal washer to be placed between the bearing
bearing.
(D)
Onand
Continue thepress
to
re-assembly gearwheel thetobearing.
offdowel
the prevent
pin mustdirt enteringpressed
be carefully the in to
Refitting
bearing.
3.Remove the the
Woodruff Gearwheel
key (E).
1mm below the diameter of the gearwheel hub and any sharp
4.DriftOn
Continue
edges re-assembly
to
(A)press
pinaround outtheofoffthe
hole the
the dowel
bearing.
camshaft
must pin must
(B) using
be removed - anyabe carefully
small
burrs will affect
pressed
3.Remove
drift. the in to
Woodruff 1mm key below
(E).
the operation of the governor thrust sleeve. the diameter of the
Fitgearwheel
4.Drift the (A) outhub
pincamshaft of theand
gearwheel any
camshaft
in thesharp
(B) edges
reverseusing
order aaround
small
to the
dismantling
Figure 2.36.2 Camshaft End Float Access hole
drift. must be removed - any burrs will affect the
Refitting
ensuring the thethin Gearwheel
flat washer is removed and that the gearwheel
operation
abuts against
On re-assembly the of
thethe governor
shoulder
dowel(F). pinthrust
mustsleeve.
be carefully
1.Remove the setscrew (A) from the end cover. Refitting Fit the camshaft gearwheel in the reverse
the Gearwheel
pressed in to 1mm below the diameter of theorder
2.Use a suitable rod through the hole to push the to dismantling
On CAUTION
re-assembly
gearwheel hub and any sharp edges aroundwasher
the ensuring
dowel pin the
must thinbe flat
carefully
the is
camshaft gearwheel as far asAccess
it will-go towards pressedremoved and that the gearwheel abuts against the
Figure 2.36.2 Camshaft End Float
Figure 2.36.2 Camshaft End Float Access hole mustinno
Ensure betopressure
1mm is
removed below
- anythe
applied diameter
burrs
to the will
outer of of
affect
ring thethe
the flywheel end. shoulder
gearwheel hub (F).and any sharp edges around the
operation of the
gear at any time. governor thrust sleeve.
3.Insert
1.Remove Figure asetscrew
clock
the2.36.2 gauge
Camshaft extension
(A) from
End the end
Float through
Accesscover.the hole holethemust be removed - anyinburrs will affect the
Fit camshaft gearwheel the reverse order
2.Use auntil it rests
suitable rodagainst
through thethegearwheel
hole to pushand zero
the the operation
to dismantlingof the ensuring
governor thrust the thin sleeve.
flat washer is
1.Remove gauge.
camshaftthe setscrewas
gearwheel (A)far
from
as the end cover.
it will-go towards Fit the camshaft gearwheel in the reverse order
removed and that the gearwheel abuts against the
2.Use a suitable
the flywheel end. rod through the hole to push the to dismantling
shoulder (F). ensuring the thin flat washer is 39
 of the gear at any time. 5.Assemble the bridge (8) and thrust nut (9) to the
screw
6.Using the correct size of spanner tighten the
Changing the Camshaft Ball Race
thrust nut until the
TS, TR, TXbush is removed.
engines workshop manual 37
1.Remove the retaining pin from the gearwheel
7.Remove the tool.
hub.
2.Support the camshaft assembly on the hub of
the ball race and push the camshaft through the Flywheel End Bush Replacement
Changing
gearwheel the andCamshaft
bearing. Ball Race
3. Fit
1.Fit thethenew nut (2) onto the screw
lubricated bush (1). to the small dolly
4. Place the screw through the dolly from the gear end.
(11).
3.Push the
1. Remove theretaining
new bearing pin from onthe to gearwheel
the camshaft hub. and 5. Place
apply pressure
2. Support the camshaft to theassembly
gearwheel the hub of the ball 2.With
on hub. thethe dotguideon the (10) bush
over the at screw
the top, to align
place thethebush in the
housing.
4.Push
race andon pushthethegearwheel
camshaftand key. the gearwheel and dolly
through 6. Fit
and bush into the crankcase from the inside
theup bridge (8) and thrust
bearing.
5.Refit the retaining pin. and line the bush with its nut (9).
location.
7. Using the correct size of spanner and checking the tool and
3. Push the new bearing on to the camshaft and apply pressure 3.Fit bush the nut (2) onto the screw (1).
alignment very carefully, tighten the thrust nut until the
to the gearwheel hub. 4.Place the screw through the dolly from the gear
2.38 THE CAMSHAFT
4. Push on the gearwheel and key.
BUSHES end.
bush is central across its housing.
8. Remove the tool.
A new bush should
5. Refit the retaining pin. be immersed in clean engine 5.Place the guide (10) over the screw to align the
lubricating oil for four hours before fitting. A small bush in the housing.
identification dot is on one outside edge of the bush 6.Fit Centre
the bridge Bush (8) Removal
and thrust nut (9).
2.38 The Camshaft Bushes
and on assembly this dot must be towards the top 7.Using 1. Fit thethenut correct
(2) onto size
theof spanner
screw (1). and checking
of the
A new bushcrankcase.
should be Itimmersed
is recommended
in clean engine that bushes
lubricating the tool
2. Fit theand large bushdollyalignment
(12) into the verybush,carefully,
on three tighten
cylinder engines
oilare replaced
for four hours as a set.
before fitting. A small identification dot is on thethe thrustflange nutmust untilbe the bushthe
facing is direction
central across in which itsthe bush
oneTooutside
gain edge access of the to bush
the and
flywheelon assemblyend expansion
this dot must housing. will be removed.
beplug
towardsandthe bushtop itofwill
the becrankcase.
necessary It is recommended
to remove thethat 8.Remove 3. Place the the screw
tool. through the dolly from the end giving the
bushes are replaced
flywheel, fanshroud as a and
set. main bearing housing. maximum protrusion of the screw outside the crankcase.
To gain access to the flywheel end expansion plug and bush it 4. Fit the bridge (8), for the flywheel end centre bush or the
Centre Bush Removal
will be necessary to
Camshaft Bush Tool 393235 remove the flywheel, fanshroud and main depth plate (7) for the gear end centre bush.
1.Fit the nut (2) onto the screw (1).
bearing housing. 5. Fit the thrust nut (9) to the screw.
2.Fit the large dolly (12) into the bush, on three
Notes: 6. Using the correct size of spanner tighten the thrust nut until
cylinder engines the flange must be facing the
The camshaft
Camshaft Bush Tool 393235 bush tool, 393235, replaces 317- the bush is removed.
direction
7. Remove in the
which tool.the bush will be removed.
50006 ; both are described and either can be 3.Place the screw through the dolly from the end
Notes:
used. The legend numbers referred to in the
The camshaft bush tool, 393235, replaces 317-50006 ; both are described and either giving the maximum protrusion of the screw
canillustration
be used. The legendand
numberstext
referredare also
to in the marked
illustration onalsothe
and text are
Centre Bush Replacement
marked outside the crankcase.
individual tool
on the individual tool items. items. 4.Fit thethebridge
1. Fit (8), for bush
new lubricated the flywheel
to the large end dolly centre
(12).
bush
2. Fitor the the nutdepth
(2) onto plate
the(7) for the
screw (1 ). gear end centre
3. With the dot on the bush at the top, place the dolly and bush
bush.
5.Fit into the appropriate
the thrust nut (9) tocentre web housing and align the bush
the screw.
by using guide (10).
6.Using the correct size of spanner tighten the
4. Place
thrust nutthe untilscrewthethrough
bush isthe dolly and place the guide (10)
removed.
over the
7.Remove the tool. screw to align the bush in the housing.
5. Assemble the bridge (8), for the flywheel end centre bush, or
the depth plate (7) for the gear end centre bush.
Centre Bush Replacement
6. Fit the thrust nut (9) to the screw.
1.Fit
7. Usingnew
the lubricated
the correct size ofbush
spanner to andthe checking
large dolly the tool and
(12).bush alignment very carefully, tighten the thrust nut until the
2.Fit bush
the nut (2) onto
is central the its
across screw
housing.(1 ).
3.With the dot
8. Remove theon tool.the bush at the top, place the
Figure 2.38.1
Figure 2.38.1 Camshaft
Camshaft BushBushTool Tool 393235
393235 dolly and bush into the appropriate centre web
housing
Camshaft and align Bush theTool
bush317-50006
by using guide (10).
Flywheel End
Flywheel End Bush Removal Bush Removal 4.Place the screw through the dolly and place the
1.Remove the flywheel end main bearing housing. Notes:
guide (10) over the screw to align the bush in the
1. Remove the flywheel end
2.Fit the nut (2) onto the screw (1). main bearing housing. The camshaft
housing. bush tool, 317-50006, has been replaced by 393235; both are described
2. Fit the nut (2) onto the screw (1).
3.Fit the small dolly (11) into the bush from inside and either
5.Assemble can be
theused. The
bridge legend numbers
(8), for referred
the to in the illustration
flywheel endand text are
3. Fit the small dolly (11) into the bush from inside the crankcase. centre also marked on the individual tool items.
bush, or the depth plate (7) for the gear
the crankcase.
4. Place the screw through the dolly from the gear end.
5. Assemble the bridge (8) and thrust nut (9) to the screw
40 the correct size of spanner tighten the thrust nut until
6. Using
the bush is removed.
7. Remove the tool.

Flywheel End Bush Replacement

1. Fit the new lubricated bush to the small dolly (11).
2. With the dot on the bush at the top, place the dolly and bush
into the crankcase from the inside and line up the bush with
its location.
 bearing is fully located in the centre web bearing
Notes: housing.
The camshaft bush tool, 317-50006, has been 5.Remove the complete tool.
replaced by 393235; both are described and
either can be used. The legend numbers TS, TR, TX engines workshop manual 38
Flywheel End Bush Removal
referred to in the illustration and text are also 1.Place the plug (A) against the bush.
marked on the individual tool items. 2.Insert the bolt (H) with plate (G) through gear end
camshaft
Flywheel bearing housing
End Bush and screw it into the
Replacement
plug.
1. Startthe
3.Place theplate
bush in
by correct
gently tapping
position it into the housing
on the centre using a
webcopper or hide the
and tighten faced hammer.
bolt.
2. Placethe
4.Ensure the tool
plug is
against the bush.
correctly lined up and tighten
the bolt until the bushplate
3. Insert the bolt with the through
is fully the gear end camshaft
removed.
bearing hole and screw it into the plug.
5.Unscrew the plug and remove the tool and
4. Place the plate into the correct position on the centre web
bush.
and tighten the bolt.
5. Ensure the tool is correctly lined up and tighten the bolt until
Flywheel
the bush End Bushlocated.
is correctly Replacement
1.Start the bush by gently
6. Unscrew the plug and remove tappingthe it into
tool.the housing
using a copper or hide faced hammer.
Figure 2.38.2 Camshaft BushTool
Tool 317-50006 2.Place the plug against the bush.
Figure 2.38.2 Camshaft Bush 317-50006
2.39theThe
3.Insert Cylinder
bolt with Barrelthe gear end
the plate through
Centre
Centre Bush
Bush Removal
Removal camshaft bearingany
Before removing hole and screw
cylinder barrelititinto the plug.
should be marked to
1.Place sleeve (B) over the plug (A) with the 4.Place ensurethe it isplate
replace into the
to its correct
original position on the
orientation.
1. Place sleeve lug
locating (B) over the plug
towards the(A)plug
withhead.
the locating lug towards centre web and tighten the bolt.
the plug head.
2.Place the sleeve and plug into the gear end 5.Ensure Cylinder the tool is correctly
Barrel Removal lined up and tighten
2. Place the sleeve and plug into the gear end camshaft bush
camshaft bush hole. the bolt until the bush is correctly located.
hole. 1. Removethe theplug
cylinder
The chamfer on the sleeve will assist in aligning 6.Unscrew and head
remove and the
sump. tool.
The chamfer on the sleeve will assist in aligning the tool. 2. Place a retaining tube, secured by a hand tight cylinder head
the tool.
3. Insert the bolt (H) through the flywheel end camshaft bearing nut, over one stud of each cylinder from which the head was
3.Insert
hole. the bolt (H) through the flywheel end 2.39 THE CYLINDER BARREL
removed.
camshaft
4. Place the washerbearing hole.
(E), which must be the same diameter as the Before Thisremoving
will prevent any
the cylinder
cylinderrising as the crankshaft
barrel it shouldis turned.
4.Place
centre the washer
bearing bush, over (E), thewhich must
bolt with thebeflatthe
facesame
towards be 3.marked
With thetoengine turned over and standing on the flywheel,
ensure it is replace to its original
thediameter
bolt head andas thescrewcentre bearing
it into the bush,
plug until over the
the washer abuts orientation.
rotate the crankcase until one connecting rod big end is at
thebolt withcamshaft
centre the flatbush.face towards the bolt head and BDC.
screw it into
5. Checking carefully forthe plug
tooluntil the washer
alignment, tighten abuts the to
the bolt 4. Remove the big end bearing cap.
centre
push camshaft
the washer bush through the centre web of the Cylinder
andbush. Barrel Removal
5. To protect the crankshaft journal from possible damage, fit
5.Checking carefully for tool alignment, tighten the
crankcase. 1.Remove the cylinder head and sump.
a suitable tube over each connecting rod bolt and secure it
bolt tothe
6. Remove push the washer
tool complete withand
bush.bush through the 2.Place a retaining
with a hand tight nut.
tube, secured by a hand tight
centre web of the crankcase. cylinder head nut,
6. Rotate the crankcase overuntil
onethe studsame of each
pistoncylinder
is at TDC.
from which the head was removed.
Centre Bush Replacement
6.Remove the tool complete with bush. 7. Mark the cylinder for position and number.
This8. will prevent
Remove the the
tubecylinder
securingrising as the crankshaft
the barrel.
1. Place the sleeve over the plug with the locating lug towards is9.turned. Lift off the barrel, piston and connecting rod as a complete
Centre
the Bush Replacement
plug head. 3.With the engine turned over and standing on
assembly.
1.Place
2. Place the the
sleevesleeve
and plugoverintothetheplug
gear with
endthe locating
camshaft bush the 10. flywheel,
Remove therotate
tubes fromthe thecrankcase
big end. until one
lug towards the plug head.
hole. connecting
11. Replace rod
the big end
big endbearing
is at BDC.cap.
2.Place
The chamfer theonsleeve
the sleeve andwillplug
assistinto the gear
in aligning end
the tool. 4.Remove
12. Remove thethe
bigpiston
end bearing
from thecap. cylinder barrel.
camshaft
3. Insert the boltbush
through hole.
the flywheel end camshaft hole, place 13. Thoroughly clean the cylinder barrel and check for scoring
the washer and bush over the bolt with the flat face towards and wear.
bolt head and screw it into the plug until the bush and washer
abuts the centre camshaft bearing hole.
41
4. Checking the tool and bush alignment very carefully, gently Cylinder Barrel Replacement
screw the bolt until the centre bearing is fully located in the 1. Fit the piston to the connecting rod.
centre web bearing housing. On TS/TR engines ensure the wording 'CAMSHAFT SIDE' on
5. Remove the complete tool. the piston crown is the same side as the identification marks
on the connecting rod big end.
Flywheel End Bush Removal 2. Insert the gudgeon pin and two circlips; ensure the circlips
are correctly located in the grooves.
1. Place the plug (A) against the bush. 3. Fit the piston rings in the order as shown in 'Figure 2.40.1'
2. Insert the bolt (H) with plate (G) through gear end camshaft 4. Ensure the piston ring gaps are staggered and fit the piston
bearing housing and screw it into the plug. into the cylinder barrel while compressing the rings.
3. Place the plate in correct position on the centre web and 5. If necessary, fit new big end bearing shells ensuring they are
tighten the bolt. correctly located in both the connecting rod and cap.
4. Ensure the tool is correctly lined up and tighten the bolt until 6. On TS/TR engines:
the bush is fully removed. Coat the bottom jointing face surface of the cylinder barrel
5. Unscrew the plug and remove the tool and bush. with Hylomar PL32M.
Fit a new joint and coat it with Hylomar PL32M.
 TS, TR, TX engines workshop manual 39

7. On TX engines: The Piston Rings

Clean and dry the cylinder head clearance shims, the cylinder
barrel and crankcase mating surfaces. Firing Ring
Place the shims, dry, onto the bottom of the cylinder barrel.
A barrel lapped chrome ring is situated at the top of the piston
8. Turn the crankshaft crankpin to TDC.
and is tapered on the sides to prevent sticking in the groove.
9. To protect the crankshaft journal from possible damage, fit
a suitable tube over each connecting rod bolt and secure it
with a hand tight nut. Compression Ring
10. On TS/TR engines: Two compression rings are fitted to the five ring piston and one
AL Ensure the deeper cylinder barrel fins will be facing towards on the three ring piston. They have a tapered face in contact
the manifold side and 'CAMSHAFT SIDE' on the piston crown with the barrel, one surface on each is marked 'TOP' and the
will face towards the camshaft. rings must be fitted the correct way up with 'TOP' towards the
ossible 10a. On TX engines:
position. piston crown.
Ensure the connecting rod identification marks will face
necting 12.Push down on the top of the piston as the
towards the camshaft.
. crankcase is rotated until the crankshaft
11. Lower the cylinder and piston assembly into position.
Oil Control Ring
on is at crankpin is at BDC.
12. Push down on the top of the piston as the crankcase is One conformable type, with a spring expander, is fitted above
13.Remove the protective tubes.
rotated until the crankshaft crankpin is at BDC. the gudgeon pin and a slotted scraper ring is fitted below the
. 14.Ensure the connecting
13. Remove the protective tubes. rod cap bolt head is gudgeon pin on five ring pistons. On a three ring piston only
correctly
14. Ensure located rod
the connecting against thehead
cap bolt shoulder on located
is correctly the one ring is fitted above the gudgeon pin.
od as a connecting rod as shown below.
against the shoulder on the connecting rod as shown
15.Fit
below. the big end bearing cap ensuring the Removing a Piston
15. Fitidentification numberscap
the big end bearing areensuring
on the same side and
the identification
identical.
numbers are on the same side and identical. 1. Remove the cylinder barrel together with the piston.
rel. 2. Withdraw the piston from the barrel.
check 3. Release the circlip from one end of the gudgeon pin.
4. Push out the gudgeon pin.
If the pin is tight, place the piston in hot water until it can be
removed; it may be necessary to protect the hands.
5. Using a suitable piston ring expander remove the piston rings.
SHAFT
side as Inspection and Servicing
rod big a. Clean the piston, removing all traces of carbon from the
crown, ring grooves and oil holes.
ensure b. Check all the piston rings in the cylinder barrel for the correct
oves. gap clearance.
own in Figure 2.39.1
Figure Bearing
2.39.1 Bearing Cap BoltHead
Cap Bolt Head Location
Location c. Clean the connecting rod and examine for bending and
twisting.
16.Replace
ggered 16.Replace the connecting
the connecting rod torque
rod nuts and nuts them
and totorque
43.5Nm d. Examine the small end bush for wear.
l while them to
(32.0lbf ft). 43.5Nm (32.0lbf ft). e. If the big end has been dismantled because of metal failure
ItItisisrecommended
recommended thatthat connecting
connecting rod bolts
rod bolts andare
and nuts the oil passages in the crankshaft must also be examined for
shells nuts areatreplaced
replaced at overhaul.
every major every major overhaul. obstruction and fragments of metal.
oth the
2.40The
2.40 THEPiston
PISTON AND
and Connecting Rod Refitting a Piston
CONNECTING ROD 1. Fit the piston to the connecting rod.
ylinder The piston is manufactured from low expansion alloy and has On TS/TR engines ensure the wording 'CAMSHAFT SIDE' on
The piston
a machined is manufactured
recessed from low
combustion chamber in expansion
the crown. All
the piston crown is the same side as the identification marks
pistons
alloy are
andfitted
has witha three cast iron
machined rings except
recessed certain TS
combustion
2M. on the connecting rod big end.
builds which have
chamber in the fivecrown.
rings. All pistons are fitted with
2. Insert the gudgeon pin and replace the circlips.
The gudgeon
three cast pin
ironisrings
retained by two
except circlips
certain TSand runs which
builds in a bush
shims, in the small end of the connecting rod.
3. Using a suitable piston ring expander replace the piston rings
mating Thehave five rings.
forged steel connecting rod is connected
in the order as shown below.
The gudgeon pin is retained by twotocirclips
the crankpin
and by
a conventional big end bearing, the cap being held in position
ylinder byruns in a bush in the small end of the connecting
two bolts and nuts. The two halves of the big end bearing
rod.
are steel backed copper lead and are precision finished and
The forged steel connecting rod is connected to
should not be scraped or touched up in any way.
ossible Thethe crankpin by a conventional big end bearing, the
gudgeon pin is a clearance fit in the small end bush.
necting cap being held in position by two bolts and nuts.
. The two halves of the big end bearing are steel
backed copper lead and are precision finished and
facing should not be scraped or touched up in any way.
SHAFT The gudgeon pin is a clearance fit in the small end
 to bear this point in mind when removing, it squ
handling or replacing it. To prevent damaging fansh
the TS or TR stator of the flywheel mounted Chec
TS, TR, TX engines workshop manual
charge windings the free length of studs or bolts 40 the s
T SERIES ENGINES WORKSHOP MANUAL
entering the flywheel must not exceed 20.0mm 4.Rem
(0.79in). 5.Fit a
nut.
6.Eithe
ve ring the c
. They preve
el, one 7.Torqu
s must (350.
rds the 8.Rem

2.42
An alu
nder, is
except
scraper
ve ring Figure 2.40.1 PistonRings
Rings Figure 2.41.1 Flywheel Tools:
s fitted
Figure 2.40.1 Piston
A - Firing Ring;
A - Firing Ring; B - Compression RingC - Oil Control Ring
Figure 2.41.1 Flywheel Tools:
A - Early Locking Tool
A - Early Locking Tool; B - Current Locking Tool; C - Puller; D - Mandrel
Remo
B - Compression Ring B - Current Locking Tool 1.Rem
C - gaps
Oil Control C - Puller 2.Rem
4. Distribute the piston ring aroundRingthe piston circumference Flywheel RemovalD - Mandrel
so that the gaps are not in line. rectifi
4.Distribute thethepiston ring
andgaps
ringsaround
with newthe piston 1. Remove the starter motor. 3.Care
ith the 5. Lightly lubricate piston engine oil.
Flywheel Removal
circumference so that the gaps are
6. Using a suitable piston ring clamp compress the rings and not in line. 2. Fit the flywheel locking tool into the tapped hole in the cable
5.Lightly
fit the piston lubricate the piston
and connecting and rings
rod assembly intowith new
the cylinder 1.Remove the starter motor.
fanshroud. 4.Rem
engine oil. 3. 2.Fit
If thethe flywheel
flywheel locking
locking tooltool intoavailable
is not the tapped wedgeholethe piece
udgeon barrel. in the fanshroud.
6.Using a suitable piston ring clamp compress crankshaft with a suitable piece of wood to prevent it from
the rings and fit the piston and connecting rod 3.If the flywheel locking tool is not available wedge
turning. The un
2.41 The Flywheel
assembly into the cylinder barrel. the crankshaft
4. Slacken the flywheelwith a suitable
retaining screw or piece of turns
nut two woodwithto a the s
er until 65mm socket
prevent spanner.
it turning.
The flywheel rotates within the flywheel housing and the type 5.Rem
protect 5. Fit the flywheel
4.Slacken the puller
flywheeltool retaining
by screwing three or
screw bolts
nutthrough
two
fitted depends on engine, speed, application and build. All
2.41 THE FLYWHEEL the fa
flywheels can be fitted with ring gears for electric starting. theturns
'B' holes into the flywheel.
with a 65mm socket spanner. 6.Rem
ove the TheThe TS/TR flywheel
cooling air rotates within
fan is fitted theoutside
to the flywheel housing
face and is made 6. Turn
5.Fitthethetool centrepuller
flywheel bolt sufficiently to loosenthree
tool by screwing the flywheel.
bolts remo
of either polypropylene or cast iron depending onspeed,
and the type fitted depends on engine, the Build; 7. Remove the puller and locking tools.
through the 'B' holes into the flywheel. fansh
theapplication
two types are andnotbuild. All flywheels can be fitted
interchangeable. 8. Remove
6.Turn the theflywheel screw or
tool centre nut and
bolt fit the correct
sufficiently flywheel
to loosen 7.Rem
The with ring gears
flywheel is keyed foronelectric starting. and held in position
to the crankshaft mandrel to
the flywheel.prevent damaging the stator and for personal
safety.
lower
carbon with The TS/TR or
a setscrew cooling airTSfan
nut. Early andisTRfitted to the
engines, up tooutside
the serial 7.Remove the puller and locking tools. sump
. face and
numbers given,is were
madefittedof either polypropylene
with a flywheel retainingorsetscrew
cast 9. Support the flywheel at all times and keeping it square, slide
8.Remove the flywheel screw or nut and fit the 8.Rem
arrel for and iron depending
locking washer.on the engines
Later Build; the aretwo types
fitted withare not
a locking it over the mandrel and lift it off.
correct flywheel mandrel to prevent damaging a.On
interchangeable.
washer and nut. 10. Remove the Woodruff key.
the stator and for personal safety. and
ne for The 35flywheel
00630 TS1 is keyed36 on00255
to theTR1 crankshaft and held 9.Support the flywheel at all times and keeping it 9.Lift o
35 06716 TS2 36 00073
in position with a setscrew or nut. Early TS and TR2 Refitting
square,theslideFlywheel
it over the mandrel and lift it off.
TR35 05963 TS3
engines, up to the36serial00112numbers
TR3 given, were 10.Remove the
The shaft and the bore Woodruff
of thekey.
flywheel must be perfectly
The retaining screw or nut
ause of fitted with a flywheel retaining setscrew should be torque loaded
andtolocking
475.0Nm Refitt
clean and should be smeared with clean lubricating oil before Refittin
(350.0lbf ft). All flywheels have
nkshaft washer. Later engines are fitted with a locking tapped holes for attaching
Refitting the Flywheel
assembly. recomm
n and couplings,
washer shaft and nut.extensions, pulleys etc.
1. Fit
The a new Woodruff
shaft and the key.bore of the flywheel must be
The tolerance for bore and face run-out must be within 0.25mm correct
35 00630 TS1 36 00255 TR1 2. Fit the correct
perfectly flywheel
clean mandrelbe
and should to prevent
smeared damaging stator
with clean
(0.010in) TIR. loaded
35 06716 TS2 36 00073 TR2 and for personal safety.
lubricating oil before assembly.
Marks showing the firing point (FP) and the TDC position for The ta
35 05963 TS3 36 00112 TR3 3. Support the flywheel at all times and keeping it square, slide
1.Fit a new Woodruff key.
each cylinder can be viewed through an aperture in the rear the cur
The retaining screw or nut should be torque loaded it over the mandrel and into the fanshroud.
of the fanshroud. torque
wording Thetomagnetic
475.0Nm (350.0lbf ft). All flywheels have tapped Check that the key has remained in position in the shaft.
rotor for the TS and TR charge windings is pressed
holes for attaching
is the into the rear face of the flywheel. couplings, shaft extensions, 4. Remove the mandrel.
on the pulleys etc. 5. Fit a new tabwasher and replace the setscrew/nut.
The tolerance for bore and face run-out must be 44 fit the flywheel locking tool or wedge the crankshaft
6. Either
WARNING
within 0.25mm (0.010in) TIR. with a suitable piece of wood to prevent it turning.
clips.
7. Torque the retaining screw or nut to 475.0Nm (350.0lbf ft).
ace the The Marksflywheel,
showing withoutthegear
firing ring or fan,
point weighs
(FP) and intheexcess
TDC
ofposition
54kg (1191bs) therefore it is important to bear this 8. Remove the locking tool.
for each cylinder can be viewed through
point in mind when
an aperture in theremoving,
rear of the handling or replacing it.
fanshroud.
To prevent damaging the TS or TR stator of the flywheel
The magnetic rotor for the TS and TR charge
mounted charge windings the free length of studs or
2.42 The Fanshroud - TS/TR
windings is pressed into the rear face of the
bolts entering the flywheel must not exceed 20.0mm An aluminium fanshroud is fitted to all engines except Build 16
flywheel. which has one of sheet metal.
(0.79in).

43
 TS, TR, TX engines workshop manual 41

Removing the Fanshroud Refitting the Flywheel Housing

1. Remove the flywheel. Refitting is carried out in the reverse order with the self-locking
2. Remove the two nuts and then remove the rectifier/regulator setscrews torque loaded to 88.0Nm (65.0lbf ft).
cover.
3. Carefully noting the position of the electrical cables, CAPTION
disconnect all four cables.
4. Remove the two nuts, washers and distance pieces and If the sump has been removed, the procedure detailed
remove the rectifier/regulator unit from the fanshroud. in "Replacing the Oil Sump" must be followed when
The unit will be fitted to either, the manifold side of the shroud refitting the fanshroud to prevent the possibility of
or above the starter motor. distorting it resulting in excessive flywheel to shroud
5. Remove the cable clip securing the cable inside the run-out.
fanshroud.
6. Remove the six screws securing the stator and remove it,
gently easing the cable through the fanshroud. 2.43 Main Bearing Housing
7. Remove the two bolts that are fitted through the lower end The main bearing housing is secured to the crankcase at the
of the fanshroud securing it to the sump. flywheel end and has an oil drain which must be located towards
8. Remove the self-lock bolts. the bottom of the crankcase when the housing is refitted. Shims
a. On older engines ease back the tab washers and remove are fitted between the housing and the crankcase to maintain
the bolts. the crankshaft end float. An oil seal is fitted to the centre bore
9. Lift off the housing. of the housing and an '0' ring is fitted in the side of the bearing
housing to provide a seal between the housing and bearing oil
Refitting the Fanshroud feed drilling in the crankcase.
On engines fitted with battery charging equipment the stator
Refitting is carried out in the reverse order and it is recommended is secured to the main bearing housing with screws.
that new tabwashers are fitted and correctly locked after the If the crankshaft is moved towards the flywheel end after the
bolts have been torque loaded to 43.5Nm (32.0lbf ft). housing has been removed the thrust washer at the gear end
The tabwashers and bolts can be replaced with the current could become detached from its recess. This can be avoided
self-locking setscrews which must be torque loaded to 88.0Nm by removing the gear end cover and placing two suitable
(65.0lbf ft). thin strips of metal between the crankshaft pinion and the
crankcase.
CAPTION To prevent the thrust washer at the flywheel end becoming
If the sump has been removed, the procedure detailed detached from the main bearing housing while removing the
in "Replacing the Oil Sump" must be followed when housing, turn the engine until No. 1 cylinder piston is at the
refitting the fanshroud to prevent the possibility of BDC position.
distorting it resulting in excessive flywheel to shroud
run-out. This is particularly important on Build 16 Removing the Main Bearing Housing
engines.
1. Remove the centre bearing locating dowel securing screw
(A) from the fuel pump side of the engine.
2.43 Flywheel Housing - TX
CAPTION
Removing the Flywheel Housing Failure to remove the dowel may result in distorting it
1. Remove the flywheel. making it difficult to remove at a later stage.
2. Remove the six self-locking setscrews.
3. Remove the fanshroud, noting that it is secured to the sump 2. Using a fuel pump securing bolt remove the centre bearing
by two bolts. dowel (B); leave the bolt in the dowel until it is refitted to
ensure the dowel is fitted the correct way round.
 distorting it making it difficult to remove at a
later stage.
X
2.Using a fuel pump securing bolt remove the
centre bearing dowel (B); leave the bolt in the TS, TR, TX engines workshop manual 42
dowel until it is refitted to ensure the dowel is
fitted the correct way round.
ecured
2.44 The Crankshaft
The crankshaft is a steel forging and is carried in steel backed
copper faced main bearings which are located in the crankcase
with the at the gear end, the flywheel end and the central web/s of the
8.0Nm crankcase.
End thrust is taken on steel backed copper faced split thrust
washers fitted at the gear end of the crankcase and in the
flywheel end main bearing housing.
cedure The main bearings are in two halves which are not
" must interchangeable; the top half has an oil groove and an oil hole
oud to which must be correctly located.
sulting Figure 2.43.1
An interference fit pinion is keyed onto the end of .the crankshaft
Figure 2.43.1Centre Bearing
Centre Bearing Dowel
Dowel
and engages with the camshaft gear.
Early crankshaft balance weights were secured with only one
3.Remove
3. Remove the securing
the bolts bolts securing
the main the main
bearing bearing
housing. retaining bolt up to the following engines:
G 4. Onhousing.
early TS engines remove the charge winding adaptor 35 00630 TS1 36 00255 TR1
to the 4.On early TS engines remove the charge winding
adapter. 35 06716 TS2 36 00073 TR2
il drain adaptor
5. Remove the adapter.
bearing housing: if it is tight use two M8 setscrews 35 05963 TS3 36 00112 TR3
of the 5.Remove
through the bearing
the threaded holeshousing:
provided and if itjack
is it
tight
off. use After these and on all TX engines the weights were secured
ms are 6. Drift
twooutM8
the setscrews
oil seal taking care notthe
through to damage
threadedthe bearings.
holes by two capscrews; the later weights and capscrews are not
case to provided and jack it off. interchangeable with the original items.
seal is Refitting
6.Drift outthe theMainoil seal Bearing
taking care Housing
not to damage
the bearings.
d an '0' When refitting the housing ensure that the oil supply holes line Crankshaft Removal
T SERIES ENGINES WORKSHOP MANUAL
sing to up and the grooved bearing shell is fitted at the top.
T SERIES ENGINES WORKSHOP MANUAL 1. Remove the cylinder barrels and pistons, main bearing
ring oil 1. Refitting
Lightly grease thethe Main steel Bearing
back of theHousing
thrust washers and housing and the sump.
When refitting
position them in the housing ensure
the housing, ensurethey thatarethe oil
correctly
6.Replace the 2. Using the Service Tool 393175 remove the crankshaft pinion.
supply
ipment located holes
and theline
copper upoil and lip the
face seal.
will grooved
be towardsbearing shell
the crankshaft.
is fitted
ousing 2. Remove 6.Replace
7.Replace
at the
the top.
oil seal the fromoil the
lip seal.
centre bearing
main locating
bearing housing.dowel/s with
3. Coat 7.Replace
1.Lightly
the the tapped
grease
bearing the
theend
housing centre
steelfacing
face bearing
back
with of thelocating
outwards.
Loctite thrust dowel/s
221, fitwashers
a shim and with
ywheel and
coat the the
8.Replacetapped
position
outside the
them
face end
of in
thefacing
locatingthe
shim. outwards.
dowel
housing, securing
ensure screw
they and
e thrust are correctly located and the copper face will be and
Continue8.Replace
torque
adding it the
to
and locating
20.5Nm
coating dowel
(15.0lbf
the securing
ft).
remaining shims. screw
tached 4. Replace
towards torque
thethe itcrankshaft.
housing to 20.5Nm
and charge (15.0lbf
windingft). adaptor, if fitted,
and torque CAUTION
moving 2.Remove the oil seal from the ft).
the bolts to 27.0Nm (20.0lbf main bearing
ble thin 5. Check CAUTION
Striking
the crankshaft
housing. theendfloat.
crankshaft may displace the
on and 6. Replace
3.Coat Striking
thrustwashers
the
theoil lipthe
bearing crankshaft
seal.housing and face mayLoctite
damage
with displace
the 221, the
bearing
7. Replace thrustwashers
locating
the centre dowel.
bearing and
locating
fit a shim and coat the outside face of the shim.damage
dowel/s with the
the bearing
tapped
eel end
end locating
facing
Continue outwards.dowel.and coating the remaining
adding
8. Replace The
shims. the locating
Main dowel securing
Bearing Oil Lip screw
Sealand torque it to
ousing
20.5Nm The(15.0lbf
1.Place Main ft). Bearing Oil Lipwinding
Seal Figure 2.44.1 Crankshaft Gear Removal Tool
ne until 4.Replace thethe new seal
housing and squarely
charge into theadaptor,
housing; do
1.Place the new seal squarely into the housing; Figure 2.44.1 Crankshaft Gear Removal
Tool Tool
notand
if fitted, usetorque
any jointing
the bolts compound.
to 27.0Nm (20.0lbf ft). do Figure 2.44.1 Crankshaft Gear Removal
CAPTION
5.Check notthe
2.Hold usethe any oil jointing
crankshaft compound.
sealendfloat.
tool onto the outside face of 3.Remove the pinion gear Woodruff key if
3.Remove
necessary.
3. Remove the gear
the pinion pinion gear key
Woodruff Woodruff key if
if necessary.
Striking2.Hold
the theand
thecrankshaft
seal oil seal
using
may tool
the onto
displace oilthethe
seal outside
tool, driveface
thrustwashers of
in the
and damage the the
seal seal
until and using
the tool
bearing the dowel.
shoulder
locating oil seal tool, drive
is against in the
the bearing necessary.
4.Remove
4. Remove eacheach
centre centre bearingdowels
bearing locating locating dowels
securing screw
seal until the tool shoulder is against the 45
housing. bearing 4.Remove each (A).
securing screw
(A). centre bearing locating dowels
housing. securing screw (A).
The Main Bearing Oil Lip Seal
2.44 THE CRANKSHAFT
2.44
1. Place the
The
newTHE CRANKSHAFT
seal squarely
crankshaft
into the housing; do not use any
is a steel forging and is carried in
jointing compound.
The crankshaft
steel is a steel forging and is carried in
2. Hold the oil backed copper
seal tool onto the faced
outsidemain
face ofbearings which
the seal and
steel
are
using the backed
oillocated
seal copper
tool,in faced
thein crankcase
drive the main
seal until thebearings
at the gearwhich
end,
tool shoulder
are
the located
flywheel in the
end
is against the bearing housing. crankcase
and the at
central the gear
web/s ofend,
the
the flywheel end and the central web/s of the
crankcase.
crankcase.
End thrust is taken on steel backed copper faced
End thrust is
split taken on
washers steel
fitted at backed
the gearcopper
end offaced
the
split thrust and
crankcase washers
in thefitted at theend
flywheel gear endbearing
main of the
crankcase
housing. and in the flywheel end main bearing
housing.
The main bearings are in two halves which are not Figure 2.44.2
Figure 2.44.2Centre Bearing
Centre Bearing Dowel
Dowel
The main bearings
interchangeable; theare
topinhalf
twohashalves which
an oil areand
groove not Figure 2.44.2 Centre Bearing Dowel
interchangeable;
an oil hole which the
must top
behalf has anlocated.
correctly oil groove and 5.Using a fuel pump securing bolt remove each
an oil
An hole whichfitmust
interference be is
pinion correctly located.
keyed onto the end of 5.Using
centre a fuel pump
bearing dowelsecuring
(B). bolt remove each
An interference
.the crankshaft fitandpinion is keyed
engages withonto
thethe end of
camshaft centrethe
Leave bearing
bolt indowel (B). until it is refitted to
the dowel
 punc
through the gear end bearing as it is quite easy to 10.Rep
score the bearing shell with the crankshaft. 11.Che
5.With the fuel pump bolt inserted in the centre 12.Fit t
TS, TR,
bearing TX engines
dowel (B), workshop manual
insert the dowel through43 13.Hea
the crankcase wall and into the centre bearing fit it
housing. '0' m
Insu
5. Using a fuel pump securing bolt remove each centre bearing cau
dowel (B). cran
Leave the bolt in the dowel until it is refitted to ensure the soft
dowel is fitted the correct way round. 14.Che
6. Remove the crankshaft balance weights.
7. Gently withdraw the crankshaft through the flywheel end
of the crankcase.
2.45
8. Remove the two socket screws and dismantle the centre 1.Set a
bearing housing/s. plung
9. Remove the gear end thrust washers. of the
2.Push
Servicing the Crankshaft Figure 2.44.3 Centre Bearing Dowel of the
Figure 2.44.3 Centre Bearing Dowel
3.Push
a. Inspect the main bearings for scoring or wear. end o
If necessary, the bearings can be removed and replaced using CAUTION
CAPTION shou
either Service Tool 393235 or 317-50006 as described in "02.47 Ensure
Ensure the dowel
the dowel has gone has gone
fully homefully home
and that it is and
not TS/
Crankshaft Main Bearings". that itT is
abutting thenot
SERIES abutting
main bearingthe
ENGINES mainshoulder
WORKSHOP
housing bearing orhousing
MANUAL
capscrew TS/
b. If the connecting rod big end has been dismantled because of shoulder or capscrew recess.
recess. 4.If the
failure of the bearing, the oil passages in the crankshaft must
also be examined for obstruction and fragments of metal. remo
also the connecting rod bearings.
c. Check the clearance between the crankshaft and journals, shim
d.Examine all bearing surfaces for scoring
the main bearings and crankpins and also the connecting and Shim
wear.
rod bearings. hous
e.Renew the split thrust washers
d. Examine all bearing surfaces for scoring and wear. if they are
e. Renew damaged or worn.
the split thrust washers if they are damaged or
worn.
Refitting the Crankshaft
Refitting
1.If the Crankshaft
necessary fit new bearing shells to the main
bearing housing, centre bearing housing/s and
1. If necessary fit new bearing shells to the main bearing
the gear end crankcase main bearing.
housing, centre bearing housing/s and the gear end
The grooved bearing shell must be to the top and
crankcase main bearing.
the oil
The grooved holes shell
bearing mustmust be lined
be toup.the top and the oil Figure 2.44.4
2.44.4 Dowel Hole Alignment
2.Re-assemble
holes must be lined up. the centre main bearing housing/s Figure Dowel Hole Alignment
A -BDowel
A - Dowel Hole; Hole
- Capscrew Head Recess
around
2. Re-assemble thethe crankshaft
centre main bearingensuring the socket
housing/s aroundscrews
the B - Capscrew Head Recess
crankshaftareensuring
tightened. the socket screws are tightened.
6. Replace the locating dowel securing screw and torque load
Ensure 'Flywheel
Ensure 'Flywheel End' on the End' on thehalves
housing housing halves is
is correctly
it6.Replace the locating
to 20.5Nm (15.0lbf ft). dowel securing screw and
correctly
located before located before assembly.
assembly. torquethe
7. Remove load
fuelitpump
to 20.5Nm (15.0lbf
bolt from ft).
the dowel.
3.Apply
3. Apply grease grease
to the to of
steel side thethesteel side of and
thrust washers
8. 7.Removetheplace
thrust
the fuel pump
Refit the crankshaft balance bolt from the
weights, dowel.
with the stamped
washers
them in the gear end and place
of the them in
crankcase withthethe
gear end of the
tab correctly
8.Refit
part the crankshaft
numbers balance
facing each other, weights,
and torque loadwith the
to 57.0Nm
crankcase
located and the copper withfacethetowards
tab correctly located and the
the crankshaft. stamped
(42.0lbf ft). part numbers facing each other, and
4. Offer up copper face towards
the crankshaft, lining up the centre
crankshaft.
bearing to ensure
Earlytorque load
balance to 57.0Nm
weights (42.0lbf
only have ft).
one retaining screw.
each dowel holeup
4.Offer is inthe
the crankshaft,
correct position. lining up the centre
9. Lock
Early balance weights only have one punch.
the bolts by preening them with a centre retaining
Take special care when passing
bearing to ensure each the crankshaft
dowel hole through
10. Replace thethe
is in
screw. the rear main bearing housing.
gear endcorrect
bearingposition.
as it is quite easy to score the bearing shell
11.9.Lock
Check thatthe the crankshaft
bolts is free tothem
by preening rotate.with a centre
with theTake
crankshaft.
special care when passing the crankshaft
12. Fit the Woodruff key at the gear end.
5. With thethrough
fuel pump bolt inserted in the centre
punch.
the gear end bearing as itbearing
is quitedowel
13.10.Replace easy to
Heat the crankshaft
the rearpinion
maintobearing
straw yellow
housing. and fit it to the
(B), insertscore
the dowel through the crankcase
the bearing shell with the crankshaft.wall and into the
crankshaft without delay ensuring the '0' mark is facing
centre5.With
bearingthe housing. 11.Check that the crankshaft is free to rotate.
fuel pump bolt inserted in the centre outwards.
12.Fit the Woodruff key at the gear end.
bearing dowel (B), insert the dowel through 13.Heat Insufficient heat or delay in fitting could well cause the
the crankshaft pinion to straw yellow and
the crankcase wall and into the centre bearing pinion to become jammed on the crankshaft, whereas
fit it to the crankshaft without delay ensuring the
housing. overheating may cause softening of the pinion.
14. Check'0' mark is facing end
the crankshaft outwards.
float.
Insufficient heat or delay in fitting could well
cause the pinion to become jammed on the
crankshaft, whereas overheating may cause
softening of the pinion.
14.Check the crankshaft end float.

2.45 CRANKSHAFT END FLOAT

1.Set a dial test indicator so that the actuating
 TS, TR, TX engines workshop manual 44
T SERIES ENGINES WORKSHOP MANUAL

2.45 Crankshaft
Notes: End Float 2.47
2.47Crankshaft
CRANKSHAFTMain Bearings
MAIN BEARINGS
Ontest
1. Set a dial current
indicatorengines 0.127
so that the and 0.254mm
actuating (0.005 Main
plunger makes
MainBearing
BearingTool 393235
Tool 393235
contactand
with the flywheel end face of the crankshaft.
0.010in) aluminium shims control the
2. Push the crankshaft
endfloat andfirmly
aretowards the gearas
assembled end of thein
given engine
"02.43
and zero the indicator.
Main Bearing Housing".
3. PushT SERIES ENGINES
the crankshaft firmlyWORKSHOP MANUAL
towards the flywheel end of the
Early TS and TR engines may have paper and
engine and check the end float; this should be:
0.076mm
TS/TR1: (0.003in) metal
0.178-0.305mm shims assembled dry,
(0.007-0.012in)
or with Wellseal.
TS/TR/TX2,3: 0.229-0.356mm (0.009-0.014in).
Notes:
4. If the end floatthe
is incorrect adjust by the addition
2.47 CRANKSHAFT MAIN BEARINGS
On 5.After
current enginesbearing housing
0.127 and has been or
0.254mm
removalthe
replaced
(0.005
of 0.127 housing
or 0.254mm (0.005
bolts areor 0.010in)toshims.
torqued 27.0Nm (20.0lbf Main Bearing Tool 393235
and are
Shims 0.010in)
fitted to thealuminium
flywheel endshims control
main bearing the ft).
housing.
endfloat and are assembled as given in "02.43
Main2.46
Notes: Bearing CHECKING
Housing". BEARING
On current CLEARANCE
Earlyengines
TS and TR0.254mm
0.127 and engines(0.005 may have
and 0.010in) paper
aluminium and
shims control
the 0.076mm and are(0.003in)
endfloat1.Place assembled as metal
given in shims
"02.43 Mainassembled
Bearing Housing".
a piece of the correct size 'Plastigauge' dry, Figure 2.47.1
Figure 2.47.1 Main Bearing
Main Bearing Tool
Tool
Earlyor
TS with
and TR engines
Wellseal.may have paper and 0.076mm (0.003in) metal shims as-
approximately 6.35mm (0.25in) off-centre across
sembled dry, or with Wellseal.
5.After the
the full widthhousing
bearing of one bearing
has been shell.
replaced the Note:
Note:
housing bolts are torqued to 27.0Nm (20.0lbf ft). ThisThis
tool replaces
tool317-50006; both are described
replaces and either can be
317-50006; used. The
both legend
are
5. After the bearing housing has been replaced the housing
numbers referred to in the illustration and text are also marked on the individual
bolts are torqued to 27.0Nm (20.0lbf ft). described and either can be used. The legend
tool components.
2.46 CHECKING BEARING numbers referred to in the illustration and
2.46 Checking Bearing Clearance text are also marked on the individual tool
CLEARANCE Gear End Main Bearing Removal
components.
1.Place
1. Place a piece
a piece of the size
of the correct correct size 'Plastigauge'
'Plastigauge' approximately
1. Fit the nut (2) onto the screw (1).
Figure 2.47.1 Main Bearing Tool
approximately
6.35mm 6.35mm (0.25in)
(0.25in) off-centre across theoff-centre across
full width of one
Gear
2. Place End
both Main
dollies (5, 6)Bearing Removal
onto the screw with the tapered ends
the full
bearing width of one bearing shell.
shell. Note: outwards
1.Fit the nut (2) onto the screw (1). the nut (2).
and the large dolly (6) next to
This toolthereplaces
3. Insert
2.Place assembly
both dollies 317-50006;
into(5,the
6)main theboth
ontobearing from
screw areinside
with thethe
crankcase.
described andends
tapered eitheroutwards
can be used.and theThe legend
large dolly (6)
4. Fitnext
numbers the referred
bridge (8) to
to the nut followed
(2).in the by illustration
the thrust nut and
(9) onto the
text screw (1). marked on the individual tool
are also
3.Insert the assembly into the main bearing from
Figure 2.46.1 Checking Bearing Clearance 5. Locate the bridge against the outside of the crankcase
components.
inside the crankcase.
6. Using the correct size of spanner tighten the thrust nut
2.Replace the bearing and torque the nuts. 4.Fit the bridge (8) followed by the thrust nut (9)
(9) until the main bearing shells are removed from the
Gear End
onto
3.Remove the bearing shell and use the scale to crankcase. Main
the Bearing
screw (1). Removal
check the width of the flattened 'Plastigauge'; 5.Locate
1.Fit the nut (2)the ontobridgethe screw against(1). the outside of the
the width at the widest point establishes the crankcase
2.Place both dollies (5, 6) onto the screw with the
Gear6.Using
Endthe Main Bearing of
correct size
Replacement
minimum clearance and at the narrowest pointtapered ends outwards and the spanner large dolly tighten
(6) the
the maximum clearance. 1.
next to thrust
Remove the nut nut(2).
the (9) until the main bearing shells are
thrustwashers from the crankcase.
2. Fitremoved
3.Insert the
the nut (2)from
assembly the
and bridgeinto crankcase.
(8) onto
the main thebearing
screw (1).from
TheFigure
Figure difference
2.46.1 between
2.46.1Checking
the
Bearing
Checking Bearing
two readings is the
Clearance
Clearance Ensure the
inside the crankcase. tang on the nut is correctly located into the slot
journal to bearing clearance.
on
4.Fit Gear the
the bridgebridge.
End(8) Main Bearing
followed by the Replacement
thrust nut (9)
2.Replace
2. Replace the bearing
the bearing and torque
and torque the nuts.
the nuts.
theCAUTION
3. Place
onto the both
screw halves
(1). of
1.Remove the thrustwashers from the new bearing into
thethecrankcase.
sleeve (3) from
3.Remove
3. Remove the bearing
bearing shell andshell andscale
use the usetothe
checkscale to
the width the end opposite the locating spigots.
Care
check themustwidth beoftaken
the the towidth
ensure
flattened the crankshaft 5.Locate
2.Fit the nut bridge(2) and against
bridgethe (8) outside
onto theof screwthe (1).
of the flattened 'Plastigauge'; at'Plastigauge';
the widest point Align the ends of the new bearings with the letter 'G' on the
is not
the width
establishes turned
theatminimum when
the widest the Plastigauge
pointand
clearance establishes is in
the
at the narrowest place,crankcase
Ensure the tang on the nut is correctly located into
sleeve and ensure the bearing oil hole is correctly lined up
and
minimum
point all
the maximum traces
clearance of it must be removed
and at the narrowest point
clearance. before 6.Using
final thethe slot correct
on the size
bridge. of spanner tighten the
with the '0' mark on the sleeve face.
Thethe assembly
difference
maximum of thethe
between
clearance. two readings is the journal to thrust
bearing. nut (9)
3.Place both until the main
halves of the bearing
new bearing
4. Place the dolly (6) with the taper outwards into the spigot
shells are into the
bearing clearance. between the two readings is the
The difference removed sleeve from (3)
end of the sleeve (3).
the crankcase.
from the end opposite the locating
journal to bearing clearance. spigots.
5. Fit the driver (4) into the other end of the sleeve, ensuring the
CAPTION Gear End
Align
guide Main
dowelthe is ends Bearing
of thelocated
positively Replacement
new bearings
in the slotwith in thethesleeve.
letter
CAUTION
Care must be taken to ensure the crankshaft is not
6. Fit 'G'
1.Remove on
the the
the assembly sleeve
onto the and
thrustwashers from
crankcaseensure
the the
crankcase.
from bearingmaking
the outside oil
Care when
mustthe bePlastigauge
taken to is ensure 2.Fit thehole
nut is
(2)correctly
and lined
bridge (8) upontowith the
the '0'
screw mark (1). on the
in place,the
andcrankshaft
sure the forked sleeve spigot is fully located on the crankcase
turned all traces of
place, Ensure sleeve
theend tang face.
on dowel.
the nut is correctly located into
it must be removed before final assembly ofisthe
is not turned when the Plastigauge inbearing. lower cover
and all traces of it must be removed before final the slot on the bridge.(6) with
7. 4.Place
Place the the
screw dolly
assembly insidethethe taper outwards
crankcase into
and fit it to
assembly of the bearing. the spigot
3.Place both halves of
the sleeve end
assembly. of the sleeve (3).
new bearing into the
5.Fit(3)
8. Place
sleeve thedepth
the driverplate
from (4) end
the intoonto
(7) the other
the
opposite screw endwith
the of the'G'sleeve,
the
locating face next
to
spigots.the driver (4).
48 Align the ends of the new bearings with the letter
'G' on the sleeve and ensure the bearing oil
hole is correctly lined up with the '0' mark on the
sleeve face.
 dropping onto the new bearing.
Flywheel End Main Bearing Removal 12.Check that the oil holes in the housing and
1.Remove the thrustwashers and the oil seal from bearings align.
the bearing housing. TS, TR, TX engines workshop manual 45
2.Fit the nut (2) onto the screw (1). Intermediate Main Bearing
3.Hold the nut firmly across its flats in a vice. The grooved bearing shell must be fitted to the
4.Place both dollies (5, 6) onto the screw with the top half of the bearing housing with the oil holes
9. Fit the thrust nut (9).
tapered ends outwards and the large dolly (6) Intermediate
aligned. Main Bearing
10. Using the correct size of spanner tighten the thrust nut (9)
next to the nut (2). TheRe-assemble
grooved bearingtheshell
centre main
must be bearing
fitted housings
to the top half of the
until the depth plate is tight to the sleeve.
5.Fit the bearing housing on the screw with the around the crankshaft ensuring the
bearing housing with the oil holes aligned. socket screws
When the plate is tight to the sleeve the bearing shells are
thrust face uppermost.
correctly located in the crankcase.
are tightened.
Re-assemble the centre main bearing housings around the
6.Fit
11. Remove the thetool
bridge
taking(8) followed
care by itthe
to prevent thrust onto
dropping nut (9) Ensure ensuring
crankshaft the 'Flywheel End'screws
the socket identification marks on
are tightened.
the newonto the screw (1).
bearing. the the
Ensure housing halves
'Flywheel are correctlymarks
End' identification located
on thebefore
housing
7.Using
12. Check that the oil theholes
correct
in the size of spanner
crankcase tighten
and bearings align.the assembly.
halves are correctly located before assembly.
thrust nut (9) until the main bearing shells are
Flywheel removed from the bearing housing.
End Main Bearing Removal Main
MainBearing
BearingTool 317-50006
Tool 317-50006
8.Remove the tool.
1. Remove the thrustwashers and the oil seal from the bearing
housing.Flywheel End Main Bearing Replacement
2. Fit theThe
nut (2)
toponto
halfthe screw
of the (1).bearing in the main bearing
plain
3. Hold the nut firmly across its flats in a vice.
housing has a locating tongue which locates into
4. Place both dollies (5, 6) onto the screw with the tapered ends
its recess in the main bearing housing when fully
outwards and the large dolly (6) next to the nut (2).
fitted.
5. Fit the bearing housing on the screw with the thrust face
1.Fit the nut (2) onto the screw (1).
uppermost.
6. Fit the2.Hold
bridgethe (8) nut firmlyby
followed across its flats
the thrust nutin(9)a onto
vice.the
3.Place
screw (1). both halves of the new bearing into the
sleeve (3) from the end opposite
7. Using the correct size of spanner tighten the thrust nut the locating
(9)
spigots.
until the main bearing shells are removed from the bearing
housing.Ensure the tag on the top half of the new bearings Figure 2.47.2
Figure 2.47.2Main
Main Bearing Tool
Bearing Tool 317-50006
317-50006
8. Removefaces outwards and is correctly located in the
the tool.
slot in the sleeve and check that the ends of the Note:
Note:
Flywheel bearings
End Main line up with the 'F'
Bearing mark on the sleeve.
Replacement ThisThis
tool hastool
been replaced
has beenby 393235; both are described
replaced and either canboth
by 393235; be used.
4.Place the dolly (6) with the taper outwards into are described and either can be used.
The top half theofspigot
the plainendbearing
of theinsleeve
the main
(3).bearing housing
has a locating tongue which locates into its recess in the main Gear End Main Bearing
bearing housing when fully fitted. 1. Fit the correct bearing locating ring (C) onto the plug (A).
1. Fit the nut (2) onto the screw (1). 49
Four bearing rings are available for standard and undersize
2. Hold the nut firmly across its flats in a vice. bearings.
3. Place both halves of the new bearing into the sleeve (3) from 2. Insert the plug and bearing ring into the main bearing shells
the end opposite the locating spigots. until the bearing ring is located completely in the bearing
Ensure the tag on the top half of the new bearings faces shells.
outwards and is correctly located in the slot in the sleeve 3. Fit the sleeve (B) inside the crankcase with the locating lug
and check that the ends of the bearings line up with the 'F' on the sleeve positioned in the thrust washer locating groove
mark on the sleeve. in the crankcase.
4. Place the dolly (6) with the taper outwards into the spigot 4. Push the bolt (H) through the ball bearing, if used, and
end of the sleeve (3). through centre of the spacer (F) with the recessed face of the
5. Fit the driver (4) into the other end of the sleeve, ensuring the spacer nearest the bolt head.
guide dowel is positively located in the slot in the sleeve. 5. Fit the bolt from inside the crankcase through the sleeve and
6. Place the depth plate (7) onto the screw (1) with the face screw it into the plug (A).
marked 'F' uppermost. 6. Maintain a firm grip on the flange of the plug and tighten
7. Place the sleeve assembly onto the screw with the driver (4) the bolt until main bearing shells are pushed fully into the
next to the depth plate (7). sleeve of the tool.
8. Place the bearing housing onto the screw with the thrust
face downwards.
Gear End Main Bearing Replacement
Ensure the sleeve spigot is located in the recess in the bearing
housing. The top section of the gear end main bearing shell has an oil
9. Fit the bridge (8) followed by the thrust nut (9) onto the groove but no locating lug. When fitting new shells extreme
screw (1). care must be taken to ensure that the oil ways in the shells and
10. Using the correct size of spanner tighten the thrust nut (9) crankcase are aligned. If not correctly aligned oil restriction or
until the depth plate (7) is against the sleeve. starvation may occur.
When the depth plate is against the sleeve the main bearing 1. Position the sleeve (B) on a flat surface with the locating lug
shells are correctly located in the housing. facing downwards.
11. Remove the tool taking care to prevent it dropping onto 2. Slide the two halves of the new bearing into the top of the
the new bearing. sleeve together, ensure the ends of the new bearings are at
12. Check that the oil holes in the housing and bearings align. 90° to the locating lug.
 1.Position the sleeve (B) on a flat surface with the
2.With the flywheel locked re-torque the flywheel
locating lug facing downwards.
retainer to 474.5Nm (350.0lbf ft).
2.Slide the two halves of the new bearing into the
top of the sleeve together, ensure the ends of the TS, TR, TX engines workshop manual
new bearings are at 90° to the locating lug. Crankshaft Extension Spanner 317-50060 46
3.Fit the correct bearing locating ring (C) onto the The tool is used when it is not possible to torque
plug (A). direct at the gear end with the flywheel locked.
3. Fit the correct bearing locating
Four bearing rings are ring (C) ontofor
available thestandard
plug (A). and
Four bearing rings are
undersize available for standard and undersize
bearings. T
bearings.
4.Fit the plug into the sleeve (B) with the bearing
4. Fit the plug
ringinto the sleeve
located (B) with the
completely bearing
in the ring shells.
bearing located
completely in the bearing shells.
5.Place the assembly into the crankcase with the
5. Place thelocating
assembly luginto
onthe
thecrankcase with the locating
sleeve positioned in the lug
thrust
flywheel using a 65mm socket (317-50052). 2.50
on the sleeve positioned in the thrust washer locating groove 4.Remove the tool.
washer locating groove in the crankcase. Nylon
in the crankcase. 5.Fit the flywheel locking tool.
6.Place the ball bearing, if used, onto the bolt (H) TR and
6. Place the ball bearing, if used, onto the bolt (H) followed by 6.Re-torque the flywheel screw or nut to
followed by the spacer (F) with plain face towards engine
the spacer (F) with plain face towards the bolt head. 474.5Nm (350.0lbf ft).
the bolt head. 35 0
7. Push the bolt into the crankcase, locating the spacer squarely
7.Push the bolt into the crankcase,
against the outside of the crankcase and screw the bolt into locating the 35 0
the plug.spacer squarely against the outside of the
2.49 THE OIL FILTER 35 0
crankcase and screw the bolt into the plug. The Figure
standard 2.48.1
Figure full Extension
flow
2.48.1 oil Spanner
filter
Extension is
Spannera 317-50060
spin-on
317-50060 cartridge
8. Tighten the bolt until the bearing shells are drawn into
8.Tighten the bolt until the bearing shells are drawn type located on the side of the crankcase and
position.
into position. 1.Fit
1. Fit the the
remote open open
endedended
mounted oil section
section behind are
filters behind
the pinion the pinion
or onto
available or
the shaft.
for all
onto
2. Place
engines.thethe shaft.
bolt through the boss and into the crankcase.
Flywheel End Main Bearing Removal / 2.Place
3. Genuine
With the
the engine bolt through
decompressed theturnboss
the and intousing
flywheel the a
Flywheel End Main Bearing Removal/ Lister Petter Power Systems approved
Replacement 65mmcrankcase.
socket (317-50052).
filters should be used as these have the correct
Replacement
The removal and fitting of bearing shells in the main bearing 3.With the
4. Remove thetool.engine decompressed turn the
The removal and fitting of bearing shells in the main bypass valve pressure to match the self regulating
housing is carried out by the same method. The bearing housing 5. Fit
oil pump, highlocking
the flywheel tool.
temperature joints, adequate filter
should be held securely in a vice or refitted to the engine. 6. Re-torque the flywheel screw or nut to 474.5Nm (350.0lbf ft).
paper characteristics and a rigid case. The fact
50assembly should first be pushed out from the centre
The oil seal that a proprietary filter may have the same external
of the housing.
The top half of the plain bearing in the main bearing housing
2.49 The Oil
dimensions and Filter
thread as the genuine one is no
guarantee that it will not fail in service.
has a locating tongue which must be fitted into the groove of The standard full flow oil filter is a spin-on cartridge type located
the sleeve to ensure the tongue locates into its recess in the on the side of the crankcase and remote mounted oil filters are
main bearing housing when fully fitted.
Changing
available the Oil Filter
for all engines.
A readily available strap wrench is required to
remove the filter from the engine but must not be
Intermediate Main Bearings Changing the Oil Filter CA
used to fit a replacement.
The grooved bearing shell must be fitted to the top half of the A readily
1.Using available strap wrench
a suitable strap iswrench,
required tounscrew
remove theandfilter The ne
bearing housing and the oil holes must be aligned. Re-assemble fromremove
the enginethebutoldmustfilter.not be used to fit a replacement. crankc
the centre main bearing housings around the crankshaft 1. Using a suitable clean
2.Thoroughly strap wrench, unscrew and
the crankcase remove
filter the old not be
housing
ensuring the socket screws are tightened. filter.
face. to be u
Ensure the 'Flywheel End' identification marks on the housing 2. Thoroughly clean the crankcase filter housing
3.Apply a small amount of clean engine oil to the oil chamfeface.
halves are correctly located before assembly. 3. Apply
filter asealing
small amount
joint. of clean engine oil to the oil filter '0' ring
sealing joint.
4.Screw on the new oil filter, by hand, until the and ing
4. Screw on the new oil filter, by hand, until the sealing joint is
2.48 Gear End Drives sealing joint is just touching the crankcase and
just touching the crankcase and tighten a further half turn.
These must be correctly torque loaded to 362.0Nm (267.0lbf ft).
tighten a further half turn. 2.51
Where it is not possible to torque direct at the gear end: The su
1. Apply torque to the flywheel screw or nut with the engine secure
decompressed. washer
2. With the flywheel locked re-torque the flywheel retainer to remain
474.5Nm (350.0lbf ft). The in
located
Crankshaft Extension Spanner 317-50060 An oil s
in the c
The tool is used when it is not possible to torque direct at the
straine
gear end with the flywheel locked.
An ant
alongsi
fitted.
Figure 2.49.1
Figure 2.49.1Changing theOilOil
Changing the Filter
Filter

5.Run
Draini
5. Run thethe engine
engine and and
checkcheck
for anyfor
oilany oil leaks.
leaks. 1.If po
6.Stop
6. Stop thethe engine,
engine, allow
allow thetooil
the oil to settle
settle and check
and check the level
drain
onthe
the level on the dipstick.
dipstick.
2.Place
7.Add
7. Add more
more oil ifoil if necessary.
necessary.
3.Remo
 T SERIES ENGINES WORKSHOP MANUAL
TS, TR, TX engines workshop manual 47
T SERIES ENGINES WORKSHOP MANUAL

2). 2.50 THE OIL DIPSTICK

2.50
NylonThe Oil dipsticks
handled Dipstick have been fitted to all Repla
TR and TX engines and were introduced on TS 1.Using
nut to Nylon handled dipsticks have been fitted to all TR and TX reces
engines from:
engines and were introduced on TS engines from:
353501426 TS1 2.Repla
01426 TS1
353506750 TS2
06750 TS2 3.Repla
353505365 TS3
05365 TS3 the su
artridge 4.Repla
se and 27.0N
for all 5.Coat
PL32
proved 6.Retur
correct 7.Fill th
Figure 2.51.1
2.51.1Oil Fillerandand Drain
ulating
Figure Oil Filler Drain grade
e filter 8.Start
4. 4.Clean
Clean andand coatcoat the threads
the threads of theofdrain
the drain plugHylomar
plug with with
circul
he fact Hylomar PL32/M
PL32/M or Three Bond 1110B. or Three Bond 1110B.
xternal not le
5.Replace
5. Replace the plug
the drain drain plug
taking caretaking care not it.to
not to overtighten
e is no 9.Stop
6. Fillovertighten
the sump toit. the correct level with the correct grade and
and r
6.Fillofthe
type sump tooil.
lubricating the correct level with the correct
Figure
Figure2.50.1 Dipsticks: 10.Add
2.50.1 Dipsticks: grade
7. Start and type
the engine andofrunlubricating
it for a fewoil. minutes to circulate the
A - Early TS; BA- -Later
EarlyTS,TS
all TR and TX

ired to
B - Later TS, all TR and TX
oil and check
7.Start
8. Stop
the drainand
the engine
the engine
plugrundoes not aleak.
it for few minutes to CA
circulate the and allowcheck
oil and time for thethedrain
oil toplug
settledoes
and re-
If the p
not be check
not the
leak.level on the dipstick.
CAPTION
CAUTION 9. Add more
carried
8.Stop theoilengine
if necessary.
and allow time for the oil to settle the fan
w and The Thenew typetype
new dipsticks are not fitted
dipsticks withfitted
are not a crankcase
with a and re-check the level on the dipstick.
adapter and an existing adapter must not be removed fanshr
crankcase adapter and an existing adapter mustto Oil Sump
9.Add more Capacity
oil if necessary.
allow the new type of dipstick to be used as the adapter face ru
ousing not be removed to allow the new type of dipstick
bore hasused
to be no lead-in chamfer.
as the If the
adapter adapter
bore hasisnoremoved
lead-in litres pints US qts
Oil Sump Capacity
damage to the '0' ring may lead to loss of crankcase
chamfer. If the adapter
o the oil vacuum and ingress of dirt. is removed damage to the 2.52 T
TS/TR1 2.7
litres 4.7
pints 2.8
US qts
'0' ring may lead to loss of crankcase vacuum The O
ntil the and ingress of dirt. TS/TR1
TS/TR/TX2 2.7
4.0 4.7
7.0 2.84.2 The en
se and 2.51 The Oil Sump strainer
TS/TR/TX2
TS/TR/TX3 4.0
6.0 7.0
10.5 4.26.3
2.51 THE OIL SUMP
The sump is manufactured from cast iron and is secured to the
to the s
TS/TR/TX3 6.0 10.5 6.3
The sump
crankcase is manufactured
by bolts and spring washers; from the
castfour
iron and bolts
corner is
Removing the Sump
aresecured
longer thanto the
theremainder.
crankcase by bolts and spring
Thewashers; the four
integral engine cornerbolt
mounting bolts are longer
drillings thanonthe
are located each
Removing
1. Remove the drain theplugSumpfrom the sump and drain the oil into
remainder.
corner of the sump. a suitable receptacle. plug from the sump and drain
1.Remove the drain
AnThe integral
oil strainer engine
is fitted mounting
inside the sumpbolt and drillings
a drilling are
in the the oilthe
2. Remove intooilalevel
suitable receptacle.
dipstick.
located on each corner of the sump.
casting carries oil from the sump through the strainer to the 2.Remove thehandled
A polypropylene oil leveldipstick
dipstick.
is currently fitted; refer to
oilAn
pump.
oil strainer is fitted inside the sump and a drilling A The
"2.50 polypropylene
Oil Dipstick". handled dipstick is currently
Aninanti-surge
the castingplate, fitted to
carries oilthe oil the
from strainer
sump lays alongside
through thethe fitted;
3. Stand therefer
engineto "02.50 The Oil using
on its flywheel Dipstick".
a suitable piece of
crankcase web when the
strainer to the oil pump. sump is fitted. 3.Stand
wood the engine
or similar materialon on
its which
flywheel using
to rest theaflywheel
suitablebut
An anti-surge plate, fitted to the oil strainer lays notpiece of wood or
the fanshroud; similar
this material
will enable on which
the engine to rotated
to be rest
Draining
alongsideand
the Filling theweb
crankcase Sump
when the sump is andthe flywheel
ease subsequent but not the fanshroud; this will enable
dismantling.
4. Remove the sump
the engine to bolts and spring
be rotated andwashers noting that two
ease subsequent
1. Iffitted.
possible run the engine immediately before draining the oil. bolts pass through
dismantling. the fanshroud into the sump.
2. Place a suitable container under the drain plug. As the bolts are
4.Remove theremoved
sump bolts from the
andsump the oil
spring pump will
washers
s.
Draining
3. Remove and Filling the Sump
the plug. move it away from the crankcase.
noting that two bolts pass through the fanshroud Care m
1.If possible run the engine immediately before 5. Remove thesump.
sump taking care not to damage the oil pump. used to
check into the
draining the oil.
As the bolts are removed from the sump the oil overha
2.Place a suitable container under the drain plug. Replacing
pump willthe Oilit Sump
move away from the crankcase. the stra
3.Remove the plug.
1. 5.Remove
Using a newthe sump
joint, taking
replace the care
sumpnot
withtothe
damage the Note
recess corner
oil pump.
adjacent to the oil pump. On re
2. Replace the four long corner bolts finger tight. distan
3. Replace the two bolts through the fanshroud into the sump that th
51 and torque them to 43.5 Nm (32.0 lbf ft).
paralle
52
 Replacing the Oil Sump
1.Using a new joint, replace the sump with the Oil Pump Lip Se
recess corner adjacent to the oil pump. The camshaft operated oil pumps are the The se
2.Replace the four long corner bolts finger tight. TS, TR, TX engines workshop manual 48
self-regulating, plunger type and they are not supplie
3.Replace the two bolts through the fanshroud into interchangeable across the ranges. are fitt
the sump and torque them to 43.5Nm (32.0lbf ft). applied
4.Replace and torque the remaining sump bolts to
4. Replace and torque the remaining sump bolts to 27.0 Nm Removing
Removing the Oil Pumpthe Oil Pump Lip typ
27.0Nm (20.0lbf ft). or brui
(20.0 lbf ft). 1.Drain the oil.
5.Coat the threads of the drain plug with Hylomar 1. Drain the oil.the dipstick and sump. path of
5. Coat the threads of the drain plug with Hylomar PL32/M or 2.Remove
PL32/M or Three Bond 1110B and refit. 2. Remove the dipstick and sump. A finely
Three Bond 1110B and refit. 3.Lift out the oil pump.
6.Returnthethe engine
to itstonormal
its normal position. 3. Lift out the oil pump.
6. Return engine position. 4.Using long nosed pliers remove the oil pump marks
7.Fill the sump to the correct level
7. Fill the sump to the correct level with the with the correct
correct grade and 4. Using long nosed pliers remove the oil pump push rod from (16 mic
push rod from the crankcase.
grade and type of lubricating oil. the crankcase.
type of lubricating oil. 5. Dismantle the oil pump making a careful note Emery
8.Start the engine and run it for a few minutes to 5. Dismantle the oil pump making a careful note of the
ug with 8. Start the engine and run it for a few minutes to circulate the of the component positions and the two different the are
component positions and the two different sized ball
oilcirculate
and checkthe the oil and
drain plug check theleak.
does not drain plug does
sized ball valves. correct
not leak. valves.
not to 9. Stop the engine and allow time for the oil to settle and re- wet mi
9.Stop
check the
the engine
level on theand allow time for the oil to settle
dipstick. oxide p
andmore
10. Add re-check the level on the dipstick.
oil if necessary. may be
correct
10.Add more oil if necessary. by 50m
CAPTION wet it w
utes to CAUTION around
g does If theprocedure
If the in items 2. and 4. is not correctly carried
procedure in items 2. and 4. is not correctly
out there is a possibility of distorting the fanshroud motion
carried out there is a possibility of distorting
o settle resulting in excessive flywheel to fanshroud run-out. The
the fanshroud resulting in excessive flywheel to
tolerances for bore and face run-out must be within 0.25 The E
mmfanshroud
(0.010 in) run-out.
TIR. The tolerances for bore and 1.Rem
face run-out must be within 0.25mm (0.010in) TIR. seal.
2.Place
2.52
2.52The
THEOil
OILStrainer
STRAINERandAND
Pump
PUMP cove
qts shou
The
The OilOil Strainer
Strainer comp
.8 The engines are fitted with a coarse lubricating oil
The enginesonarethe
fitted with aside
coarse lubricating oil strainer 3.Using
.2 strainer suction of the oil pump; accesson Figure
Figure2.52.2 TheOilOil Pump
the suction side of the oil pump; access to the strainer is gained 2.52.2 The Pump into p
to the strainer is gained by removing the sump.
.3 by removing the sump. it is fl
Refitting
Refitting the theOilOil Pump
Pump In an
1.Check that the oil pump is correctly assembled suita
1. Check that the oil pump is correctly assembled as shown.
as shown.
2. Check that that
the pump used
d drain 2.Check the is working
pump is freely by compressing
working freely by it
between the palms of the hands.
compressing it between the palms of the hands.
3. Replace the oil pump push rod with the larger diameter The M
3.Replace the oil pump push rod with the larger 1.Rem
urrently towards the camshaft.
diameter towards the camshaft.
4. Replace the oil pump with the plunger end towards the old s
4.Replace
push rod.
the oil pump with the plunger end 2.Place
uitable towards the push rod.
5. Replace the sump, drain plug and the dipstick. not u
to rest 5.Replace thewith
sump,
6. Refill the sump oil. drain plug and the dipstick. 3.Hold
enable 6.Refill the sump with oil. face
equent
shou
Figure
Figure2.52.1 OilStrainer
2.52.1 Oil Strainer 2.532.53The THE OilOIL SealsSEALS In an
ashers
LipLip
typetype
sealsseals
are fitted to all TR and current TS engines
are fitted to all TR and current TS although suita
shroud Care Caremust must be taken
be taken to ensure to ensure
that ragsthat ragsused
are not aretonot wipe two other types have been fitted to early TS engines:
engines although two other types have been fitted used
theused
insidetoofwipe the inside
the crankcase duringof the crankcase
overhauls duringthe
to eliminate Rotary type - very early TS2, 3.
the oil possibility
overhauls to eliminate thestrainer
possibility of fluff entering to early TS engines:
of fluff entering the and causing a restricted Screw type - early TS2, 3. The R
e. oilthe
flow.strainer and causing a restricted oil flow. Rotary type - very early TS2, 3.
A lip seal is fitted to the gear end cover with a rotary, screw or If a rot
age the Note - Early TS Engines: Screw
in thetype - early
endTS2, 3.
lip type fitted flywheel main-bearing housing. engine
Note - Early TS Engines: A lip seal is fitted to the gear end cover with a
On re-assembly take care to replace the The thr
On re-assembly take care to replace the distance piece under the top plate and ensure rotary, screw or lip type fitted in the flywheel end
thatdistance
the anti-surgepiece under
plate on the strainerthe toptoplate
is parallel andweb.
the crankcase ensure Lip Seals
main-bearing housing.
a.A rot
that the anti-surge plate on the strainer is the c
Lip type seals will not seal if the shaft is scratched or bruised
parallel to the crankcase web. mach
Oil Pump within 5 mm (0.20 in) either side of the path of the lip of the
seal.
The camshaft operated oil pumps are the self-regulating, A finely and accurately ground shaft without chatter marks and
plunger type and they are not interchangeable across the with a surface finish of 0.4 microns Ra (16 micro inches CLA)
ranges. maximum is advisable.
Emery cloth of any grade must not be used in the area of the
lip. Very fine scratches should be corrected by polishing the
working surface with a wet mixture of metal polish and optical
 TS, TR, TX engines workshop manual 49

aluminium oxide powder, failing this domestic scouring powder The Screw Type Seal
may be used. Fold a strip of rag some 400 mm long by 50 mm
wide lengthwise into a 10 mm belt and wet it with the abrasive The crankcase may be sealed at the crankshaft by a screw type
mixture, wrap the belt once around the shaft and use it with a oil seal and a felt ring. The seals are marked with an arrow to
reciprocating motion. show the engine rotation for which they are intended.
The seal must be concentric with the crankshaft, with the
maximum permissible variation of gap being 0.075 mm (0.005
The End Cover Lip Seal in).
1. Remove the end cover and press out the old seal. A ring type oil thrower is fitted over the crankshaft at the
2. Place a new seal into the outside neck of the end cover, lip flywheel end before the main bearing housing is replaced.
side first, and position it squarely on the shoulder of the seal 1. Apply a small amount of Hylomar PL32/M to the outside
boss; do not use any jointing compound. diameter of the seal
3. Using the oil seal tool. 317-50065 press the seal into position 2. Before inserting the felt, the inside of the grooves should be
within the oil seal housing boss until it is flush with the inside coated with Wellseal.
face of the boss. 3. Lightly oil the felt sealing surface.
In an emergency if the tool is not available a suitable plug, 4. Assemble the seal to the crankshaft.
preferably hard wood, can be used.

The Main Bearing Housing Lip Seal WARNING

Under no circumstances must the felt seal be distorted or
1. Remove the bearing housing and press out the old seal. damaged in any way before or during fitting.
2. Place the new seal squarely into the housing; do not use any
jointing compound.
3. Hold the oil seal tool, 317-50065, onto the outside face of the
seal and drive in the seal until the tool shoulder is against the
bearing housing.
In an emergency if the tool is not available a suitable plug,
preferably hard wood, can be used.

The Rotary Oil Seal

If a rotary seal requires changing on a very early engine it can
be replaced by the current lip type.
The 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 spacing between the impeller and the inner edge of
the retaining cap and to ensure the components are square
to the crankshaft.
The impeller must not be allowed to touch the retaining cap
otherwise damage will result.
Special care must be taken when fitting the impeller not to
damage the oil sealing thread or oil leaks will occur.
 TS, TR, TX engines workshop manual 50

3. Engine Fluids

3.1 Engine Fluids - Lubricating Oil Oils designed for this service provide protection from high
temperature deposits and bearing corrosion in diesel engines,
European Oil Specifications and also from rust, corrosion, and low temperature deposits in
gasoline engines.
ACEA specifies the following: These oils were introduced in 1961.
Gasolene engines: A1-96, A2-96, A3-96.
Light duty diesel engine operation:
Heavy duty and commercial vehicle diesel engine operation: API Service Category CD:
E1-96, E2-96, E3-96. Service typical of certain naturally aspirated, turbocharged or
supercharged diesel engines where highly effective control
The Oil Classification System of wear and deposits is vital, or when using fuels with a wide
quality range (including high-sulphur fuels).
The information contained in this section has been extracted Oils designed for this service were introduced in 1955 and
from "Lubricant and Fuel Performance", with the permission of provide protection from high-temperature deposits and
'The Lubrizol Corporation. bearing corrosion in these diesel engines.

CAPTION API Service Category CD-11:

Some of the following classifications may not be Severe duty two-stroke
available in your country. In cases of difficulty, it is
suggested contact be made with a reputable oil supplier Service typical of two-stroke cycle diesel engines requiring
or any Lister Petter Distributor. highly effective control of wear and deposits.
Oils designed for this service meet all performance requirements
of API Service Category CD.
Note:
US 'S' grade oils are for gasolene engines and are not recommended for Lister Petter
Power Systems diesel engines. API Service Category CE - 1983:
Service typical of certain turbocharged or supercharged heavy
Past and Current US API Grade Oils duty diesel engines, manufactured since 1983 and operated
under both low speed, high load and high speed, high load
API Service Category CA:
conditions.
Service typical of diesel engines operated in mild to moderate Oils designated for this service may also be used when API
duty with high-quality fuels; occasionally has included gasoline Service Category CD is recommended for diesel engines.
engines in mild service.
Oils designed for this service provide protection from bearing API Service Category CF-4 -1990:
corrosion and ring-belt deposits in some naturally aspirated
diesel engines when using fuels of such quality that they impose Service typical of high-speed, four-stroke cycle diesel
no unusual requirements for wear and deposit protection. engines.
They were widely used in the 1940's and 1950's but should not API CF-4 oils exceed the requirements for the API CE category,
be used in any engine unless specifically recommended by the providing improved control of oil consumption and piston
equipment manufacturer. deposits.
These oils should be used in place of API CE oils.
They are particularly suited for on-highway, heavy duty truck
API Service Category CB:
applications. When combined with the appropriate 'S' category,
Service typical of diesel engines operated in mild to moderate they can also be used in gasoline and diesel powered personal
duty, but with lower quality fuels, which necessitate more vehicles - i.e., passenger cars, light trucks, and vans - when
protection from wear and deposits; occasionally has included recommended by the vehicle or engine manufacturer.
gasoline engines in mild service.
Oils designed for this service were introduced in 1949. They API Service Category CF:
provide necessary protection from bearing corrosion and from
high temperature deposits in naturally aspirated diesel engines Indirect injection
with higher sulphur fuels. Service typical of indirect-injected diesel engines and other
diesel engines that use a broad range of fuel types, including
API Service Category CC: those using fuel with high sulphur content; for example, over
0.5% weight.
Service typical of certain naturally aspirated diesel engines Effective control of piston deposits, wear and copper-containing
operated in moderate to severe duty service, and certain heavy bearing corrosion is essential for these engines, which may be
duty gasoline engines.
 these engines, which may be naturally aspirated, oils. Straight mineral oils are not suitable, neither
turbocharged or supercharged. are oils of less detergency than specified.
Oils designated for this service have been in 4.API CF-4, API CG-4, API CH or API CI oils are
existence since 1994 and may be used when API recommended for heavy
TS, TR, TX engines duty manual
workshop load applications,51
Service Category CD is recommended. with API CC or API CD for light duty load
applications.
API Service Category CF-2: 5.For engines in long running installations Lister
naturallySevere
aspirated, turbocharged
duty, two-strokeorcycle
supercharged. Petter Power Systems should be consulted.
Oils designated
Servicefor this service
typical have beencycle
of two-stroke in existence since
diesel engines CAPTION
1994 and may be highly
requiring used when API control
effective Service over
Category CAUTION
CD isand Lister Petter
cylinder Power Systems recommend that oils
recommended. Lister Petter Power Systems recommend that oils
ring-face scuffing and deposits. of different brands or types are not mixed together.
of different brands or types are not mixed together.
Oils designed for this service have been in existence
API Service
since 1994Category
and mayCF-2: also be used when API Engine Oil Viscosity
Oil Viscosity
Severe duty, two-stroke cycle Serviceistypical
Service Category CD-11 recommended.
of two-stroke cycle
Theserequiring
diesel engines oils do not necessarily
highly effective meet
controlthe requirements
over cylinder
of API
and ring-face CF and
scuffing or deposits.
CF-4 unless they pass the test
requirements
Oils designed for these
for this service have categories.
been in existence since 1994
and may also be used when API Engine Service Category CD-11
API Service Category CG-4 - 1994:
is recommended.
These oils do notduty
Severe necessarily meet the requirements of API
CF or CF-4 unless
API Service they pass theCG-4
Category test requirements
describes oils forfor
these
use in
categories.
high-speed four-stroke-cycle diesel engines used in
both heavy-duty on-highway (0.05% weight sulphur
API Service
fuel) and Category CG-4(less
off-highway - 1994:
than 0.5% weight
sulphur
Severe duty fuel) applications.
CG-4 oils provide effective control over
API Service Category CG-4 describes oils for use in high-speed
high-temperature piston deposits, wear, Notes:
four-stroke-cycle diesel engines used in both heavy-duty on- Notes:
corrosion, foaming, oxidation stability,
highway (0.05% weight sulphur fuel) and off-highway (less than and soot A. Intermittent
A. Intermittent
running. running.
accumulation.
0.5% weight sulphur fuel) applications. B. Synthetic
B. Synthetic oils only. oils only.
CG-4 oilsThese oils arecontrol
provide effective especially effective in piston
over high-temperature engines °F =°F (1.8=x °C)
(1.8+ 32.x °C) + 32.
designed to meet 1994 exhaust emission
deposits, wear, corrosion, foaming, oxidation stability, and soot standards 1.SAE 5W-20 oils are recommended on the recommended
basis that they are fully synthetic, and are
1.SAE 5W-20 oils are on the
and may also be used in engines requiring API technically suitable for use up to 25°C (77°F).
accumulation. basis that they are fully synthetic, and are
These oilsService Categories
are especially effective inCD, CE, designed
engines and CF-4. to meetOils Nontechnically
synthetic oils at very low temperatures will suffer
suitable for use upfrom
to wax
25°C crystallisation.
(77°F).
designed
1994 exhaust emissionfor this service
standards andhave
maybeen
also be in used
existence
in Monograde SAE 5W is not normally available as a synthetic oil and therefore is not
since 1994.
Non synthetic oils at very low temperatures
engines requiring API Service Categories CD, CE, and CF-4. quoted.
Oils designed for this service have been in existence since will suffer from wax crystallisation.
2. In order to maintain the cold starting characteristics of any recommended grade it
1994. The Oil Specification Monograde
is essential SAE
that oil changes are5W
madeis not normally available as
a synthetic oil and
To help assist engine running-in, all engines are within the Lister Petter Power Systems recommendations.
therefore is not quoted.
The Oildespatched
Specification 2. In order to maintain the cold starting
with an initial fill lubricating oil which An oil change is recommended immediately if the engine fails to reach its normal cold
must be changed after 100 hours. characteristics
start of any
cranking speed due to excessive recommended grade
oil viscosity.
To help assist engine running-in, all engines are despatched Fuelit is
dilution essential
of the lubricating that
oil will oil
adversely changes are
affect cold starting and made
oil consump-
1.Thefilltemperatures
with an initial lubricating oil which mentioned
must beinchanged
the table afterare tion.within the Lister Petter Power Systems
100 hours. the ambient temperatures at the time when the 3.SAE 30 and 10W-30 oils may be used at up to 52°C (126°F) but oil consumption
engine ismentionedstarted. However, recommendations.
1. The temperatures in the tableifare
monograde
the ambientoils may be affected.
are used
temperatures at the and running
time when the ambient temperatures
engine is started. An
However,are 10W-40, 15W-40 oil change is recommended immediately
and 20W-40 multigrades are recommended for continuous full load
significantly
if monograde oils are usedhigher than starting
and running ambienttemperatures, if the
temperatures a operation at this engine fails to reach its normal cold
temperature.
higher higher
are significantly viscosity oilstarting
than shouldtemperatures,
be selectedasubject start cranking
higher to 4 .Monograde speed due to excessive oil
SAE 40 oils are not recommended.
viscosity oil should be selected subject to satisfactory starting viscosity.
performance. Multigrade oils may be used to overcome the
56
problem. 3.2 Engine Fluids - Fuel
2. Where it is not practical to continually change oils to suit
varying ambient temperatures a suitable multigrade oil is The Fuel Specification
recommended to ensure adequate starting performance at The engine must only be used with diesel fuel oil which
the lowest temperature likely to be encountered. conforms to one of the following:
3. The engines must be run on heavy duty lubricating oils. a. BS 2869:1988 Class A2.
Straight mineral oils are not suitable, neither are oils of less b. BS EN590:1995 Class A1.
detergency than specified. c. USA Specification ASTM D-975-77 Grades No.1-D and 2-D.
4. API CF-4, API CG-4, API CH or API CI oils are recommended d. BSMA 100 Class M1 for marine use.
for heavy duty load applications, with API CC or API CD for The fuel must be a distillate, and not a residual oil or blend.
light duty load applications. Vaporising oils are not suitable as fuels for Lister Petter Power
5. For engines in long running installations Lister Petter Power Systems engines.
Systems should be consulted. The user is cautioned that although the engines may operate
on fuels outside the above specifications, such operation may
well result in excessive wear and damage.
 TS, TR, TX engines workshop manual 52

The engine must only be used with diesel fuel oil which Low Temperature Fuels
conforms to one of the following:
a. BS 2869:1988 Class A2. Special winter fuels are often available for use at ambient
b. BS EN590:1995 Class A1. temperatures below 0°C (32°F).
c. USA Specification ASTM D-975-77 Grades No.1-D and 2-D. These fuels have a lower viscosity and limit the formation of
d. BSMA 100 Class M1 for marine use. wax at low ambient temperatures.
The fuel must be a distillate, and not a residual oil or blend.
Vaporising oils are not suitable as fuels for Lister Petter Power CAPTION
Systems engines. Wax formation can rapidly reduce the flow of fuel
The user is cautioned that although the engines may operate through the fuel filter element.
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.
 TS, TR, TX engines workshop manual 53

4.T SERIES
Operating Instructions
ENGINES WORKSHOP MANUAL

T SERIES ENGINES WORKSHOP MANUAL

4.1 Preliminary Instructions
4. OPERATING INSTRUCTIONS
WARNING
The following information is of a general nature and should Do not attempt to use a handle if it is damaged in any
be4.1 PRELIMINARY
read in INSTRUCTIONS
conjunction with, or substituted
manufacturers instructions.
4. OPERATING INSTRUCTIONS
by, the equipment • The two types of handle are not interchangeable
way.
and care must be taken to ensure the correct type
The following information is of a general nature and
is retained
• The with the engine.
should4.1be PRELIMINARY
read in conjunction with, INSTRUCTIONS
or substituted • The two
two types
types
of handle are not interchangeable
of handle are not interchangeable
WARNING • Always and use
care themust correct
be starting
taken handle
to ensure which
the hasand
correct type
care
by, the
Theequipment
followingmanufacturers
information is ofinstructions.
a general nature and must be taken to ensure the correct type is retained with
been is designed
retained for
with thetheengine.
engine.
Startingshould
any diesel engine
be read in can be dangerous
conjunction with,inor
thesubstituted
hands the engine.
WARNING
of inexperienced people. Before
by, the equipment attemptinginstructions.
manufacturers to start any
• Ensure • Always there use are the
• Always use the correct starting
no burrs
correct on thathandle
starting part ofwhich
handle which
the has
has been
Starting
engine any diesel
the operator shouldengine
read thecan be dangerous
"Safety Precautions
handle which
been designed fits onto the engine.
for the engine.
designed for the engine.
in Safe
and WARNING
the Working
hands of inexperienced
Practices" people. with
and be conversant Before • Ensure • Ensure
• Ensure
the handle
therethere
grip is
are noare burrsnoon clean,
burrs dry
that parton andthat free toof the
of theparthandle which
attempting
the useStarting toany
of the engine start any
controls engine
and the the
correct operator
starting turn on its
handle shaft.
which fits onto the engine.
diesel engine can be dangerous fits onto the engine.
should
procedures. readhands
the "Safety Precautionspeople. and Safe • Clean andthe
• Ensure lightly
the oil that
handlegrip part
grip of
is thedryhandle
clean, anddry which
freeand freeon to its
in the of inexperienced Before • Ensure handle is clean, to turn
Working Practices" and be conversant with fits ontoturn
shaft. the
on engine.
its shaft.
attempting to start any engine the operator
the use of the
should engine
read controlsPrecautions
the "Safety and the correct • Firmly
and Safe • Clean • Cleanhold
andandthe
lightlyhandle
lightly
oil thatgrip,
oil partwith
that part
of the the thethumb
ofhandle handle
whichonwhich
fits onto
CAPTION
starting procedures. top offits
the the ontogrip,
engine. the during
engine. the starting procedure.
Working Practices" and be conversant with
ETHER the
BASEDuse of the
COLD START engine
AIDS IN controls
AEROSOL andCANSthe correct • Firmly• Firmly hold holdthe thehandlehandle
grip, grip,
with the withthumbthe thumb
on top of onthe
MUSTCAUTION
starting
NOT BE USED procedures.
UNDER ANY CIRCUMSTANCES. top of the grip, during the starting procedure.
grip, during the starting procedure.
ETHER BASED COLD START AIDS IN AEROSOL
CANS MUST CAUTION NOT BE USED UNDER ANY
CIRCUMSTANCES.
ETHER BASED COLD START AIDS IN AEROSOL
CAPTION
CANS
Systems MUST NOT BE USED on TX UNDER ANY
Systems maymay be fitted,
be fitted, exceptexcept
on TX engines, engines,
to allow
a to
CIRCUMSTANCES.
allow quantity
measured a measured quantity
to be injected intotothe
beinlet
injected
into Systems
manifold,thebutinlet
these manifold,
must be usedbutin these
accordance
may be fitted, except on TX must
with be
the
engines,
usedtoinallow
manufacturers accordance
instructions. with the manufacturers
a measured quantity to be injected
instructions.
into the inlet manifold, but these must be
used in accordance with the manufacturers
WARNING
WARNING
instructions.
DO NOT BREATH EXHAUST GASES AS THEY Figure 4.1.2 Holding the Starting Handle
DO NOT BREATH EXHAUST GASES AS THEY CONTAIN
CONTAINWARNING
CARBON MONOXIDE, A COLOURLESS,
CARBON MONOXIDE, A COLOURLESS, ODOURLESS AND Automatic Excess Fuel Device
ODOURLESS
DO NOT AND
BREATH POISONOUS
EXHAUST GAS THAT CAN
GASES AS THEY Figure Figure4.1.2
4.1.2Holding
Holding the theStarting
Starting Handle
Handle
POISONOUS GAS THAT CAN CAUSE UNCONSCIOUSNESS ‘T Series’ engines are fitted with an automatic
CAUSE UNCONSCIOUSNESS
CONTAIN
AND DEATH. CARBON MONOXIDE, AND DEATH.
A COLOURLESS,
excess fuel device which
Automatic Excess becomesFuel operative, ready
Device
ODOURLESS AND POISONOUS GAS THAT CAN Automatic Excess Fuel Device
Starting Handle Precautions AND DEATH. for the ‘T Series’ engines are fittedis with
next start, when the engine stopped.
an automatic
CAUSE UNCONSCIOUSNESS
Starting Handle Precautions
A non-limited kick-back handle (A) or limited If the
‘T engine
Series’
excess engines
fuel stops are
device other
fitted than
with
which an by the
automatic
becomes operation
excess fuel
operative, device
ready
kick-back handle
Starting
A non-limited (B)
Handle
kick-back system
handle (A) ormay
Precautions bekick-back
limited the of theforengine
fitted to handle which becomes
the next control, the control
operative,
start, when ready for
the enginemust is
the bestopped.
next turned
start, when the
engine
anti-clockwise is stopped.
If the engine to thestops ‘STOP’ otherposition
than and by released
the operation
(B)engine.
A may
system non-limited
be fitted tokick-back
the engine.handle (A) or limited If the engine stops other than by the operation of the engine
before the device can operate.
kick-back handle (B) system may be fitted to the control, the control must be turned anti-clockwisebeto turned
of the engine control, the control must
the ‘STOP’
As the engine runstoupthe
anti-clockwise to‘STOP’
speed position
the excess and fuelreleased
engine. position and released before the device can operate.
device will automatically
before the device can reset to the normal running
operate.
As the engine runs up to speed the excess fuel device will
position. As the engine runs up to speed the excess fuel
automatically reset to the normal running position.
device will automatically reset to the normal running
Coldposition.
Starting Aid - TS/TR
TheCold Starting
cold starting aid Aid
may be - TS/TR
fitted to the combustion
air Theintake
Cold ports
Starting
cold starting and is
aid may used
Aidbe- fitted when
TS/TR to thethe ambientair intake
combustion
temperature
portsTheand coldisisstarting
below
used when-10°C
aid the (14°F).
may ambient
be fitted temperature
to the combustion is below
1.With
-10°C the fuel
(14°F). turned on, turn
air intake ports and is used when the ambient the engine for up to
20 revolutions
With the fueltois
1. temperature prime
turned
belowon, the fuel (14°F).
turn
-10°C andengine
the lubrication
for up to 20
systems.
revolutions to prime the fuel and
1.With the fuel turned on, turn the engine for up to lubrication systems.
2. Withdraw
2.Withdraw the
20 revolutionstheplunger
plunger (A)
to(A)primeand
andfill fillone
the onethird
fuel of the
third
and of cup (B) with
the
lubrication
Figure 4.1.1 The Starting Handle
Figure 4.1.1 The Starting Handle
cupthe (B) samewith
systems. typethe ofsame
lubricating
type oil
of as used in theoil
lubricating engine.
as
used in the engine.
2.Withdraw the plunger (A) and fill one third of the
WARNING Figure 4.1.1 The Starting Handle
cup (B) with the same type of lubricating oil as
Do not attempt to use a handle if it is damaged
used in the engine.
in any way.WARNING
Do not attempt to use a handle if it is damaged
 TS,ENGINES
T SERIES TR, TX engines workshop manual
WORKSHOP MANUAL 54
Figure 4.1.3 Cold Start T SERIES ENGINES WORKSHOP
Figure 4.2.3 MANUAL
Decompressor Lever
A - TS/TR; B - TX
3.Replace the plunger and inject the oil just before
starting the engine. 4. If4.If
the ambient temperature
the ambient is below -10°C
temperature is (14°F)
below refer to "Cold
-10°C
Starting
(14°F) Aid - TS/TR".
refer to "Cold Starting Aid - TS/TR".
CAUTION If using
5a. 5a.If a non-limited
using kick-back
a non-limited handle:
kick-back handle:
The device must not be used more than three Insert
Insertthethe
correct handle,
correct refer torefer
handle, 'A' in 'Figure 4.1.1'
to 'A' in , into the
'Figure
times in succession during the same attempt to starting
4.1.1',housing.
into the starting housing.
start the engine.

4.2 HAND STARTING

Before attempting to start the engine refer to
"Starting Handle Precautions".
1.Select the excess fuel position by turning the
Figure
engine Figure 4.1.3
control4.1.3
lever Cold Start
anti-clockwise to the ‘STOP’ Figure 4.2.3 Decompressor Lever
Cold
Figure 4.1.3 Cold Start
Start Figure 4.2.3A - Decompressor
TS/TR; B - TX Lever
position and releasing it. A - TS/TR; B - TX
3.Replace the plunger and inject the oil just before
3.Replace
3. Replace the
thethe plunger
plunger and and
inject inject thejust
the oil oil before
just before
starting 4.If the ambient temperature is below -10°C
starting engine. 4.If the ambient temperature is below -10°C
thestarting
engine. the engine. (14°F) refer to "Cold Starting Aid - TS/TR".
(14°F) refer to "Cold Starting Aid - TS/TR".
CAUTION
CAUTION 5a.If using a non-limited kick-back handle:
5a.If using a non-limited 4.2.3 kick-back handle:
CAPTION
The device must not be used more than three
The device must not be used more than three
Insert the correct
Insert the
Figurehandle,
correct Figure
Starting
4.2.3 Starting
handle, refer
Handle
referHandle
to 'A'
Housing
to 'A'Housing
in 'Figure
in 'Figure
Thetimes
devicein succession
must not be used during more thethansame
threeattempt to
times into 4.1.1', into the starting housing.
times in succession during the same attempt 4.1.1', Slowly
into the rotate
startingthe housing.
start theduring
succession engine.
start the engine. the same attempt to start the engine. Slowly rotate the handlehandle in the of
in the direction direction
crankingof until
cranking
it fully engages.until it fully engages.
5b.5b.If using a limited kick-back handle:
4.2 HAND
4.2 HAND STARTING
STARTING If using
Swivel
a limited
the
kick-back
starting handle
handle:
housing
4.2 Hand Starting Swivel the starting handle housing covercover
(A) to(A)
onetoside
Before attempting to start the engine refer to one side and insert the correct handle, refer to 'B'
Before attempting to start the engine refer to and insert the correct handle, refer to 'B' in 'Figure 4.1.1',
"Starting
Before Handle
attempting to Precautions".
start the engine refer to "Starting Handle in
into 'Figure
the 4.1.1',
housing. into the housing.
"Starting Handle Precautions".
1.Select the excess fuel position by turning the
Precautions". Slowly
Slowly rotate
rotate the handle
the handle in the of
in the direction direction
crankingof until
1.Select the excess fuel position by turning the
engine
1. Select control
the excess lever
fuel Figureanti-clockwise
4.2.1
position byThe Engine
turning toControl
the the ‘STOP’
engine control it cranking
fully until
engages. it fully engages.
engine control lever anti-clockwise to the ‘STOP’
position
lever and releasing
anti-clockwise it. position and releasing it.
to the ‘STOP’
position and releasing it.
2.If a variable speed control lever is fitted move it
to the fast position.
3.Move the decompressor lever towards the
flywheel. Figure 4.2.3 Starting Handle Housing
Figure 4.2.3 Starting Handle Housing

Slowly rotate the handle in the direction of

Slowly rotate the handle in the direction of
cranking until it fully engages.
cranking until it fully engages.
5b.If using a limited kick-back handle:
5b.If using a limited kick-back handle:
Swivel the starting handle housing cover (A) to
Swivel the starting handle housing cover (A) to
one side and insert the correct handle, refer to 'B'
one side and insert the correct handle, refer to 'B'
in 'Figure 4.1.1', into the housing.
in 'Figure 4.1.1', into4.2.4
the housing.
Slowly rotateFigurethe handle
Figure
Starting
in Handle
4.2.4 Starting
Housing of
the direction
Figure 4.2.1 The Engine Control Slowly rotate the handle in Handle Housing
the direction of
Figure
Figure 4.2.1The
4.2.1 The Engine
EngineControl
Control cranking until it fully engages.
cranking until it fully engages.
6. If the cold starting aid was not used turn the engine slowly
59
2.If
2. If2.If aTvariable
a variable speed
SERIES speed
control
ENGINES control
lever lever
is ismove
fitted
WORKSHOP fitteditmove
to
MANUAL theitfast for up to 20 turns to prime the combustion chamber and
a variable speed control lever is fitted move it
to the fast position.
position. lubricating oil system.
to the fast position.
3.Move
3. Move the the decompressor
decompressor lever leverthetowards
towards flywheel. the 7. Firmly hold the handle grip, with the thumb on top of the
3.Move the decompressor lever towards the
flywheel. grip as shown in 'Figure 4.1.2', and crank the engine really fast,
flywheel.
when sufficient speed is obtained move the decompressor
lever towards the gear end and continue to crank until the
engine fires.
Retaining a firm grip on the handle remove the handle from
the housing.

WARNING
Figure 4.2.4 Starting Handle Housing
Do not pull4.2.4
Figure the starting
Starting handle away from the engine
Handle Housing
while cranking.
59
59 as
8. If a variable speed control is fitted reduce the speed
Figure
Figure 4.2.3 Decompressor
4.2.3 Decompressor LeverB - TX
Lever - A - TS/TR; required.
A - TS/TR; B - TX
t before
4.If the ambient temperature is below -10°C
 8.If a variable speed control is fitted reduce the 4.If the ambient temperature
WARNING
speed as required. Figure 4.3.2 The Engine Controlis below -10°C
(14°F) refer to items 2. and 3. in "Cold Starting
Do not pull the starting handle away from the
Aid - TS/TR".
3.If a variable speed control lever is fitted move it
engine while cranking.
4.3 ELECTRIC STARTING 5a.If a TS,
to the fast start
TR,key is being
TX engines
position. used: manual
workshop 55
8.If aIf variable speed control is fitted reduce
an oil pressure switch bypass button is fitted4.If the it the ambient temperature isand
Turn the start key clockwise hold it at position
below -10°C
speed as be
required. ‘3’, until the engine fires and then release it
must depressed during engine cranking and(14°F) refer to items 2. and 3. in "Cold Starting
immediately.
until the engine attains full speed. Aid - TS/TR".
4.3 4.3Electric
ELECTRIC
If the engine Starting
failsSTARTING
to start within 30 seconds, release 5a.If a start key is being used:
If an the key, or start button, and attempt to restart after Turn the start key clockwise and hold it at position
If an oil oil pressure
pressure switchswitch
bypass bypass
buttonbutton is itfitted
is fitted mustitbe ‘3’, until the engine fires and then release it
must allowing
depressed beduring
sufficient
depressed
engine cranking
time for
during all moving
engine
and
parts to stop.
cranking
until the engine andattains
1.Check that the decompressor lever, if fitted, isimmediately.
fulluntil
speed.the engine attains full speed.
If the
If the engine towards
engine tothe
failsfails to gear
startstart
withinend.
within 30 seconds,
30 seconds, release
release the key,
or the
startkey,
button,or start button, to
and attempt and attempt
restart after to restartsufficient
allowing after
timeallowing sufficient
for all moving time
parts for all moving parts to stop.
to stop.
1.Check
1. Check thatthat the decompressor
the decompressor lever,isiftowards
lever, if fitted, fitted, theis
gear end.
towards the gear end.

Figure
Figure4.3.3 StartKey
4.3.3 Start Key

5b.5b.If a starter
If a starter buttonbutton is used:
is being being used:
Press the starter button
Press the starter button until until the
the engine
engine fires
fires and
and then
then release it
release it immediately.immediately.
Figure 4.3.3 Start Key
Figure 4.3.1 Decompressor Lever 6.Turn
6. Turn the the engine
engine control control lever anti-clockwise
lever anti-clockwise to the 'RUN'to
A - TS/TR; B - TX the
position. 'RUN' position.
5b.If a starter button is being used:
7. If7.If
Press a variable
a variable
the speed
starter speed
control
button control
is fitted
until is fitted
reduce
the engine thereduce
fires and asthe
speed
required.
speed as required.
2.Turn the engine control lever anti-clockwise tothen release it immediately.
the ‘STOP’ position and release it. 6.Turn the engine control lever anti-clockwise to
Figure 4.3.1 Decompressor LeverB - TX
AL
Figure 4.3.1 Decompressor
A - TS/TR; B - TX
Lever - A - TS/TR;
4.4
the 4.4
'RUN'Stopping
position. the
STOPPING Engine
THE ENGINE
7.If a1.Onvariable
enginesspeed control is fittedfuel reduce the
2. Turn the engine control lever anti-clockwise to the ‘STOP’ 1. On engines not not fitted
fitted withwith
a fuela controlcontrol solenoid,
solenoid, turn the T
2.Turn the engine control lever anti-clockwise to speed as required.
engine control anti-clockwise to the ‘STOP’ positiontoand
turn the engine control anti-clockwise the
hold
position and release it.
the ‘STOP’ position and release it. ‘STOP’
it there untilposition andcomes
the engine hold ittothere
rest. until the engine
urn the
4.4 STOPPING
comes to rest. THE ENGINE
me the
1.On engines not fitted with a fuel control solenoid,
C
ystem. Turnin
on top turn the engine control anti-clockwise to the
stop th
d crank ‘STOP’ position and hold it there until the engine
soleno
peed is comes to rest.
owards 2.On e
ntil the the k
60
ove the C
Never
decom
60 Figure 4.3.2
Figure 4.3.2The Engine
The Engine Control
Control
occur.
Figure 2.7.1 The Engine Control
om the Figure 2.7.1 The Engine Control
3. If3.If a variable
a variable speedspeed control
control lever islever
fittedismove
fitteditmove
to the itfast
to the fast position.
position. Afterthe
After theengine
engine
hashas stopped
stopped turn turn the key,
the start startifkey,
fitted,if to
ce the 4. If4.If the ambient
the ambient temperature
temperature is below -10°C is (14°F)
below refer-10°C
to items fitted, to the OFF
the OFF position. position.
(14°F)
2. and 3. inrefer
"Cold to itemsAid
Starting 2. -and
TS/TR".3. in "Cold Starting
5a. IfAid
a start key is being used:
- TS/TR". CAPTION
Turn athe
5a.If startkey
start key clockwise
is being andused: hold it at position ‘3’, until
Turn the start key clockwise and hold it at position Turning the start key to the ‘OFF’ position will not stop
fitted it the engine fires and then release it immediately.
‘3’, until the engine fires and then release it the engine unless an optional fuel control solenoid is
ng and fitted.
immediately.
2. On engines fitted with a fuel control solenoid turn the key
elease
to the 'OFF' position.
rt after
o stop.
tted, is CAPTION
Never stop the engine by operating the decompressor
lever or valve damage may occur.
 TS, TR, TX engines workshop manual 56

5. Routine Maintenance

5.1 Preliminary Instructions • The fuel injector can only be checked and set off the engine
using suitable specialist test equipment.

WARNING The Use of Genuine Parts

Routine maintenance must be performed by qualified
persons who are conversant with the hazards of oil, fuel, Parts that have not been approved by the Lister Petter Power
electricity and machinery. Systems organisation cannot be relied upon for correct material,
dimensions or finish.
This Company cannot therefore, be responsible for any damage
arising from the use of such parts and the guarantee may be
CAPTION invalidated.
Before commencing any work on the engine read the When purchasing parts or giving instructions for repairs users
"Safety Precautions and Safe Working Practices" at the should, in their own interests, always specify Genuine Lister
front of this manual. Petter Power Systems Parts.

This routine maintenance section is designed primarily for use

by trained technicians but it does contain sufficient information,
5.2 Routine Maintenance - Schedule
illustrations and detail to allow the operator to perform basic Hours
maintenance work.
This work can only be carried out if the necessary hand and Daily
service tools are available. When the user has insufficient tools,
Check the fuel and lubricating oil levels.
experience or ability to carry out adjustments, maintenance and
repairs this work should not be attempted. Check for fuel and oil leaks.
Where accurate measurements or torque values are required
they can only be made using calibrated instruments. Clean or replace the air cleaner element under very dusty
conditions.
Under no circumstances should makeshift tools or equipment
be used as their use may adversely affect safe working Every 125 hours
procedures and engine operation.
These recommendations and instructions cover several engine The above and the following items.
models therefore they are of a general nature. Check the condition of the battery, if fitted.
The engine may include optional equipment not specifically
covered in this book. Clean or replace the air cleaner element under moderately dusty
• Long periods of light or ‘no load’ running early in the conditions.
engine’s life may lead to cylinder bore glazing and high oil On TX engines operating above 35°C (95°F) drain the sump, refill
consumption. with new oil and renew the oil filter element.
• The instructions given in "05. Maintenance - schedule hours" Every 250 hours
are based on average operating conditions and cover the
minimum requirements to keep an engine running at peak The above and the following items.
performance with trouble free operation.
Drain the sump and refill with new oil.
• Under very dusty conditions, air cleaners, lubricating oil and
fuel filters will require more frequent attention Renew the oil filter element.
• Decarbonising may be required more often if the engine has
been running on light loads for long periods. Clean or replace the injectors if the exhaust is dirty.
• Before carrying out any maintenance work on an engine it is Renew the fuel filter element if the fuel being used is not
advisable to remove the battery. perfectly clean.
The battery and alternator must be disconnected before
commencing any electric welding when a pole strap is directly Check the TX axial fan drive belt tension.
or indirectly connected to the engine. Every 500 hours
• It is essential to ensure that nuts and bolts are tightened to
the torques specified in this Workshop Manual. The above and the following items.
• When re-assembling an engine lubricate all moving parts
with engine oil. Replace the air cleaner element.
• Renew nuts and bolts that have been taken from high stress Examine the exhaust and induction systems for leaks, damage or
locations. In particular nuts and/or bolts from the connecting restrictions.
rods should be renewed.
 TS, TR, TX engines workshop manual 57

Renew the fuel filter element. 5.3 Spanner Torque Settings

Check the battery charge winding system. The tolerance for all spanner torque settings is +5%-0 and for
practical purposes the figures have been rounded.
Every 1000 hours
Location Nm lbf ft
The above and the following items.
Governor link adjusting screw 3.0 2.0
Check the valve clearances.
Polypropylene flywheel fan - TS1 4.0 3.0
Decarbonise if the engine performance has deteriorated.
Injector stud nut - TX
Clean the cylinder and cylinder head cooling fins under dusty Injector leak-off banjo screw 6.0 4.5
conditions. Nylon side shield retainer - TS/TR1
Check the TX axial fan drive belt condition; replace if necessary. Cold start oil cup (taper thread) 8.0 - 14.5 6.0 - 10.5
Every 2000 hours Polypropylene flywheel fan - TS2, 3 8.0 6.0
The above and the following items. Decompressor screw nut
Fuel filter to tank cap screw
Check the injector nozzles and decarbonise, if necessary. 9.0 6.5
Manifold nuts (bottom row) - TS/TR
Fuel pump retaining bolts
Replace the TX axial fan drive belt irrespective of its condition.
Inlet manifold nuts - TX 13.5 10.0
Check the fuel pump timing.
Camshaft catchpin retaining screw 16.0 12.0
Check the governor and controls for free movement.
Fuel filter adaptor
19.0 14.0
Examine the charge winding stator and rotor for damage. (steel into aluminium)

Clean and check the TX axial fan for damage. Main bearing dowel locating plug 20.0 15.0
Injector clamp screw
Every 6000 hours Valve rocker adjusting screw nuts
21.0 15.5
Manifold nuts (top row) - TS/TR
The above and carry out a major overhaul.
Exhaust manifold nuts - TX
Every Year - Marine Injector pipe nuts 22.0 16.0
Change the lubricating oil, oil filter and air cleaner elements if Main bearing housing screws
these were not changed at the prescribed intervals. Sump retaining bolts 27.0 20.0
Injector top plug
Notes: Connecting rod nuts
1. It is recommended that the fuel lift pump diaphragm is inspected at frequent Fanshroud securing bolts 43.0 32.0
intervals if it is known the fuel is contaminated. It should also be inspected at regular (only if fitted with tabwashers)
intervals on engines in low duty cycle applications; for example, stand-by generating
sets. Fuel pump delivery valve holder 35.0 - 45.0 26.0 - 33.0
2. On engines in dumper truck applications the lubricating oil and filter change periods Alternator pulley nut - TX 40.0 - 55.0 40.0 - 55.0
may be extended to every 300 hours.
Balance weight retaining bolt 57.0 42.0

Cylinder head nuts - TX 61.0 45.0

Cylinder head nuts - TS/TR 68.0 50.0

Fanshroud securing bolts
88.0 65.0
(only if slef-locking)
Crankshaft extension and pulley - TX 197.0 145.0
Gear end shaft extension nut
230.0 170.0
(marine builds only)
Gear end crankshaft drives 362.0 267.0

Flywheel retaining screw/nut 475.0 350.0

 TS, TR, TX engines workshop manual 58

5.4 Jointing Compounds End Cover Bush - TS/TR

Coat the outside diameter of the bush before assembly with
Some engines will have been assembled with jointing Loctite 601 or Three Bond 1303.
compounds that have been superseded Providing ail traces of
Speeder Spring Anchor Pin
the old compound and joint are removed the later specified Coat the threads with Loctite 222 or Three Bond 1344 before
compounds can be used. assembling the anchor pin to the speed control spindle.
End Cover
Valve Gear Cover
Assemble the joint between the cover and crankcase with all
Assemble the joint dry and with all surfaces clean and dry.
surfaces cleans and dry.
Bottom of cylinders - TS/TR
Push Rod Tube Seals
Coat the cylinder on the jointing face with Hylomar PL32/M, stick
Lightly coat the bore of the seal with Hellerine rubber lubricant
the joint to it and coat the joint.
to aid assembly.
Valve Guides - TS/TR
Oil Sump
Coat the outside diameters of the guides with Wellseal before
Assemble the joint between the sump and crankcase with all
driving in the plug.
surfaces clean and dry.
Camshaft Expansion Plug
Dipstick - TX
Coat the outside diameter of the plug with Wellseal before
Lightly coat the 'O' ring to aid fitting into the crankcase.
driving in the plug.
Flanged Oil Sump Drain Plug
Coat the threads with Wellseal. 5.5 Dimensions of Wearing Parts
Taper Plugs The following information is given as a guide to the extent
Bind the threads with PTFE tape or coat the threads with Three
by which components may reasonably be expected to wear,
Bond 1110B before screwing in the plug.
without appreciable loss of performance. To maintain the
Oil Seals (not lip type) - TS/TR engine in good running order it is therefore recommended that
Apply a little Hylomar PL32/M to the outside dameter of the seal.
when the "Maximum Clearance" figure is reached, one or more
Cylinder Head Gasket and Shims - TS/TR components affecting the clearance be replaced.
Smear a small amount of High Melting Point Grease where the The wear to be allowed in parts refitted to an engine depends
shims seat, the side of the recess, both sides of each shim and on the life required to the next overhaul and the relative cost
the gasket.
of labour and materials. If labour costs are high it may pay to
Cylinder Barrel Shims - TX replace parts before the maximum wear condition is reached
Assemble the shims dry with surfaces clean and dry. to avoid further work before the next scheduled overhaul.
Valve Rocker Stub Shafts - TS/TR
Coat the sealing groove nearest to the bolt hole with Wellseal or
Hylomar PL32/M.
Cylinder Bore Wear
Oil Pump Feed Plug The maximum advisable piston to cylinder clearance given is
Coat the outside diameter of the plug with Wellseal. the clearance between the bottom of the piston skirt, across
Decompressor Bore the faces, and the cylinder bore measured in the region of travel
Apply Wellseal to the outside diameter of the TS/TR plug before of the piston skirt. The clearance is not to be measured at the
fitting. top of the bore.
Apply Wellseal or Hylomar PL32/M to the outside diameter of the When cylinders are rebored the lower skirt should be etched
TX plug before fitting. or painted with the amount of the over-size.
Flywheel End Bearing Housing Shims
Coat the bearing housing face with Loctite 221, place a shim Piston Ring Wear
in place and coat the shim. Coat both sides of any subsequent
shims. The ring gaps given in the table are those to be anticipated
Cylinder Head Nuts and the Top Threads of the Cylinder Head when checking rings in an unworn part of the bore. For every
Studs - TS/TR 0.01 mm (0.0004 in) by which the actual bore size exceeds the
Coat the threads at the top of the stud, the nut threads and the initial dimension, the ring gap will increase by approximately
area of the top plate in contact with the nut with Wellseal. 0.03 mm (0.0012 in).
Fuel Lift Pump The firing ring side clearance is measured with a new ring flush
Assemble the joint between the pump and crankcase with all with the top piston land.
surfaces clean and dry.
Crankcase Breather Pipe - TS/TR Oversize and Undersize Items
Coat the knurls of the pipe with Loctite 601 and push it into the
top plate. Before the pipe reaches the hole in the cylinder head Oversize pistons and piston rings, and undersize big end and
coat the lower end of it. main bearing shells are available.
Take care not to block the bore of the pipe. Reference should be made to the relevant Master Parts Manual
Crankshaft Bucket Plug for the relevant part numbers.
Coat the plug periphery with Loctite 572 or Three Bond 1110B.
 TS, TR, TX engines workshop manual 59

The variations from the standard dimensions are: Non-standard sizes are marked, by the amount they are under
0.010 in (0.254 mm) or oversize, as a suffix to the part numbers which can be found
0.020 in (0.508 mm) in the following locations:
0.030 in (0.762 mm) a. Piston Rings - stamped on the face of the ring.
0.040 in (1.016 mm) b. Pistons - stamped on the top surface.
c. Bearings - stamped on the steel outside surface of the bearing.

TS, TR Wearing Parts

Component TS/TR Initial Dimension (mm) Initial Clearance (mm) Max. Clearance (mm)
TS - Builds 01 - 43
95.275
Cylinder Bore
95.300 0.261
0.35
95.065 0.210
Piston Diameter - bottom of skirt across thrust face
95.039
0.30 0.38
Firing Ring Gap 0.98
0.50 0.66
0.20 0.28
Compression Ring Gap 0.90
0.40 0.56
0.25 0.33
Conformable Oil Ring Gap 0.90
0.45 0.61
0.30 0.38 0.85
Slotted Oil Ring Gap
0.50 0.66 0.86
0.00
Firing Ring Side Clearance 0.10
0.06
0.2380
Compression Ring Width
2.355 0.122
0.23
2.502 0.172
Compression Ring Groove Width
2.527
2.456 0.076
2nd Compression Ring Groove Width 0.23
2.482 0.127
4.763
Oil Ring Width
4.737 0.050
0.15
4.813 0.102
Oil Ring Groove Width
4.839
TS - Builds 60-65
95.275
Cylinder Bore
95.300 0.128
0.22
95.212 0.063
Piston Diameter - bottom of skirt across thrust face
95.172
0.30 0.36
Firing Ring Gap 0.85
0.50 0.66
0.20 0.28
Compression Ring Gap 0.90
0.45 0.61
0.25 0.33
Conformable Oil Ring Gap 0.90
0.45 0.61
0.00
Firing Ring Side Clearance 0.10
0.06
2.380
Compression Ring Width
2.355 0.122
0.23
2.502 0.172
Compression Ring Groove Width
2.527
4.763
Oil Ring Width
4.737 0.050
0.15
4.813 0.102
Oil Ring Groove Width
4.839
 TS, TR, TX engines workshop manual 60

TS - All Builds
98.450
Cylinder Bore
98.475 0.192
0.28
98.323 0.127
Piston Diameter - bottom of skirt across thrust face
98.283
0.30 0.38
Firing Ring Gap 0.85
0.50 0.66
0.20 0.28
Compression Ring Gap 0.90
0.40 0.56
0.25 0.33
Conformable Oil Ring Gap 0.90
0.45 0.61
0.00
Firing Ring Side Clearance 0.10
0.06
2.380
Compression Ring Width
2.355 0.076
0.23
2.456 0.127
Compression Ring Groove Width
2.482
4.763
Oil Ring Width
4.737 0.050
0.15
4.813 0.102
Oil Ring Groove Width
4.839
TS and TR - All Builds
33.3807
Small End Bearing Diameter
33.3934 0.0432
0.09
33.3375 0.610
Gudgeon Pin Diameter
33.3324
67.2080
Big Enf Bore - in rod
67.2210
0.8352 0.0376
Bearing Shell Thickness 0.14
1.8263 0.0814
63.5000
Crankpin Diameter
63.4870
67.196
Main Bearing Housing Bore
67.221
1.8352 0.0386
Bearing Shell Thickness 0.16
1.8263 0.0934
63.4870
Crankshaft Journal Diameter
63.4750
2.360 0.178
Thrust Bearing Thickness - TS/TR1 0.37
2.310 0.254
2.360 0.229
Thrust Bearing Thickness - TS/TR2, 3 0.43
2.310 0.305
44.407
Camshaft Bush Bore - centre
44.506 0.0586
0.22
44.3484 0.1703
Camshaft Journal Diameter - centre
44.3357
39.975
Camshaft Bush Bore - flywheel end
40.060 0.023
0.20
39.952 0.121
Camshaft Journal Diameter - flywheel end
39.939

1mm = 0.03937 in
 TS, TR, TX engines workshop manual 61

24.987
Fuel Pump Tappet Diameter
24.962 0.013
0.10
25.000 0.068
Fuel Pump Tappet Guide Bore
25.030
15.850
Oil Pump Tappet Diameter
15.830 0.025
0.12
15.875 0.070
Oil Pump Tappet Crankcase Bore
15.900
29.960
Oil Pump Plunger Diameter
29.935 0.040
0.13
30.000 0.070
Oil Pump Cylinder Diameter
30.033
Valve Spring - approximate free length 52.00 50.40
8.731
Valve Guide Bore
8.752 0.0683
0.13
8.6627 0.1020
Valve Stem Diameter
8.6500
25.4620
Valve Rocker Bush Bore
25.4750 0.018
0.07
25.4440 0.0395
Valve Rocker Shaft Diameter
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
100.000
Cylinder Bore
100.025 0.164
0.25
99.879 0.121
Piston Diameter - bottom of skirt across thrust face
99.861
0.40 0.40
Firing Ring Gap 1.05
0.65 0.73
0.40 0.40
Compression Ring Gap 1.02
0.65 0.73
0.25 0.25
Conformable Oil Ring Gap 0.90
0.55 0.63
0.00
Firing Ring Side Clearance 0.10
0.06
2.490
Compression Ring Width
2.478 0.070
0.18
2.560 0.102
Compression Ring Groove Width
2.580
3.990
Oil Ring Width
3.978 0.030
0.11
4.020 0.062
Oil Ring Groove Width
4.040
33.3807
Small End Bearing Diameter
33.3934 0.0437
0.09
33.3370 0.0624
Gudgeon Pin Diameter
33.3310

1mm = 0.03937 in
 TS, TR, TX engines workshop manual 62

67.2080
Big End Bore - in rod
67.2210
1.8352 0.0376
Bearing Shell Thickness 0.14
1.8263 0.0814
63.5000
Crankpin Diameter
63.4870
67.196
Main Bearing Housing Bore
67.221
1.8352 0.0386
Bearing Shell Thickness 0.16
1.8263 0.0934
63.4870
Crankshaft Journal Diameter
63.4750
2.360 0.229
Thrust Bearing Thickness 0.43
2.310 0.305
46.772
Camshaft Bush Bore - centre
46.878 0.017
0.22
46.755 0.138
Camshaft Journal Diameter - centre
46.740
39.975
Camshaft Bush Bore - flywheel end
40.060 0.023
0.20
39.952 0.121
Camshaft Journal Diameter - flywheel end
39.9390
24.987
Fuel Pump Tappet Diameter
24.962 0.013
0.10
25.000 0.068
Fuel Pump Tappet Guide Bore
25.030
15.850
Oil Pump Tappet Diameter
15.830 0.025
0.12
15.875 0.070
Oil Pump Tappet Crankcase Bore
15.900
29.960
Oil Pump Plunger Diameter - Tx2
29.935 0.040
0.13
30.000 0.098
Oil Pump Cylinder Diameter - Tx2
30.033
32.960
Oil Pump Plunger Diameter - Tx3
32.935 0.040
0.13
33.000 0.098
Oil Pump Cylinder Diameter - Tx3
33.033
Valve Spring - approximate free length 48.00 46.6
7.957
Valve Guide Bore
7.980 0.073
0.15
7.884 0.119
Valve Stem Diameter
7.861
16.000
Valve Rocker Bush Bore
16.0270 0.020
0.10
15.980 0.067
Valve Rocker Shaft Diameter
15.960
Backlash Between Gears 0.13 1 0.20

Notes:
1
Maximum Initial Clearance
1mm = 0.03937 in
 TS, TR, TX engines workshop manual 63

5.5 Long Term Storage Returning the Engine to Service

Refer to the appropriate sections for the relevant detailed
Preparing the Engine for Storage instructions as necessary to complete this work.
The following routine should be carried out when it is known a. Remove the tie-on labels and all the protective coverings
that the engine will not be required for some months. from openings and apertures.
If the following procedure is not carried out the engine should b. Check the drive belt for deterioration and correct tension.
be run on full load for approximately 45 minutes once a c. Fill the fuel tank.
month. d. Refill the lubricating oil sump with new oil of the correct
specification and viscosity.
CAPTION e. Remove the batteries from store. If they are still fully charged
reconnect them to the engine.
As a direct result of combustion the lubricating oil may
Coat the terminals with petroleum jelly.
contain harmful acids and therefore it should not be left
f. Start the engine and check for fuel and oil leaks before
in the sump if it is known engine will not be used for
applying load.
extended periods.

a. Replace the fuel in the tank with a small supply of suitable

inhibition fluid.
b. Drain the lubricating oil from the sump and refill with new
oil.
c. Run the engine for a period to circulate the oil through the
system and to ensure the inhibition fluid is passed through
the fuel pumps and injectors.
d. Stop the engine and drain the lubricating oil from the
sump.
The crankshaft should NOT be turned until the engine is again
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 stating what steps have been
taken to inhibit the engine during storage.
 TS, TR, TX engines workshop manual 64

6. Troubleshooting

6.1 Preliminary Information 6.2 Method of Troubleshooting

Troubleshooting mechanical engine problems can be difficult. 1. Diagnose the problem by eliminating the easiest things first.
This section lists possible engine problems that could be 2. Before starting to remove or dismantle any components
encountered with possible causes and corrections. The double check your observations.
information given is of a general nature as it covers the basic 3. During dismantling keep all cylinder related items together.
engine and your particular application may be different. This will ensure they are refitted in the original orientation.
Electrical wiring diagrams can be found in section 9. 4. When electrical troubleshooting always start at the battery
If you are in any doubt, contact your local Lister Petter Power first.
Systems distributor.
Before starting any dismantling procedure the following should
be considered:
a. Do you know and understand the engine and all the related
systems?
b. Do you have sufficient electrical and mechanical knowledge
and skills to understand the symptoms?
c. Do you have suitable electrical diagnostic equipment
available?
d. Do you have, or access to, the necessary Lister Petter Power
Systems spare parts before you commence dismantling?

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 specification.
Incorrect fuel. Use fuel of the correct specification.
No fuel in the tank. Refill the tank.
Choked fuel filter. Replace the filter.
Air lock in the fuel system. Check the fuel level. Prime the fuel filter.
Water or dirt in the fuel system. Drain, flush, refill and prime the filter.
Dirty or faulty injector. Replace the injector or have it serviced.
Discharged battery. Recharge or replace the battery.
Fuel pump solenoid not energised. Check the electrical supply.
Poor battery connections. Clean, replace and coat with petroleum jelly.
Faulty fuel pump. Contact a Lister Petter Power Systems distributor.
Excessive Carbon Deposits
Choked air filter. Dismantle and clean the cap and element.
Choked exhaust system. Dismantle and clean.
Unsuitable fuel. Use fuel of the correct specification.
Unsuitable lubricating oil. Use oil of the correct viscosity and specification.
Continuous low, or no load running. Investigate your load management programme.
 TS, TR, TX engines workshop manual 65

Problem Method of Correction

White Exhaust Smoke
Water in the fuel system. Drain, flush, refill and prime the filter.
Faulty fuel pump. Contact a Lister Petter Power Systems distributor.
Light Blue Exhaust Smoke
Generally as a result of light load. Investigate the load management programme.
Heavy Blue Exhaust Smoke
Lubricating oil passing the piston rings. Check the crankcase vacuum. Check for wear.
Stuck, worn or broken piston rings. Check for damage, decarbonise, replace the rings.
Worn cylinder bore. Replace the piston and piston rings.
Overfull oil sump. Correct the level.
Black Exhaust Smoke
Overload. Reduce the load.
Choked air filter. Dismantle and clean the cap and element.
Inlet air temperature too high. Investigate the reason.
Water in the fuel system. Drain, flush, refill and prime the filter.
Unsuitable fuel. Use fuel of the correct specification.
Engine Stops
Lack of fuel. Check the system. Refill the tank.
Air in the fuel system. Prime the fuel filter.
Water in the fuel system. Drain, flush, refill and prime the fuel filter.
Choked fuel filter. 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.
Automatic shutdown, if protective devices are fitted. Investigate the cause and rectify.
Lack or Loss of Power
Loss of compression. Check the piston rings and the valves.
Choked air filter. Dismantle and clean the cap and element.
Choked exhaust system. Dismantle and clean.
Overload. Reduce the load.
Choked fuel filter. Replace the filter.
Worn engine. Give the engine a major overhaul.
Overheating
Overload. Reduce the load.
Lubricating oil level too low. Add oil of the correct specification and viscosity.
Incorrect fuel. Drain the system, add fuel of the correct specification.
Recirculation of exhaust gasses or cooling air. Investigate and eliminate the cause.
Check for restrictions and clean the cylinder head and cylinder
Air cooling system obstructed.
barrel cooling fins.
 TS, TR, TX engines workshop manual 66

Problem Method of Correction

High Fuel Consumption
Incorrect type of fuel. Drain the system, add fuel of the correct specification.
Overload. Reduce the load.
Dirty or faulty injector. Clean or replace.
Choked air filter. Dismantle and clean the cap and element.
Undercharging
Excessive electrical load from added accessories. Remove accessories.
Poor electrical connections to alternator or battery. Inspect, clean and rectify the cause.
Faulty battery. Test, recharge or replace.
Faulty alternator or charge windings. Test or replace.
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 tighten the connections.
Worn out battery. Replace the battery.
Loose alternator drive belt. Replace or re-tension the drive belt.
Starter Motor does not Operate
Loose or corroded connections. Clean and tighten the connections.
Worn out battery. Replace the battery.
Faulty starter panel or connections. Check the connections or replace the panel.
 TS, TR, TX engines workshop manual 67

7. Dismantle & Rebuild

TS/TR Dismantle and Rebuild 21. Fit the service tool (317-50063) and remove the end cover.
22. Remove the thrust washer and shim from the camshaft.
These notes are of a general nature and are included as an aide 23. Remove all fuel pump inspection doors.
memoir and in no way are they intended as instructions. 24. Disconnect the governor link from all fuel pump racks.
25. Remove the two fulcrum pins from the governor lever
Dismantling assembly pivot supports taking care to retain the spring
and shims.
Before beginning any work on the engine drain all of the fuel 26. Using long nosed pliers, remove the speeder spring from
and oil from the engine and disconnect all services, including its control.
the battery. Remove the air filter, silencer and fuel tank (if 27. Remove the governor lever assembly complete.
fitted). 28. emove the governor sleeve assembly from the camshaft.
1. Remove the bolts from the lifting eye and lift it off. 29. Remove the fuel pump taking care to retain the timing shims
2. Remove the cylinder head covers. with the correct pump.
3. Slacken both ends of the fuel pipes from the pumps to the 30. Remove the fuel pump tappet and cap using long nosed
injectors and remove the pipes. pliers.
4. Remove the injector clamp. 31. Remove the fuel pump tappet guide locating bolts from the
5. Remove the injector and leak off pipe. side of the crankcase.
Note that a washer is fitted over the nozzle of each injector. 32. Remove the fuel pump tappet guides noting which way
6. Remove the inlet and exhaust manifolds and the two they are fitted.
gaskets. 33. Remove the oil dipstick.
7. Unscrew and remove the cold start pots, if these are fitted. 34. Stand the engine on its flywheel using a suitable piece of
8. Ensure the fuel pipe from the filter to the pumps is timber between the recessed flywheel and the plinth.
removed. 35. Remove the sump.
9. Remove the fuel lift pump, if fitted. 36. Remove the oil pump and oil pump push rod.
10. Remove the fuel filter, if engine mounted. 37. If necessary dismantle the oil pump.
11. Remove the gear end side shield, the air cowling and the 38. Ensure the push rod cam followers are at their highest
flywheel end side shield. positions to clear the camshaft.
12. Remove the valve rocker oil feed pipe and unions from the 39. Keeping the camshaft square' gently ease it out of the
crankcase and cylinder heads. crankcase.
13. Remove the four cylinder head nuts from No.1 cylinder. 40. Rotate the crankcase until No. 1 piston is at BDC.
14. Lift off the cylinder head and place it on its side on a 41. Remove NO.1 connecting rod cap.
bench. 42. Rotate the crankcase until No.1 piston is at TDC.
15. Remove the gasket and shims if these have remained on 43. Remove the retaining tube and gently lift off the cylinder
the top of the cylinder barrel. barrel piston and connecting rod as one unit.
16. Remove the push rods and tubes. 44. Replace the bearing cap on to the connecting rod.
17. Fit a retaining tube over one cylinder head stud and secure 45. Repeat items 40 to 44 for the remaining cylinders.
it with a hand tight nut. 46. Remove the Allen screws and crankshaft balance weights.
This will prevent the cylinder from rising if the crankshaft 47. Remove the cam followers.
is turned. 48. Replace the sump holding it with four bolts (one each
18. Repeat items 13 to 17 for the remaining cylinders. side).
19. Remove the air baffles. 49. Turn the engine to its normal position.
20. Remove the plastic dustcap in the end cover boss. 50. Unscrew the flywheel retaining bolt two turns using a
65mm socket.
On early engines: 51. Use the service tool and break the tapered seal between
a. Turn the crankshaft until the spring pin of the starting the flywheel and the crankshaft, in an emergency tap the
handle catch pin in the camshaft is visible through the flywheel retaining bolt with a copper hammer.
hole in the cover boss. 52. Using a crane if available and with the hook in one of the
b. Tap out the pin with a suitable punch. flywheel fins just take the strain.
c. Turn the engine through 90" and drift out the starting 53. Remove the flywheel retaining bolt and fit the mandrel,
handle catch pin. 317-50046, in its place.
54. Keeping the flywheel square ease the flywheel out from the
On later engines: housing and place it in a safe position.
d. Remove the grub screw from the end of the camshaft. 55. Remove the rectifier cover.
e. Drift out the pin. 56. Mark the four rectifier cables for identification and remove
them from their respective positions.
 TS, TR, TX engines workshop manual 68

57. Remove the rectifier from the flywheel housing. 14. Replace the flywheel key.
58. Remove the cable retaining clip from inside the housing. 15. Heat the crankshaft pinion gear and ensure the "0" timing
59. Remove the stator gently easing the cable through the mark will be facing outwards when the gear is refitted to
housing as this is being done. the crankshaft.
60. Remove the fanshroud. 16. Replace the sump with four bolts (one each side).
61. Use a brass drift to remove the flywheel key. 17. Turn the crankcase the correct way up.
62. Remove the intermediate bearing retaining bolts from the 18. Replace the fanshroud.
side of the crankcase. 19. Replace the stator.
63. Remove the intermediate bearing dowels by screwing a 20. Replace the cable clip.
suitable bolt into the dowel and withdrawing it. 21. Turn the crankshaft until the flywheel key is at TDC and fit
The bolt should be left in the dowel to identify the correct the mandrel, Service Tool 317-50045.
assembly procedure as the dowel is threaded at one end 22. Rub chalk over the flywheel timing marks to aid identification
only. during later procedures.
64. Remove the alternator adaptor plate. 23. Use a crane (if available) to replace the flywheel ensuring
65. Remove the flywheel end main bearing housing. that it is offered up dead square.
66. Use the Service Tool. 317-50058 or 39317 to remove the 24. Remove the mandrel and replace the flywheel retainer.
crankshaft gear. 25. Check that the 'key is still in position and turn the flywheel
67. Gently remove the crankshaft from the crankcase. to check for free movement.
68. Remove the split thrust washers from inside the crankcase 26. Replace the rectifier, cables and cover.
at the gear end and from the main bearing housing. The two large cutouts in the cover are towards the bottom
of the rectifier.
Rebuild 27. Stand the engine on its flywheel using a suitable piece of
timber between the recessed flywheel and the plinth.
When assembling the engine use normal engine lubricating oil 28. Remove the sump.
to spray all moving parts during assembly. All bearing surfaces 29. Replace the push rod cam followers. a tool with a rubber
must be well lubricated including the valve stems and the cups suction pad (as used to grind in valves) can be used to
of the push rods. advantage.
New camshaft bushes should be immersed in clean engine oil 30. Gently replace the camshaft keeping it square at all times,
for four hours before fitting. and ensure that the "0" timing marks on the camshaft and
The pistons with rings and connecting rods assembled, must crankshaft gears coincide exactly with each other on final
be submerged in oil just before fitting into the cylinder. assembly.
After submersion drain both ways so that no oil is left in the 31. Replace the fuel pump tappet guides, the end with the two
combustion chamber or inside the piston. flats enters the crankcase first.
Replace all joints and gaskets. Take extreme care to ensure the bolt holes are correctly
1. Turn the crankcase on to its manifold side using a suitable aligned.
piece of wood to support it. 32. Replace the fuel pump tappet guide bolt making sure a
2. Remove the sump. copper washer is fitted under the bolt head.
3. Grease the steel backs of the split thrust washers and refit 33. Using the flywheel as a pivot rotate the crankcase until No.1
them into the gear end of the crankcase and the main bearing cylinder crankshaft throw is at TOC
housing. 34. Replace No.1 cylinder, connecting rod and piston.
4. Replace the crankshaft taking care to ensure the bearing 35. Fit a retaining rube on to one end of the cylinder studs and
locating dowel is in line with the hole in the crankcase before secure it with a hand tightened nut.
the dowel enters the housing. 36. Push down on the top of the piston as the crankcase is
If, on the final assembly, the holes are not in line use a brass turned' until the piston is at BDC.
drift to rotate the bearing housing. 37. Fit the connecting rod bearing cap.
Check exact alignment by using a tapered rod. 38. Rotate the crankcase to check for free movement.
5. Replace the Intermediate bearing dowel with a bolt fitted to 39. Repeat items 33 to 38 for the remaining cylinders.
ensure the threaded section is facing outwards. 40. Replace the oil pump push rod and then the pump.
6. Refit the crankshaft balance weights in their correct order with 41. Replace the sump ensuring the oil strainer is fitted
the larger flanges (and part numbers) facing each other. correctly.
7. Replace the crankshaft end float shims on to the main bearing 42. Turn the engine the normal way up and replace the oil
housing and refit the housing and all bolts. dipstick.
8. Check and adjust if necessary the crankshaft end float. 43. Replace the fuel pump tappets and tappet caps.
9. Remove the bearing housing bolts. 44. Refit the air baffles with the spring clips facing the manifold
10. Replace the alternator adaptor making sure the slot on the side.
face is towards the top of the crankcase. 45. Replace the fuel pumps and shims.
11. Remove the centre bearing dowel. 46. Replace the governor sleeve assembly with the spring ring
12. Replace the oil seal to the bearing housing. facing outwards.
13. Replace the centre bearing dowel and the dowel retaining
bolt.
 TS, TR, TX engines workshop manual 69

It will be necessary to open the governor weights to ensure

the assembly is pushed fully on to the shaft.
TX Dismantle and Rebuild
47. Replace the governor lever assembly and both fulcrum pins These notes are of a general nature and are included as an aide
taking care to ensure the holes are facing outwards. memoir and in no way are they intended as instructions.
48. Measure and adjust as necessary, the end play between
pivot and lever assembly. Dismantling
49. Connect the governor interconnecting lever to the fuel
pump racks. Before beginning any work on the engine drain all of the fuel
50. Adjust the fuel pump racks. and oil from the engine and disconnect all services, including
51. Reconnect the speeder spring to its control. the battery. Remove the air filter, alternator, starter and fuel
52. Check the governor lever and rack for correct operation. tank.
53. Set the governor. 1. Remove the lifting eye bracket.
54. Replace the camshaft end float shims and then the camshaft 2. Remove the exhaust manifold.
thrust washer. 3. Remove the axial fan cowling.
55. Replace the end cover using the service tool, 317-50063, to 4. Remove the inlet manifold.
protect the oil seal. 5. Slacken the alternator and remove the drive belt.
56. Check the camshaft end float. 6. Remove the alternator.
57. Refit the starting dowel and pin. 7. Remove the axial fan and bracket.
58. Remove the retaining tube from No.1 cylinder. 8. Pull off the injector leak-off pipes.
59. Replace the cylinder head and diagonally torque the nuts. 9. Remove all of the fuel pipes.
60. Check the cylinder head clearance. 10. Remove the fuel lift pump. if fitted.
61. With the cylinder head removed, replace the push rods 11. Remove the fuel filter.
and tubes. 12. Remove the gear and flywheel end air shields.
A very small mount of grease added to the tube sealing 13. Remove the injector clamp.
rubbers will ease the fitting of the heads. 14. Lift out the injector; note that a washer is fitted over the
62. Replace the cylinder head complete with gasket and shims nozzle of each injector.
making sure it is fully seated and then replace the nuts 15. Remove the valve rocker cover (6mm Allen key).
hand tight. 16. Remove the valve rocker assembly and oil restrictor plate.
63. Repeat items 58 on page 111 to 62 for the remaining 17. Remove the inlet and exhaust valve stem caps.
cylinders. 18. Lift out the push rods.
64. Replace a manifold with one nut on each cylinder head to 19. Remove the valve rocker oil feed pipe and unions from the
ensure the heads are correctly aligned. crankcase and cylinder heads.
65. Torque the cylinder head nuts. 20. Remove the four cylinder head bolts from each cylinder.
66. Remove the manifold. 21. Lift off the cylinder heads and place them on a bench.
67. Spill time the fuel pumps. 22. Remove the push rod tubes.
68. Replace the side shields at the gear and flywheel ends. 23. Fit a suitable retaining tube over one cylinder head bolt
69. Replace the air cowling with the gasket on the outside of for each cylinder and replace the bolt hand tight this
the cowling. will prevent the cylinders from rising if the crankshaft is
70. Replace both manifolds using the thick spacer on the top turned.
studs between both manifolds. 24. Remove the air baffles between the cylinders.
71. Replace the valve rocker oil feed pipe to the heads and 25. Remove the end cover.
crankcase. 26. Remove the thrust washer and shim from the camshaft.
72. Turn the engine to TDC No. 1 cylinder firing stroke and set 27. Remove all the fuel pump inspection doors.
the inlet and exhaust valve clearances. 28. Disconnect the governor link from all the fuel pump racks.
73. With the engine still at TDC No.1 firing stroke set the 29. Remove the two fulcrum pins from the governor lever
decompressors. assembly pivot supports taking care to retain the spring
74. Repeat items 72 to 73 for the remaining cylinders. and shims.
75. Check and reset, if necessary, the fuel injector setting. 30. Using long nosed pliers, remove the speeder spring from
76. Replace the injectors and leak off pipes complete. its control.
Ensure a new washer is fitted at the nozzle end. 31. Remove the governor lever assembly complete.
77. Replace the fuel pump to injector pipes leaving the nuts 32. Remove the governor sleeve assembly from the camshaft.
finger tight. 33. Remove the fuel pump taking care to retain the timing shims
78. Replace the injector clamp. with the correct pump.
79. Tighten all of the fuel pipes. 34. Remove the fuel pump tappet and cap using long nosed
80. Replace the fuel pump inspection doors. pliers.
81. Replace the cylinder head covers. 35. Remove the fuel pump tappet guide locating bolts from the
82. Replace the lifting eye. side of the crankcase.
83. Refit air filter, silencer and fuel tank, reconnect all services 36. Remove the fuel pump tappet guides noting which way
and replenish the fuel and oil supplies. they are fitted.
37. Remove the oil dipstick.
 TS, TR, TX engines workshop manual 70

38. Stand the engine on its flywheel using a suitable piece of 2. With the sump removed grease the steel backs of the split
timber between the recessed flywheel and the plinth. thrust washers and refit them into the gear end of the
39. Remove the sump. crankcase and the main bearing housing.
40. Remove the oil pump and oil pump push rod. 3. Replace the crankshaft taking care to ensure the bearing
41. If necessary dismantle the oil pump. locating dowel is in line with the hole in the crankcase before
42. Ensure the push rod cam followers are at their highest the dowel enters the housing.
positions to clear the camshaft. If, on the final assembly, the holes are not in line use a brass
43. Keeping the camshaft square gently ease it out of the drift to rotate the bearing housing.
crankcase. Check exact alignment by using a tapered rod.
44. Rotate the crankcase until No. 1 piston is at BDC. 4. Replace the Intermediate bearing dowel with a bolt fitted to
45. Remove No.1 connecting rod cap. ensure the threaded section is facing outwards.
46. Rotate the crankcase until No.1 piston is at TDC. 5. Refit the crankshaft balance weights in their correct order
47. Remove the retaining tube and gently lift off the cylinder with the larger flanges facing each other.
barrel, piston and connecting rod as one unit. 6. Replace the crankshaft end float shims on to the main bearing
48. Replace the bearing cap on to the connecting rod. housing and refit the housing and all bolts.
49. Repeat the procedure for the remaining cylinders. 7. Check and adjust the crankshaft end float.
50. Remove the Allen screws and crankshaft balance weights. 8. Replace the oil seal to the bearing housing.
51. Remove the cam followers. 9. Replace the centre bearing dowel and the dowel retaining
52. Replace the sump holding it with four bolts (one each bolt.
side). 10. Replace the flywheel key.
53. Remove the crankshaft gear. 11. Heat the crankshaft pinion gear and ensure the "0" timing
54. Turn the engine to its normal position. mark will be facing outwards when the gear is refitted to
55. Unscrew the flywheel retaining nut two turns using a 65mm the crankshaft.
socket. 12. Replace the sump with four bolts; one on each side.
56. Use the service tool and break the tapered seal between 13. Turn the crankcase the correct way up.
the flywheel and the crankshaft. 14. Replace the flywheel housing.
57. Remove the flywheel nut and fit the mandrel 317-50046, 15. Turn the crankshaft until the flywheel key is at TDC and fit
in its place. the mandrel. Service Tool 317-50045.
58. Keeping the flywheel square ease the flywheel from the 16. Rub chalk over the flywheel timing marks to aid identification
crankshaft and place it in a safe position. during later procedures.
59. Remove the flywheel housing. 17. Replace the flywheel ensuring that it is offered up dead
60. Use a brass drift to remove the flywheel key. square.
61. Remove the intermediate bearing retaining bolts from the 18. Remove the mandrel and replace the flywheel nut.
side of the crankcase. 19. Check that the key is still in position and turn the flywheel
62. Remove the intermediate bearing dowels by screwing a to check for free movement.
suitable bolt into the dowel and withdrawing it. 20. Stand the engine on its flywheel using a suitable piece of
The bolt should be left in the dowel to identify the correct timber between the recessed flywheel and the plinth.
assembly procedure as the dowel is threaded at one end 21. Remove the sump.
only. 22. Replace the push rod cam followers; a tool with a rubber
63. Remove the flywheel end main bearing housing. suction pad, as used to grind in valves, can be used to
64. Gently remove the crankshaft from the crankcase. advantage.
65. Remove the split thrust washers from inside the crankcase 23. Gently replace the camshaft keeping it square at all times,
at the gear end and from the main bearing housing. and ensure that the "0" timing marks on the camshaft and
crankshaft gears coincide exactly with each other on final
Rebuild assembly.
24. Replace the fuel pump tappet guides, the end with the two
When assembling the engine, use normal engine lubricating oil flats enters the crankcase first.
to spray all moving parts during assembly. All bearing surfaces Take extreme care to ensure the bolt holes are correctly
must be well lubricated including the valve stems and the cups aligned.
of the push rods. 25. Replace the fuel pump tappet guide bolt making sure a
New camshaft bushes should be immersed in clean engine oil copper washer is fitted under the bolt head.
for four hours before fitting. 26. Using the flywheel as a pivot rotate the crankcase until No.1
The pistons with rings and connecting rods assembled, must cylinder crankshaft throw is at TDC.
be submerged in oil just before fitting into the cylinder. 27. Replace No.1 cylinder, connecting rod and piston.
After submersion drain both ways so that no oil is left in the 28. Fit a retaining tube on to one cylinder head bolt and secure
combustion chamber or inside the piston. it hand tightened.
Replace all joints and gaskets. 29. Push down on the top of the piston as the crankcase is
1. Turn the crankcase onto its side using a suitable piece of turned until the piston is at BDC.
wood to support it. 30. Fit the connecting rod bearing cap.
 TS, TR, TX engines workshop manual 71

31. Rotate the crankcase to check for free movement. 52. Check the cylinder head clearance.
32. Repeat the procedure for the remaining cylinders. 53. With the cylinder head removed, replace the push rods
33. Replace the oil pump push rod and then the pump. and tubes: a very small mount of grease added to the tube
34. Replace the sump ensuring the oil strainer is fitted sealing rubbers will ease the fitting of the heads.
correctly. 54. Replace the cylinder head making sure it is fully seated and
35. Turn the engine the normal way up and replace the oil then replace the bolts hand tight.
dipstick. 55. Repeat the procedure for the remaining cylinders.
36. Replace the fuel pump tappets and tappet caps. 56. Replace a manifold with one nut on each cylinder head to
37. Refit the air baffles with the spring clips facing the manifold ensure the heads are correctly aligned.
side. 57. Torque the cylinder head nuts.
38. Replace the fuel pumps and shims. 58. Remove the manifold.
39. Replace the governor sleeve assembly with the spring ring 59. Spill time the fuel pumps.
facing outwards. 60. Replace the side shields at the gear and flywheel ends.
40. Replace the governor lever assembly and both fulcrum pins 61. Replace the air cowling.
taking care to ensure the holes are acing outwards. 62. Replace both manifolds.
41. Check the end play between pivot and lever assembly is 63. Replace the valve rocker oil feed pipe to the heads and
correct. crankcase.
42. Connect the governor interconnecting lever to the fuel 64. Turn the engine to TDC No. 1 cylinder firing stroke and
pump racks. set the inlet and exhaust valve clearances: repeat for the
43. Adjust the fuel pump racks. remaining cylinders.
44. Reconnect the speeder spring to its control. 65. Check the fuel injector setting.
45. Check the governor lever and rack for correct operation. 66. Replace the injectors with a new washer and leak off pipes.
46. Set the governor. 67. Replace the injector clamp.
47. Replace the camshaft end float shims and then the camshaft 68. Replace the fuel pipes.
thrust washer. 69. Tighten all of the fuel pipes.
48. Replace the end cover using the service tool to protect the 70. Replace the fuel pump inspection doors.
oil seal. 71. Replace the valve rocker covers.
49. Check the camshaft end float. 72. Replace the lifting eye.
50. Remove the retaining tube from No.1 cylinder. 73. Refit the air filter, alternator, starter and fuel tank, reconnect
51. Replace the cylinder head and diagonally torque the bolts. all services and replenish the fuel and oil supplies.
 TS, TR, TX engines workshop manual 72

8. Flywheel Charge Windings

8.1 Charge Windings 8.2 Syncro Charge Windings

One of two types of charge windings may be fitted to TS and Maximum Output - voltage held at 13 Volts
TR engines.
1. Syncro - TS and TR up to, but not on, the engine numbers r/min Amps
shown.
2. Nicsa - TS and TR first fitted on the following engines: 1000 8.0
41 00433 TS1 41 00240 TR1
1500 12.5
41 01651 TS2 41 00281 TR2
41 01568 TS3 41 00301 TR3 2000 15.0
The Syncro and Nicsa charge winding components are not
interchangeable. 3000 17.0
The flywheel charge winding system comprises of three
components: a stator, rotor and regulator.
The rotor, in the form of permanent magnets, is attached to the Fault Finding
back of the flywheel. The most common faults associated with this system are dealt
The stator consists of coils of copper wire wound onto a with in the flow charts.
laminated iron core which is attached to the main bearing In cases where no electric start is possible reference should
housing. firstly be made to 'Starter Motor, Battery and Charge System
The stator output leads pass through the flywheel housing Fault Diagnosis Flow Chart', proceeding through to other charts
to the regulator unit which is attached to the outside of the if a charge system fault becomes evident.
housing. Should any of the output cables be attached to the In cases where a specific charging fault is known to exist refer
wrong terminal the regulator unit will be permanently damaged directly to the relevant flow chart.
when the battery is connected into the circuit. The necessary instruments and connection diagram to carry
out the tests are given in "Nicsa Charge Windings".
Battery Charge Indicator Light
Some engines may be fitted with an impulse transmitter and Stator Winding Resistance at 20°C (68°F)
warning light to provide an indication of when the system is
faulty. The transmitter is fitted between the rectifier/regulator Resistance
and the battery, during periods of running the indicator light Black to Black 0.22 - 0.33
will remain unlit unless there is a fault in the charging system.
The battery charge indicator light will always be lit to indicate Red to Red 2.00 - 3.00
a charging fault. The light will also be switched on with a fully
serviceable system under the following circumstances:
a.If the charge rate drops below 2 Amps at normal engine speed Stator Winding AC Open Circuit Voltages
and the battery is fully charged. at 20°C (68°F)
b.The charge rate drops below 4 Amps at idling speed.
The values given are True rms AC Volts.

r/min Black to Black Red to Red

1000 16 - 24 42 - 63

1500 23 - 35 62 - 93

2000 31 - 46 81 - 121

2500 37 - 56 99 - 149

3000 45 - 68 121 - 181

 TS, TR, TX engines workshop manual 73

T SERIES ENGINES WORKSHOP MANUAL

Syncro Fault Finding Flow Charts

cro au Fault
Syncro t Fin Finding
ing FlowFlow
Charts
Charts

83
 TS, TR, TX engines workshop manual 74
T SERIES ENGINES WORKSHOP MANUAL

Syncro Fault Finding Flow Charts

Syncro Fault Finding Flow Charts
c F tF Flo C

84
 T SERIES ENGINES WORKSHOP MANUAL

TS, TR, TX engines workshop manual 75

8.3 NICSA CHARGE WINDINGS Stator Winding Resistance at 20°C (68°F)
Fault Finding Leads Resistance
The most common faults associated with this
8.3 Nicsa
system are Charge
dealt with Windings
in the flow charts on the
Stator
YellowWinding
to Yellow Resistance at- 0.55
0.45 20°C (68°F)
following
Fault Findingpages. Red to one Yellow 0.225 - 0.275
Resistance
In cases where no electric start is possible reference Red to the other Yellow 0.225 - 0.275
Theshould
most common
firstly befaults
made associated
to "Starter with this system
Motor, areand
Battery dealt Yellow to Yellow 0.45 - 0.55
with in the flow charts on the following pages.
Charge System Diagnostic Flow Chart", proceeding
In through
cases where no electric
to other charts startif isa possible
charge reference should Stator Winding
system fault AC Open Circuit0.225
Red to one Yellow Voltages
- 0.275
firstly be made
becomes evident.to "Starter Motor, Battery and Charge System at 20°CRed(68°F)
to the other Yellow 0.225 - 0.275
Diagnostic Flow Chart", proceeding through to other charts if
In cases where a specific charging fault is known to
a charge system fault becomes evident. r/min Yellow to Yellow Red to Yellow
exist refer directly to the relevant flow chart.
In cases where a specific charging fault is known to exist refer
The following instruments are necessary to carry Stator
1000 Winding AC Open Circuit
30 - 34 13 -Voltages
17
directly to the relevant flow chart.
out the tests.
The following instruments are necessary to carry out the at 20°C
1500 (68°F) 43 - 49 21 - 24
1.0-20A moving coil ammeter.
tests.
2.0-20V moving coil voltmeter or a DC multimeter. 2000r/min 53Yellow
- 62 to Yellow 26 - 32 Red to Yellow
1.0-20A moving coil ammeter.
3.0-200V
2.0-20V movingmoving iron orvoltmeter
coil voltmeter or an AC
a DC multimeter. 2500 69 - 77 33 - 39
1000 30 - 34 13 - 17
multimeter.
3.0-200V moving iron voltmeter or an AC multimeter. 3000 82 - 92 30 - 46
4.0-5
4.0-5 Ohm Ohm
metermeter or multimeter.
or multimeter. 1500 43 - 49 21 - 24

Output Charge
2000 Rate - voltage
53 - 62 held at 26 - 32
12.5 Volts
2500 69 - 77 33 - 39
r/min
3000 82 - 92 Amps 30 - 46
1000 5.5 - 7.0

Output1500
Charge Rate - 10.0 - 11.5
2000
Voltage Held at 12.5 Volts13.0 - 14.5
Figure 7.3.1 Test 2500 15.0 - 16.5
Figure 7.3.1 TestInstrument Connection
Instrument Connection Diagram
Diagram X- X - r/min Amps
Removed B+ Battery Terminal
Removed B+ Battery Terminal 3000 16.0 - 17.5
1000 5.5 - 7.0

1500 10.0 - 11.5

2000 13.0 - 14.5

2500 15.0 - 16.5

3000 16.0 - 17.5

85
 TS, TR, TX engines workshop manual 76

T SERIES ENGINES WORKSHOP MANUAL

Nicsa Fault Finding Flow Charts

Nicsa Fault Finding Flow Charts
F l l

86
 TS, TR, TX engines workshop manual 77
T SERIES ENGINES WORKSHOP MANUAL

Nicsa Fault Finding Flow Charts

Nicsa Fault Finding Flow Charts
l i F

87
 TS, TR, TX engines workshop manual 78
T SERIES ENGINES WORKSHOP MANUAL

Nicsa Fault Finding Flow Charts

Nicsa Fault Finding Flow Chart

88
 TS, TR, TX engines workshop manual 79

9. Electrical Wiring Diagrams

9.1 Wiring Diagrams

Cable Colour Code for all Diagrams
All cables must be PVC insulated automobile cable to BS6862.
The cable sizes given relate to the cables between the control Red = Red
panel, or loose components, and the engine being a maximum Y = Yellow
length of 1.5 m (4.9 ft) with "Syncro' charge windings and 2.0 B = Black
m (6.6 ft) with 'Nicsa' charge windings, and the cables between
the battery and engine being a maximum length of 0.94 m Rectifier/regulator Terminals
(3.1 ft).
In cases where "Nicsa' charge windings are used without a BAT POS = Battery +
starter motor the cable size given relates to the cable between BAT NEG = Battery -
the regulator and battery being a minimum length of 0.5m
(1.6ft).
The small numbered 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 transmitter.
7. Oil pressure override push-button.
8. Oil pressure switch.
9. Regulator.
10. Starter battery.
11. Starter motor.
12. Control switch (5A rating) - not supplied.
13. Warning lamp.
14. Protective switch relay.
15. Starter solenoid.
16. Socket (16a) and Plug (16b).
All terminal arrangements are shown as viewed from the rear.
17. Heater plug.
18. Resistance.
 TS, TR, TX engines workshop manual 80

ct ical ENGINES
T SERIES Wiring WORKSHOP
i g MANUAL

90
 TS, TR, TX engines workshop manual 81

Elect i al
T SERIES ENGINES Wiring Diagram
WORKSHOP MANUAL

91
 TS, TR, TX engines workshop manual 82

ctr ca ENGINES
T SERIES Wi ing Diagrams
WORKSHOP MANUAL

92
 TS, TR, TX engines workshop manual 83

Electrical
T SERIES ENGINES Wiring MANUAL
WORKSHOP iagram

93
 TS, TR, TX engines workshop manual 84

T ect ica ENGINES

SERIES Wiring WORKSHOP
Diagrams MANUAL

94
 TS, TR, TX engines workshop manual 85

T SERIES ENGINES WORKSHOP MANUAL

95
 TS, TR, TX engines workshop manual 86

10. Technical Data

10.1 Engine Mechanical Data - TS

TS1 TS2 TS3
Injection Direct Direct Direct
Cooling Air Air Air
Cooling fan Flywheel Flywheel Flywheel
Direction of rotation - looking on flywheel end Anti clockwise Anti clockwise Anti clockwise
mm 95.25 95.25 95.25
Nominal bore - not to be used for machining purposes
in 3.75 3.75 3.75
mm 88.9 88.9 88.9
Stroke
in 3.50 3.50 3.50
Number of cylinders 1 2 3
litre 0.63 1.27 1.89
Cylinder capacity - total
in3
38.66 77.31 115.95
Compression ratio 15.5:1 15.5:1 15.5:1
m/sec 7.41 7.41 7.41
Mean piston speed at 3000r/min
ft/min 1458 1458 1458
bar 2.0 2.0 2.0
Lubricating oil pressure - mean
lbf/in 2
29.0 29.0 29.0
litre 2.7 4.0 5.5
Lubricating oil sump capacity pt 4.7 7.0 5.8
US qt 2.8 4.2 5.8
litre 8.25 / 13.5 13.5 13.5
Engine mounted fuel tank capacity pt 14.5 / 23.7 23.7 23.7
US qt 8.7 / 14.2 14.2 14.2
kg 132 132 132
Maximum crankshaft end thrust
lb 290 290 290
Number of flywheel gear ring teeth 110 110 110
Minimum idling speed r/min 850 850 850

Injector Setting Crankcase Vacuum

Injector Type bar Atmos Minimum Average
Bryce 195-210 192-207 mm WG 20.0 35.0
TS1
New 220-230 217-227 in WG 0.8 1.4
OMAP
Used 200-210 197-207 mm WG 25.0 45.0
TS2
New 195-210 192-207 in WG 1.0 1.8
Delphi
Used 200-210 197-207 mm WG 30.0 75.0
TS3
in WG 1.2 2.9
 TS, TR, TX engines workshop manual 87

10.2 Engine Mechanical Data - TR

TS1 TS2 TS3
Injection Direct Direct Direct
Cooling Air Air Air
Cooling fan Flywheel Flywheel Flywheel
Direction of rotation - looking on flywheel end Anti clockwise Anti clockwise Anti clockwise
mm 98.42 98.42 98.42
Nominal bore - not to be used for machining purposes
in 3.875 3.875 3.875
mm 101.6 101.6 101.6
Stroke
in 4.00 4.00 4.00
Number of cylinders 1 2 3
litre 0.773 1.55 2.32
Cylinder capacity - total
in3
47.17 94.35 141.52
Compression ratio 15.5:1 15.5:1 15.5:1
m/sec 8.47 8.47 8.47
Mean piston speed at 3000r/min
ft/min 1667 1667 1667
bar 2.0 2.0 2.0
Lubricating oil pressure - mean
lbf/in 2
29.0 29.0 29.0
litre 2.7 4.0 5.5
Lubricating oil sump capacity pt 4.7 7.0 5.8
US qt 2.8 4.2 5.8
litre 8.25 / 13.5 13.5 13.5
Engine mounted fuel tank capacity pt 14.5 / 23.7 23.7 23.7
US qt 8.7 / 14.2 14.2 14.2
kg 132 132 132
Maximum crankshaft end thrust
lb 290 290 290
Number of flywheel gear ring teeth 110 110 110
Minimum idling speed r/min 850 850 850

Injector Setting Crankcase Vacuum

Injector Type bar Atmos Minimum Average
Bryce 195-210 192-207 mm WG 20.0 35.0
TS1
New 220-230 217-227 in WG 0.8 1.4
OMAP
Used 200-210 197-207 mm WG 25.0 45.0
TS2
New 195-210 192-207 in WG 1.0 1.8
Delphi
Used 200-210 197-207 mm WG 30.0 75.0
TS3
in WG 1.2 2.9
 TS, TR, TX engines workshop manual 88

10.3 Engine Mechanical Data - TX

TS1 TS3
Injection Direct Direct
Cooling Air Air
Cooling fan Axial Axial
Direction of rotation - looking on flywheel end Anti clockwise Anti clockwise
mm 100.00 100.00
Nominal bore - not to be used for machining purposes
in 3.937 3.937
mm 101.6 101.6
Stroke
in 4.00 4.00
Number of cylinders 1 3
litre 1.59 2.39
Cylinder capacity - total
in3
97.77 146.65
Compression ratio 15.5:1 15.5:1
m/sec 10.16 10.16
Mean piston speed at 3000r/min
ft/min 2000 2000
bar 0.7 0.7
Lubricating oil pressure - minimum at 1000 r/min
lbf/in 2
10.0 10.0
bar 1.25 1.25
Lubricating oil pressure - minimum at 1500 r/min
lbf/in2 18.0 18.0
litre 4.0 6.0
Lubricating oil sump capacity pt 7.0 10.6
US qt 4.2 6.3
litre 25.0 25.0
Engine mounted fuel tank capacity pt 43.9 43.9
US qt 26.3 26.3
kg 132 132
Maximum crankshaft end thrust
lb 290 290
Number of flywheel gear ring teeth 110 110
Minimum idling speed r/min 850 850

Injector Setting Crankcase Vacuum

Injector Type bar Atmos Minimum Average
New 210-215 207-212 mm WG 25.0 45.0
Bryce TX2
Used 200 197 in WG 1.0 1.8
New 210-220 207-217 mm WG 30.0 75.0
OMAP TX3
Used 200 197 in WG 1.2 2.9
New 210-215 207-212
Delphi
Used 200 197
 TS, TR, TX engines workshop manual 89

10.4 Builds - TS
Where the build number is preceded by a 9 this indicates that the engine is either of a non-standard configuration, or contains
non-standard parts or accessories.
When new parts are required for such a build it is suggested that reference be made to Lister Petter Power Systems to determine
the exact engine specification and which parts are non-standard.
Where an engine number appears with GTS this indicates that it was built into a generating set by Lister Petter Power Systems.
Some builds may not be available in all cylinder configurations.

Build Detail
01 Variable speed up to 2500 r/min (2000 r/min on TS1) with no overload
02 Variable speed up to 2500 r/min (2000 r/min on TS1) with no overload
03 Variable speed up to 3000 r/min with no overload, high speed flywheel
04 Variable speed up to 3000 r/min with no overload
05 Variable speed up to 2500 r/min with overload, provision for hydraulic pump
06 Variable speed up to 2500 r/min (2000 r/min on TS1) with overload, provision for hydraulic pump
07 Variable speed up to 2500 r/min (2000 r/min on TS1) with overload, provision for hydraulic pump
08 Genset Build, 1500 r/min with overload
09 Fixed speed 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 fanshroud
18 Genset Build, up to 2200 r/min with no overload
40 Marine Build, variable speed - up to 2600 r/min with no overload
41 Marine Build, variable speed- up to 2000 r/min with no overload
42 Marine Build, variable speed - up to 2600 r/min with no overload
43 Marine Genset Build, fixed speed 1500/1800r/min with overload
60 Variable speed - up to 2500 r/min with no overload, low noise Q Build
61 Variable speed - up to 2500 r/min* with no overload, low noise Q Build
62 Fixed speed - 1500 r/min with overload, low noise Q Build
63 Fixed speed - 1500 r/min with overload, low noise Q Build
64 Fixed speed - 1800 r/min with overload, low noise Q Build
65 Fixed speed - 1800 r/min with overload, low noise Q Build
66 Fixed speed - 1500 r/min with overload, low noise Q Build, provision for hydraulic pump
78 Fixed speed - 1500 r/min with overload
101 Fixed speed - 1500 r/min with overload
102 Variable speed - 2500 r/min with no overload
103 Variable speed - 2500 r/min with no overload
104 Variable speed - 2500 r/min with overload
 TS, TR, TX engines workshop manual 90

10.5 Builds - TR
Where the build number is preceded by a 9 this indicates that the engine is either of a non-standard
configuration, or contains non-standard parts or accessories.
When new parts are required for such a build it is suggested that reference be made to Lister Petter Power Systems to
determine the exact engine specification and which parts are non-standard.
Where an engine number appears with GTS this indicates that it was built into a generating set by Lister Petter Power Systems.
Some builds may not be available in all cylinder configurations.

Build Detail
01 Variable speed up to 2500 r/min (2000 r/min on TR1) with no overload
02 Variable speed up to 2500 r/min (2000 r/min on TR1) with no overload
03 Variable speed up to 3000 r/min with no overload, high speed flywheel
04 Variable speed up to 3000 r/min with no overload
05 Variable speed up 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 r/min with overload
10 Genset Build - 1800 r/min with overload
11 Genset Build - 1800 r/min with overload
12 Fixed speed - 3000 r/min with overload, high speed flywheel
13 Fixed speed - 3000 r/min with overload, high speed flywheel
14 TR1 - Variable speed - up to 2500 r/min with overload
TR2 - Variable speed - up to 2000 r/min with no overload
15 TR1 - Variable speed - up to 2500 r/min with overload
TR2 - Variable speed - up to 2000 r/min with no overload
16 Variable speed - up to 2500 r/min with overload, sheet metal fanshroud
18 Genset Build - up to 2200 r/min with no overload
50 Fixed Speed - up to 2500 r/min with no overload
78 Fixed speed - 1500 r/min with overload
101 Fixed speed - 1500 or 1800 r/min with overload
 TS, TR, TX engines workshop manual 91

10.6 Builds - TX
Where the build number is preceded by a 9 this indicates that the engine is either of a non-standard configuration, or contains
non-standard parts or accessories.
When new parts are required for such a build it is suggested that reference be made to Lister Petter Power Systems
to determine the exact engine specification and which parts are non-standard.
Where an engine number appears with GTS this indicates that it was built into a generating set by Lister Petter Power Systems.
Some builds may not be available in all cylinder configurations.

Build Detail
01 Variable speed up to 2500 r/min with no overload
02 Variable speed up to 2500 r/min with overload
03 Variable speed up to 3000 r/min with no overload
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 Fixed speed - 3000 r/min with no overload
13 Variable speed up to 2900 r/min with no overload
14 Variable speed up to 2500 r/min with no overload
15 Variable speed up to 2500 r/min with no overload
16 Variable speed up to 2500 r/min with no overload
17 Variable speed up to 2500 r/min with no overload
20 Variable Speed - 2800 r/min with no overload, compressor build
21 Variable Speed - 2500 r/min with no overload, compressor build
51 Fixed speed - 1800 r/min with overload
52 Variable speed - 2000 r/min with no overload
78 Variable speed - 1500 r/min with no overload
 TS, TR, TX engines workshop manual 92

11. Conversion Factors

11.1 Formulae
BMEP Piston Speed
kW x 60000 x 20000 stroke (mm) x r/min
Bar = metres/second =
Cylinders x r/min x bore area (mm ) x stroke (mm)
2
30000

bhp x 792000 stroke (in) x r/min

lbf/in2 = feet/minute =
Cylinders x r/min x bore area (in ) x stroke (in)
2
6

Torque Mechanical Efficiency

kW x 9549 x load factor bhp x 100
Nm = %=
r/min ihp

bhp x 5252 x load factor Cyclic Irregularity

lbf ft =
r/min
max flywheel speed - min flywheel speed
Load factor: mean flywheel speed
No overload = 1,0 10% overload = 1,1
Power
Fuel Consumption r/min x torque(Nm)
A Specific Gravity of 0.84 is assumed kW =
9549
g/kWh x kW x load factor
l/h = r/min x torque (lb ft)
840 bhp =
5252
lb/bhp h x bhp x load factor
pt/h =
1.05 Temperature
The temperature unit in most practical use in any countries is
Load Factor - Naturally aspirated engines the degree Celsius (°C), however the terms Centigrade (°C) and
100% = 1.0 50% = 0.58 Fahrenheit (°F) are still in use. The Fahrenheit scale is not formally
75% = 0.78 25% = 0.40 defined but it is generally recognized that the temperature
difference of 1°F is equal to five ninths of the temperature
Load Factor - Turbocharged engines difference of one degree °C.
100% = 1.0 50% = 0.55 1°F = 9/5 °C + 32
75% = 0.76 5% = 0.38 1°C = 5/9 (°F - 32)
The refinements of temperature scales are abstruse, but for
Oil Consumption most practical purposes the following relationships apply. For
the same temperature, if t and Ø represent the temperature on
A Specific Gravity of 0.886 is assumed the Fahrenheit or Celsius scales, similarly rand T the Rankine
(absolute Fahrenheit °R) and Kelyin (absolute Celsius K)
g/kWh x kW
litres/24hours = temperatures, respectively, then
4922 Ø = 5/9 - (t - 32)
T = 5/9 (t + 459.67)
lb/bhp h x bhp r = t + 459.67
pints/24hours = The temperature at the triple point of water, (where water, ice
0.15
and water vapour are in equilibrium) is very slightly removed
from the temperature of the melting point of ice at atmospheric
pressure (the ice point).
 TS, TR, TX engines workshop manual 93

Calorific Value Of Fuel Intermittent Power

kJ/kg - 42800 1.1bhp = 1.115CV = 0.821kW
Btu/lb - 18400 1.1kW = 1.474bhp = 1.495CV
1.1CV = 1.085bhp = 0.810kW
Air Density 1CV = 1CH = 1PS

= 1.205kg/m3 = 0.0752Ib/ft3
Continuous Power
1bhp = 1.014CV = 0.746kW
1kW = 1.340bhp = 1.359CV
1CV = 0.986bhp = 0.736kW
1CV = 1Ch = 1PS

11.2 Conversion Factors

The conversion tables in this section have been derived from BS350.
To use the tables the left hand base unit is multiplied by the relevant conversion factor given in one of the right hand columns.
For example:
To convert 6.28 metres to inches using the 'Length' Table
6.28 x 39.3701 (factor from 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 UK gallon = 4.5464 8.0000 9.6076
1 US pint = 0.4732 0.8327 0.1041
1
Also known as the Imperial pint 1 UK gallon = 1.2009 US gallon
2
Also known as the Imperial gallon 1 US gallon = 0.8326 UK gallon

Volume
cubic metre, m3 litre, l cubic inch, in3 cubic foot, ft3
1 cubic metre = 1000.0 61023.8 35.3147
1 litre = 0.0010 61.0238 0.0353
1 cubic inch = 1.6387 x 10 -5 0.0164 5.7870 x 10 -4
1 cubic foot = 0.0283 28.3168 1728.0

1dm = 1litre
3
1 in = 16.3871 cm
3 3
 TS, TR, TX engines workshop manual 94

Linear Velocity
metre per second, m/s foot per second, ft/s foot per minute, ft/m inch per second, in/s
1 metre/second = 3.2808 196.850 39.3701
1 foot/second = 0.3048 60.000 12.0000
1 foot/minute = 0.0051 0.0167 0.2000
1 inch/second = 0.0254 0.0833 5.0000

Rate of Flow - Mass

kilogram per second, kilogram per hour, pound per second, pound per hour,
kg/sec kg/hr lb/sec lb/hr
1 kilogram/second 3600.0 2.2046 7936.6
1 kilogram/hour 2.7777 x 10 -4
6.1239 x 10 -4
2.2046
1 pound/second 0.4535 1632.9 3600.0
1 pound/hour 1.2599 x 10 -4 0.4535 2.7777 x 10 -4

Rate of Flow - Volume

cubic metre per second, litre per second, cubic foot per second, UK gallon per second,
m3/sec l/sec ft3/sec gal/sec
1 m3/sec 1000.0 35.3147 219.969
1 l/sec 0.0010 0.0353 0.2200
1 ft /sec
3
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
kilogram-force per
newton per square pound-force per square pound-force per square
square centimetre,
millimetre, N/mm2 inch, lbf/in2 foot, lbf/ft2
kgf/cm2
1 N/mm2 10.1972 145.038 20885.4
1 kgf/cm2 9.8066 x 10 -2 14.2233 2048.16
1 lbf/in2 6.8947 x 10 -3 0.703 144.000
1 lbf/ft 2
4.7880 x 10 -5
4.8824 x 10 -4
6.9444 x 10 -3

Pressure - Table 2
kilogram-force per
pound-force per square
bar, bar atmosphere, atm square centimetre,
inch, lbf/in2
kgf/cm2
1 bar 0.9869 1.0197 14.5038
1 atm 1.0132 1.0332 14.6959
1 kgf/cm 2
0.9807 0.9678 14.2233
1 lbf/in 2
0.0689 0.0680 0.073
 TS, TR, TX engines workshop manual 95

Pressure - Table 3
inch of water, foot of water, millimetre of mercury, inch of mercury,
in H2O ft H2O mm Hg in Hg
1 in H2O 0.0833 1.8683 0.0735
1 ft H2O 12.000 22.4198 0.8827
1 mm H2O 0.5352 0.0446 0.0394
1 in Hg 13.5951 1.1329 25.400

1 in H2O = 0.00248 bar

Torque (Moment of Force)

newton metre, kilogram-force metre, pound-force foot, pound-force inch,
Nm kgf m lbf ft lbf in
1 Nm 0.1020 0.7376 8.8507
1 kgf m 9.8066 7.230 86.8507
1 lbf ft 1.3558 0.1382 12.000
1 lbf in 0.1130 0.0115 0.0833

The kilogram is known as the kilopond (kp) in Germany. 1 kgf m = 1 kp m

Force (Mass x Acceleration)

newton, kilogram-force, pound-force, poundal,
N kgf lbf 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/s² 1 N = 1 kg m/s²

Energy - Table 1
kilowatt hour, kilogram-force metre, foot-pound force, horsepower hour,
kWh kgf m ft lbf hp h
1 kWh 3.6709 x 105 2.6552 x 106 1.3410
1 kgf m 2.7240 x 10 -6
7.2330 3.6530 x 10 -6
1 ft lbf 3.7661 x 10 -7 0.1382 5.0505
1 hp h 0.7457 2.7373 x 106 1.98 x 106

Energy - Table 2
joule, horsepower hour, calorie, British thermal unit,
J hp h cal Btu
1 joule 3.7250 x 10 -7 0.2388 9.4781 x 10 -4
1 hp h 2.6846 x 106 641186 2544.43
1 cal 4.1868 1.5596 x 10 -6
3.9683 x 10 -3
1 Btu 1055.06 3.9301 x 10 -4 251.996
 TS, TR, TX engines workshop manual 96

Power - Table 1
kilowatt, metric horsepower, brake horsepower, British thermal unit per
kW CV bhp hour, Btu h
1 kW 1.3596 1.3410 3412.14
1 CV 0.7355 0.9863 2509.63
1 bhp 0.7457 1.0139 2544.43
1 Btu h 0.00029 3.9846 x 10 -4 3.9301 x 10 -4

Power - Table 2
watt, kilo calorie per hour, British thermal unit,
W k cal/h 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 pounds per Cherval grams per kilowatt grams per Cheval
hour, Vapeur hour, hour, Vapeur hour,
lb/hp h lb/CV h g/kW h 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 2.205 x 10 -3 1.3600

The Cheval Vapeur (CV) is also known as the metric horsepower (1CV = 1CH = 1PS)
1 lb = 453.592 grams
 TS, TR, TX engines workshop manual 97

12. Index

A E
Agglomerator 23 Electrical Wiring Diagrams 79
Air Baffles 14 Electric Start 55
Air Cleaner 12 End Cover 21
Air Cowling 14 End Cover Oil Seal 22
Air Density 93 Engine Control 34
Associated Publications 2 Engine Features 9
Axial Fan 14 Engine Fluids 50
Excess Fuel Device 53
Excess Fuel Trip - TX 32

B
Battery Charge Light 72
Battery Cold Cranking Performance 11
F
Battery Details 10 Fanshroud 40
Battery Polarity 10 Flywheel 40
Belt Tension 15 Flywheel Housing 41
Breather 15 Formulae 92
Builds - TR 90 Fuel Filter 22
Builds - TS 89 Fuel Injector 24
Builds - TX 91 Fuel Lift Pump 23
Fuel Pump 25
Fuel Pump Timing 27
Fuel Pump Timing Gauge 28
C Fuel Pump Timing Tables 28
Camshaft 35 Fuel Specification 51
Camshaft Bushes 37 Fuel Tank 22
Camshaft Endfloat 36
Camshaft Gearwheel 36
Charge Windings 7
Cold Cranking Performance 11
G
Cold Start Aid 12 Gear End Cover 21
Connecting Rod 39 Gear End Drives 46
Conversion Factors 92 Genuine Parts 56
Crankcase Breather 15 Governing Ranges 29
Crankshaft 42 Governor 'A' Setting 31
Crankshaft End Float 44 Governor Combination Code 30
Crankshaft Main Bearings 44 Governor 'E' Setting 31
Crankshaft Pulley 21 Governor 'G' Setting 32
Cylinder Barrel 38 Governor Modifications 29
Cylinder Bore Wear 58 Governor 'Q' Setting 31
Cylinder Cooling Fins 14 Governor Weights 30
Cylinder Head 15
Cylinder Head Clearance 16
Cylinder Head Cover 15
H
Hand Starting 54
Head Clearance 16
D
Decompressor 20
Dimensions of Wearing Parts 58
Dismantling and Rebuilding 12 I
Drive Belt Tension 15 If Problems Occur 5
impulse transmitter 72
 TS, TR, TX engines workshop manual 98

Injector Back Pressure 25

Injector Setting 86
R
Introduction 5 Rate of Flow - Volume 94
Rocker Stub Shaft 17
Rotary Oil Seal 49
Routine Maintenance 56
J
Jointing Compounds 58
S
Safety Precautions 6
L Safety Precautions and Safe Working Practices 6
Lift Pump 23 Safety Symbols 8
Limited Excess Fuel Trip 32 Safe Working Practices 6
Linear Velocity 94 Spanner Torque Settings 57
Liquid Capacity 93 Speed Adjustment 34
Long Term Storage 63 Speed Control Lever 35
Lubricating Oil 50 Starter Battery Precautions 7
Starting 54
Starting Handle 53
Stopping 55
M Sump 47
Sump Capacity 47
Main Bearing Housing 41
Syncro Charge Windings 72
Main Bearings 44
Maintenance - Schedule Hours 56
Manifold 13
Manifold Loading 12 T
Manifolds 13
Technical Data 86
Temperature 92
Timing 27
N Timing Gauge 28
Timing Tables 28,?33
Nicsa Charge Windings 75
Torque Settings 57
Troubleshooting 64

O
Oil Pump 48 U
Oil Seals 48
Undersize Items 58
Oil Specification 51
Using this Workshop Manual 5
Oil Strainer 48
Oil Sump 47
Operating Instructions 53
V
Valve Clearance 20
P Valve Guides 18
Valve Rocker Stub Shaft 17
Piston 39
Valves 18
Piston Rings 39
Valve Seats 19
Piston Ring Wear 58
Volume 93
Polarity 10
Precautions 7
Priming the Fuel System 23
Publications 2 W
Pump Timing 27
Pump Timing Gauge 28 Wearing Parts 58
Pump Timing Tables 28 Wiring Diagrams 79
TS, TR, TX engines workshop manual 99
 TS, TR, TX engines workshop manual
P027-08270 | edition 8 | April 2021 © Lister Petter Power Systems

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