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Generators & Electric Motors General Discussion

3hp Lister No.CS25358 Spec. 28/10


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  #21  
Old 07-27-2019, 09:05:39 AM
AngrySailor AngrySailor is offline
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Plan today is to finish cleaning her up,clean the water jackets and bolt her to the skid. I need to get some flat belting to couple the generator. I think I have some lacing kicking around and some surplus gilmer belts from an equipment lot a friend bought, was thinking to lace two together and run them on the smooth side for testing.
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Old 07-27-2019, 03:33:28 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Cleaning done for the most part. Skid all bolted together. Just run to get more hardware to bolt her down. Pics in coming soon. Cleaned A PILE of crud from
The water jackets also
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  #23  
Old 07-27-2019, 04:27:05 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Some pics. Fired her up for about 30 seconds once I bolted her down. I hope the weight of the generator, fuel and cooling tank help because on the smooth cement she was marching for the door

I知 planning to machine three or four holes through the broken part of the flywheel, then use that as a drill guide, drill and tap the flywheel to bolt the broken piece back in. I plan to use Allen head cap screws but when I counterbore for the head I will leave it shallow, then I can carefully grind the protruding head off flush and will be a fairly invisible repair.

Will finish cleaning the scum off the generator this weekend and get it mounted. I think a 30? Gallon barrel (one that gear oil/grease and chain commonly comes in) will work good size wise to fit on the cart for cooling. I知 looking for one or maybe a milk can... I think I値l make a screen cooler top with a circ pump. That痴 all easily changed though, just going for proportional looks right now, if I actually want to use it I would need to source a 36v battery bank and big azz inverter so for now she痴 mostly display. Maybe I値l build a DC load bank to grunt her down for show until I have a use for it.
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  #24  
Old 07-27-2019, 06:41:49 PM
Railroads Railroads is offline
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Quote:
Originally Posted by AngrySailor View Post
Some pics. Fired her up for about 30 seconds once I bolted her down. I hope the weight of the generator, fuel and cooling tank help because on the smooth cement she was marching for the door

I知 planning to machine three or four holes through the broken part of the flywheel, then use that as a drill guide, drill and tap the flywheel to bolt the broken piece back in. I plan to use Allen head cap screws but when I counterbore for the head I will leave it shallow, then I can carefully grind the protruding head off flush and will be a fairly invisible repair.

Will finish cleaning the scum off the generator this weekend and get it mounted. I think a 30? Gallon barrel (one that gear oil/grease and chain commonly comes in) will work good size wise to fit on the cart for cooling. I知 looking for one or maybe a milk can... I think I値l make a screen cooler top with a circ pump. That痴 all easily changed though, just going for proportional looks right now, if I actually want to use it I would need to source a 36v battery bank and big azz inverter so for now she痴 mostly display. Maybe I値l build a DC load bank to grunt her down for show until I have a use for it.
Lookin good to me. I think a 30 gal drum would work and look just fine.

Me, I'd be interested in having a large round fuel tank for hours and hours of run time if I go with a Lister as a battery charger. They are ideal for that task. Somethin like this. http://www.agraonline.com/dieselgen.html

Robert
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Old 07-27-2019, 06:59:35 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

I’m planning to use the original tank for the time being but that pic looks nice also and as you said better for long runs. I bet the three or so gallons the original holds would last overnight no problem though. This could be a neat addition to a solar/battery bank down the road... in the last 6 years I’ve had two 4+ day power outages and many shorter ones...
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  #26  
Old 07-27-2019, 07:04:06 PM
Railroads Railroads is offline
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Quote:
Originally Posted by AngrySailor View Post
I知 planning to use the original tank for the time being but that pic looks nice also and as you said better for long runs. I bet the three or so gallons the original holds would last overnight no problem though. This could be a neat addition to a solar/battery bank down the road... in the last 6 years I致e had two 4+ day power outages and many shorter ones...
I have in my mind the need for 5 gallons of fuel in the tank. I guess it has to do with not wanting to worry about having to go and get more diesel or the possibility of not having enough on hand. 5 in the tank should run the Lister for a couple days at part load.

Robert
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  #27  
Old 07-27-2019, 07:44:49 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

I heat my house with air to air heat pumps mostly, but I do have an oil furnace with a wood boiler. I always have 250 gal of diesel on hand so it would be nice to be able to make use of the Lister during an outage. Like I said that would involve a decent sized inverter and battery bank though... maybe in the near future. There are a few guys local who seem pretty knowledgeable about solar/off grid power, I’ll look into making her usefull
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  #28  
Old 07-27-2019, 08:49:07 PM
Railroads Railroads is offline
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Quote:
Originally Posted by AngrySailor View Post
I heat my house with air to air heat pumps mostly, but I do have an oil furnace with a wood boiler. I always have 250 gal of diesel on hand so it would be nice to be able to make use of the Lister during an outage. Like I said that would involve a decent sized inverter and battery bank though... maybe in the near future. There are a few guys local who seem pretty knowledgeable about solar/off grid power, I値l look into making her usefull
Maybe not, That Lister can drive a 3KW ST generator head. You could either run batteries/inverter, or generate AC and run part of your house off of AC. The ST is cheaper to import direct from China. But, You could give Central Georgia Generators a call and see what one shipped to Canada would cost? CGG sells them on Ebay time to time. This one has AVR fitted. They have them with and without AVR boards.

https://www.ebay.com/itm/3KW-ST-Gene...4383.l4275.c10

Robert
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Old 07-27-2019, 09:46:52 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

I have a hopper-cooled 3/1, same as.
One tidbit I picked up regarding corrosion in the head was to put oil in on top of the hopper after it's up to temp, then drain out the bottom - the warm iron will take a film of oil as it goes past.

The manual (I can't find the link now sorry - I do have it on my PC) Specifies how high above the hopper should be for effective thermosiphon. vis:
Quote:
Originally Posted by Lister Manual
WATER TANK
The tank should be so arranged that the outle, about 3 (75 mm) from the
bottom of the tank, is not lower that the inlet at the bottom of the engine cylinder,
unless a circulating pump is fitted. The connection from the top of the cylinder to
the top of tank must slope upwards ot every point, say 1 in 8, and on no account must
there be any dip in this pipe.

[hopper img]


It is essential that the water temperature at the engine be maintained
between 165ー F and 185ー F (75ー and 85ー C) by checking over a reasonable period
of normal running and adjusting the tap in the pipe connection so that the
amount of water circulating is restricted and the water temperature maintained
as recommended. Thes should be carried out at the NORMAL load of the
engine. This control can be effected outomatically by fitting a thermostat in
the pipe line which is a simple and inexpensive matter. (The temperature
of the water measured in the mouths of the pipe at the top of the Cooling
Tank should be from 160ー F to 175ー F on the normal installation. This will
vary in different cases.)
Keep water level above top connection in tank.
Before starting always see that there is no obstruction to water circulating
and that 3-way tay is on.
Turn on 3-way top before refilling tank so as to avoid air locks.
In frostyweather drain cylinder jacket by turning 3-way tap so that
cylinder and pipes are drained, but water remains in tank. Also open water
jacket drain cocks..


REMEMBER THAT A DIESEL ENGINE IS A 滴EAT ENGINE
AND THEREFORE IT SHOULD BE RUN HOT

The water outlet pipe from the cylinders shoud be TOO HOT TO HOLD
BUT THE WATER SHOULD NOT BOIL
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  #30  
Old 07-29-2019, 11:14:06 AM
AngrySailor AngrySailor is offline
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Here痴 a pic of the chipped flywheel. I plan to repair by bolting It in strategically with counter bored heads to hide the repair. Maybe I値l get to that this evening, we致e got good weather here and some outdoor jobs need attention.

Also started cleaning up the generator, lots of original paint there also. I will remove the screens to clean and check internals also. Bearings feel perfect, spins free.

I may need to put another plank under the center of the skid to tie all the 2x8痴 together. When she runs she flexes the two boards she痴 mounted on every firing pulse. Not too bad but could be more rigid.
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  #31  
Old 07-29-2019, 11:21:20 AM
Railroads Railroads is offline
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

I wonder if there is a replacement flywheel available? Since Lister clones are common in India, it might be possible to obtain a new cast flywheel.

Robert
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  #32  
Old 07-29-2019, 11:32:17 AM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

There probably is but this engine is pretty unmolested, I’m not sure a new
Flywheel would look identical and would not have the original paint... the broken piece fits perfectly, I don’t want to attempt welding or brazing for the same reason of damaging paint by the required preheat. I’m planning 3-4 1/4” grade 8 cap screws at angles to hold it in place. I really have nothing to loose as I can just plug the holes and leave the piece off if things go bad. I will post pics of the process when I start.
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Old 07-30-2019, 05:28:17 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Cast iron is right up there on my least-favorite-things to weld. But it is doable 'cold'.

Using CI/nickel MMAW rods, do short stitches, not much more than tacks, and peen them till cool. Then move to the other end of the repair and do the same.
The peening helps prevent stresses developing, and "pushes" the deposit into the grain.

I don't TIG, but if you have access to one, and some old CI piston rings, you can get a damn-near invisible weld using the rings as filler rod.
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  #34  
Old 07-31-2019, 02:06:52 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

The cast TIG may work for hiding a repair but it does take a good bit of heat to flow a puddle and the penetration will be very shallow which is why I’m thinking to use some mechanical means to hold the piece in. I don’t want it to fly off running!
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Old 08-01-2019, 06:23:40 AM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

I have a suggestion. Clamp broken piece on. Drill 1 hole inwards from other face with tap drill size. Remove broken piece. Drill clearance hole through flywheel. Drill counterbore/deep countersink on inside flywheel face to accept a socket head cap screw. Tap broken piece. Bolt together with loctite. JB weld to disguise cracks and fill SHCS head (only after successfully running and meeting your approval)
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Old 08-07-2019, 11:41:46 AM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

That’s a good idea, very similar to what I was planning but from the inside... I may have to pull the flywheel to execute this method. Would prefer to drill that depth on the milling machine as it would be almost 3” deep hole and would hate to wander “out” the surface of the flywheel... interesting...

I’ve been real busy last few days with stuff around the house and also took a day to attend a tractor pulling event over the weekend, then went for a “3 hour tour” with friends in their pleasure boat. We were able to paddle in at least...
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Old 08-09-2019, 05:56:55 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Added two 2x4痴 to tiethe deck boards together. The engine was flexing the wood pretty good. This made a big difference. I fired her up for a minute just now and much less movement. Also mounted the generator, tried to split the difference between the engine mount bolts and the generator mounts with the 2x4 but I知 a little tight for the nuts and washers for the generator... nothing a little wood 堵oing away won稚 solve though.
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Old 08-09-2019, 06:07:00 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Cleaned up the water jacket covers and made some new gaskets too.
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Old 08-12-2019, 12:59:59 AM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Buttoned up those water jackets today, cut the Center of those gaskets out which was different from the original or what was there anyways... the full gasket seemed to hold water behind it and I plan to drain this engine when not in use so I cut that center out to let things dry/not rust/freeze.

I filled the jacket with water and she ran near 20 mins before I figured was time to shut down. I could still hold my hand on the upper pipe and no boiling. Just nice to give her a run long enough to warm through. Hand held tach said 400 rpm, here痴 a short video

https://youtu.be/Ss5qm5iRVPw
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Old 08-12-2019, 12:02:42 PM
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Default Re: 3hp Lister No.CS25358 Spec. 28/10

Nothing wrong with 3HP for an awesome battery charger..
Music to my ears.. I'm officially completely jealous
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