Petter Ava1 Manual

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My Johnson 2HG Dumper Restoration Project

I got my dumper on 31/01/06 for £100. It was mechanically sound but in need of a total restoration and repaint. It's a manual tip variety and starts with a handle. I thought it was a nice restoration project because it's quite unusual as it has rear wheel drive unlike most dumpers which have the driving wheels under the skip. Once completed, the dumper can tow my Fleming Micron digger around, move spoil and be used for bringing back firewood.

I had no idea who made the dumper when I got it. Dumpers are often hard to identify so I put a free advert and picture in Classic Plant and Machinery magazine in the hope of finding out a bit more. I am grateful to Alistair who got in touch and who was an apprentice for Johnson's in the 70's. He told me the dumper is a Model 2HG. The 'G' denotes gravity tip as opposed to hydraulic. It was made by Johnson Machinery Ltd who were based in Adswood, Stockport, Cheshire. Martin very kindly telephoned and posted me a photocopy of the workshop manual. Jim Perkins (of Petter fame) also responded to the advert and was able to tell me from the engine number that the engine was built in November 1967. I think we can safely assume that the dumper is a 1967 or 1968 machine. That makes it just a few years older than me!

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Basic information about my dumper

  • Johnson Model 2HG
  • 2 wheel drive
  • 1 ton capacity when fully loaded
  • Petter PH1 single cylinder diesel engine number 35688PH1 Model 52. 6.75 hp at 1650 rpm.
  • 3 speed gearbox with reverse
  • Rod operated drum brakes on the rear axle only
  • Probable year of manufacture 1967 or 1968
  • Original colour - Orange
  • Early models had a toothed rubber drive belt, others (including mine) have a chain
  • Some 2HG dumpers have the Petter AVA1 engine, some the Petter PH1

Detailed technical information and sales literature (all in PDF format)

  • Workshop manual and parts list (45 pages) - click here
  • Original Sales Brochure - click here
  • Petter PH1 Engine Datasheet - click here
  • Petter PH1 Operators Handbook - click here
  • Petter PH1 Workshop Manual - click here
  • Petter PH1 Parts List and Exploded Diagrams - click here

The restoration

I had good intentions of starting to restore the dumper fairly soon after getting it. However, I was so busy with other jobs and family commitments it didn't actually enter the garage until 26/10/08 and work started February 2009. One of the problems was tidying the garage out to make space which took a long time as I had to get rid of 12 years worth of accumulated junk. I did use the dumper in its un-restored state in 2007 and 2008 for bringing back a large load of firewood. This confirmed to me just how useful it is.

Although the dumper looks awful it starts and works perfectly well. Here it is loaded with logs and sporting its new air filter bowl which my mate Rodney kindly donated.

Here's the dumper finally in the garage. I cannot believe that I have actually managed to make enough space for it!

Aim of the restoration

The aim of the restoration is to get the dumper back to good useable condition so it can be preserved, not to turn it into 'as new' condition.

Plan of works

  • The rear chassis is not saveable so it needs to be stripped of all parts and a new chassis fabricated using the old one as a pattern. This will mean separating the two halves of the dumper.
  • Clean, repair and paint all parts as necessary before refitting them
  • Build some mudguards as illustrated in the Workshop Manual as the originals have disappeared
  • Make a new handbrake lever as the original has disappeared
  • Get a new seat
  • Repair the tinwork on the engine, clean and repaint it and give it a service
  • The front chassis is saveable and needs to be cleaned and repainted
  • The skip needs repairing and repainting (I think it can be saved at this stage but will let you know)
  • Fit 3 new tyres (already done 1 as it was bald and I don't like getting stuck)
  • Investigate getting a number plate for the dumper and the cost of tax and insurance

Stripping the rear chassis

The footplates are badly rusted and replacements will need to be fabricated.

Removing the seat and footplates was the first job I tackled.

Most of the bolts on the dumper are so badly corroded that they just have to be cut off with the angle grinder. Check out the size of the giant rust flake!

The rear chassis is made of 4x2 inch channel which is too rusty to save. The bucket was to catch the oil from the chain case. All that came out was grey oily water!

Here's the clutch on the Petter PH1. Its a Borg and Beck and looks in pretty good condition. The engine is unbolted but I need to borrow an engine crane to lift it off.

Here's the gearbox and chaincase removed and stored. The cardboard box contains any bolts that are re-useable.

Here I am cutting the bolts on the steering box bracket. These were hard to get to with the grinder so I resorted to a cold chisel and hammer. This ended the work for the first week

We have borrowed Gordon's engine crane and here the boys are helping to lift the engine off the dumper. Its dry weight is 185KG according to the Petter Data Sheet from Jim Perkins.

The Petter PH1 safely lowered to the floor where it can sit while the new chassis is fabricated.

Under the engine there was a nice area of original Johnson orange paint. Note the elongated mounting holes so the chain (or belt) tension can be adjusted.

Removing the pedal assemblies was fairly easy as most of the bolts would undo. I had to drill out one rivet and heat the end of the throttle linkage to knock it off.

The pedals are all heavy duty forgings and with a bit of cleaning and repair will be fine.

One side of the axle is leaking oil which has gone onto the brake linings. That's going to need attention. See how rusty the axle bolts and chassis rails are on this side.

Petter Ava1 Manuals

The axle was lowered after grinding off the nuts. I now need to tidy up the removed parts, move the dumper forward slightly and separate the front and back sections.

Splitting the dumper in half

Before working under the dumper I ensured that the front wheels were chocked and the rear chassis was safely supported on wooden blocks. I also took the precaution of tying a rope from the skip to the front chassis to make absolutely certain it couldn't tip if the rather worn release mechanism did suddenly let go while I was underneath. The curved runners would make a deadly guillotine for any fingers in the way.

Petter ava1 workshop manual

The large castle nut on the pivot shaft was hard to remove as it had a split pin through it which was rusted solid. I broke the split pin off and undid the nut with a large socket.

The steel collar. This had a completely rusted grub screw so I had to cut it off with the angle grinder. I will either get a replacement made or weld the collar back together.

Once the nut and collar were removed I supported the rear chassis with the engine crane and using a crowbar levered the 2 halves of the dumper apart.

Rear chassis propped up ready for measuring up for the new steel.

Front half of the dumper carefully supported by axle stands and wooden blocks.

This is the cutting list for the steel I need to make the rear chassis. I accidentally left off the 35 5/8' piece of channel. As Homer Simpson would say, 'DOHHHHH'!

The Steel

I ordered the steel from D C Ould at Roche. They could supply everything except the chequer plate and cut the channel and flat bar to length on their oil fed saw so it is all nice and square. This will save me a lot of work. I collected it on 27/02/09 and over the following weekend started drilling the holes prior to welding the chassis together. Unfortunately I had left one piece of channel off the list by mistake. Rather than driving all the way to Ould's again I popped into a local fabricators and luckily they had a piece of channel in their off-cuts which I purchased for £5.

Petter Ava1 Manual

I have managed to get a small piece of chequer plate from another local fabricators. They only charged me £5 for it which is great as I now have all the steel for the rear chassis.

I have made a start on drilling the new pieces of steel so they have all the right holes in the same places as on the old chassis.

I'm using the old chassis as a sort of workbench and laying the new steel out on top helps with measuring and marking out the holes with a tape, square and centre punch

Checking the new holes for accuracy by offering up the old removed parts.

The nice thing about working on the dumper is that all the holes are set out in easy Imperial measurements. Good old British pre-computer manufacturing

Having finished drilling all the steel, I clamped the four main parts to the old chassis. I used all my clamps and some borrowed ones and then resorted to bolting scraps of metal through the pre-drilled holes to make sure the new chassis is the right size. I also checked the diagonals before tack welding it together. I then re-checked before putting some proper welds on.

My pillar drill has been invaluable on this job. It's only a cheap Chinese one but I have had it for years and it works perfectly well and can accept Morse taper bits.

I am using a Silverline fan-cooled arc welder for the welding. It was only £30 and welds pretty well. It was very noisy but I gave the case a bash and that cured that problem.

Click here for more on the dumper restoration on PAGE 2

More Johnson Resources

There is now a Johnson Machinery Section of the website dedicated to preserving the history of this company. This has lots of interesting pictures and information about the Johnson range of products.

Images shown below are by no means a definitive guide as to the identification of Lister diesel engines, but show general ranges in certain specifications. Almost all Lister and Lister-Petter engines were produced in numerous guises and specifications, with differing engine rotations, power take offs and ancillaries, all of which can lead to different appearances of the same engine model. It must also be remembered that many Lister and Lister-Petter diesel engines look very similar but only for a few small distinguishing external features, so the images below should be taken as no more than a rough guide. Only some models are illustrated.

Lister Petter AA1 Single Cylinder Air Cooled Diesel Engine Lister Petter AB1 Single Cylinder Air Cooled Diesel Engine Lister Petter AB1W Single Cylinder Water Cooled Diesel Engine Lister Petter AC1 Series 1 (indirect injection) Single Cylinder Air Cooled Diesel Engine

Lister Petter AC1M Single Cylinder Air Cooled Marine Propulsion Engine with SOM Gearbox

Lister Petter AC1 Series 2 (direct Injection) Single Cylinder Air Cooled Diesel Engine

Lister Petter AC1W Single Cylinder Water Cooled Diesel Engine

Lister Petter AC1Z Single Cylinder Air Cooled Diesel Engine Lister Petter AC1Z Reverse Rotation Single Cylinder Air Cooled Diesel Engine

Lister Petter AC2 Twin Cylinder Air Cooled Diesel Engine

Lister Petter AC2 Twin Cylinder Air Cooled Marine Propulsion Engine with Hurth Gearbox

Lister Petter AC2WM Twin Cylinder Water Cooled Marine Propulsion Engine (Petter MiniTwin) with Hurth Gearbox

Lister Petter AD1 Single Cylinder Air Cooled Diesel Engine

Lister-Petter AD2 Twin Cylinder Air Cooled Diesel Engine

Petter BA1 Single Cylinder Air Cooled Diesel Engine

Petter BA2 Twin Cylinder Air Cooled Diesel Engine

Lister CD Single Cylinder Water Cooled Diesel Engine

Lister CDM Single Cylinder Water Cooled Marine Propulsion Engine

Lister CE Twin Cylinder Water Cooled Diesel Engine

Lister CEM Twin Cylinder Water Cooled Marine Propulsion Engine

Lister CS 3-1 and CS 6-1 Single Cylinder Water Cooled Diesel Engine

Lister CS 10-2 and 12-2 Twin Cylinder Water Cooled Diesel Engine

Lister Petter CR3 Three Cylinder Water Cooled Diesel Engine

Lister Petter CRK3 Three Cylinder Water Cooled Marine Propulsion Engine with PRM Gearbox

Lister Petter CS4 Four Cylinder Water Cooled Marine Propulsion Engine with PRM Gearbox

Lister Petter CS6 Six Cylinder Water Cooled Marine Propulsion Engine with PRM Gearbox

Lister Petter CST6 Six Cylinder Turbo Charged Water Cooled Marine Propulsion Engine with PRM Gearbox

Lister FR1 Single Cylinder Water Cooled Diesel Engine

Lister FR2 Twin Cylinder Water Cooled Diesel Engine

Lister FR3 Three Cylinder Water Cooled Diesel Engine

Lister FR4 Four Cylinder Water Cooled Diesel Engine

Lister FR6 Six Cylinder Water Cooled Diesel Engine

Lister FR6M Six Cylinder Water Cooled Marine Propulsion Engine with Lister 3G Gearbox

Lister HA2 and HB2 Twin Cylinder Air Cooled Diesel Engine

Lister HA3 and HB3 Three Cylinder Air Cooled Diesel Engine

Lister HA3M and HB3M Three Cylinder Air Cooled Marine Propulsion Engine with Lister 2G Gearbox

Lister HA3M and HB3M Three Cylinder Air Cooled Marine Propulsion Engine with Hydraulic Gearbox and Starting

Lister HA4 and HB4 Four Cylinder Air Cooled Diesel Engine

Lister HA6 and HB6 Six Cylinder Air Cooled Diesel Engine

Lister HL3, HL4 and HL6 Range of Air Cooled Diesel Engines

Lister HL6M Six Cylinder Air Cooled Marine Propulsion Engine with Twin Disc MG506 Gearbox

Lister HR2 Twin Cylinder Air Cooled Diesel Engine

Lister HR2G Twin Cylinder Air Cooled Gas Engine

Lister HR3 Three Cylinder Air Cooled Diesel Engine

Lister HR3M Three Cylinder Air Cooled Marine Propulsion Engine with Lister 2G Gearbox

Lister HR3M Three Cylinder Air Cooled Marine Propulsion Engine with Hurth Gearbox

Lister HR4M Four Cylinder Air Cooled Marine Propulsion Engine with Lister 3G Gearbox

Lister HRW2 Twin Cylinder Water Cooled Diesel Engine

Lister HRW2M Twin Cylinder Water Cooled Marine Propulsion Engine with Lister 2G Gearbox

Lister HRW3 Three Cylinder Water Cooled Diesel Engine

Lister HRW3M Three Cylinder Water Cooled Marine Propulsion Engine with Lister 2G Gearbox

Lister HRW3M Three Cylinder Water Cooled Marine Propulsion Engine with Hurth Gearbox

Lister HRW4 Four Cylinder Water Cooled Diesel Engine

Lister HRW4M Four Cylinder Water Cooled Marine Propulsion Engine with Lister 3G Gearbox

Lister HRW6 Six Cylinder Water Cooled Diesel Engine

Lister HRW6M Six Cylinder Water Cooled Marine Propulsion Engine with Twin Disc MG506 Gearbox

Lister HW2 Twin Cylinder Water Cooled Diesel Engine

Lister HW2M Twin Cylinder water Cooled Marine Propulsion Engine with Lister 2G Gearbox

Lister HW3 Three Cylinder Water Cooled Diesel Engine

Lister HW3M Three Cylinder Water Cooled Marine Propulsion Engine with Lister 2G Gearbox

Lister HW6M Six Cylinder Water Cooled Marine Propulsion Engine with Lister 3G Gearbox

Lister JA6 Six Cylinder Air Cooled Diesel Engine

Lister JA6M Six Cylinder Air Cooled Marine Propulsion Engine with Lister LH500 Gearbox

Petter Ava1 Manual Pdf

Lister JAS6 Six Cylinder Turbo Charged Air Cooled Diesel Engine

Lister JW6 Six Cylinder Water Cooled Diesel Engine

Lister JWSC6 Six Cylinder Turbo Charged Intercooled Water Cooled Diesel Engine

Lister JWSC6M Six Cylinder Turbo Charged Intercooled Water Cooled Marine Engine with Twin Disc MG509 Gearbox

Lister JK6 Six Cylinder Water Cooled Marine Propulsion Engine with Lister Blackstone Gearbox

Lister CS 9-1 and JP1 Single Cylinder Water Cooled Diesel Engine

Lister CS 18-2 and JP2 Twin Cylinder Water Cooled Diesel Engine

Lister JP2M Twin Cylinder Water Cooled Marine Propulsion Engine

Lister CS 27-3 and JP3 Three Cylinder Water Cooled Diesel Engine

Lister CS 38-4 and JP4 Four Cylinder Water Cooled Diesel Engine

Lister JP4M Four Cylinder Water Cooled Marine Auxilary Engine

Lister JP4 Four Cylinder Water Cooled Marine Propulsion Engine with Lister Blackstone Gearbox

Lister JP616 / JP6 Six Cylinder Water Cooled Diesel Engine

Lister JP6M Six Cylinder Water Cooled Marine Auxiliary Engine

Lister JP616M Six Cylinder Water Cooled Marine Propulsion Engine

Lister JS3M Three Cylinder Water Cooled Marine Propulsion Engine with Lister Blackstone Gearbox

Lister LD1 and SL1 Single Cylinder Air Cooled Diesel Engine

Lister LD1M and SL1M Single Cylinder Air Cooled Marine Propulsion Engine with Lister LM100 Mechanical Gearbox

Lister LD2 and SL2 Twin Cylinder Air Cooled Diesel Engine

Lister LR1 Single Cylinder Air cooled Diesel Engine

Lister LT and LV Twin and Single Cylinder Air Cooled Diesel Engines

Lister LT1 Single Cylinder Air Cooled Diesel Engines

Lister LT1A Anticlockwise Rotation Single Cylinder Air Cooled Diesel Engine

Lister LT2 and LV2 Twin Cylinder Air Cooled Diesel Engine

Lister LV2M Twin Cylinder Air Cooled Marine Propulsion Engine with Hurth Gearbox

Lister Petter P600/2 Twin Cylinder Air Cooled Diesel Engine

Lister Petter P600/3 Three Cylinder Air Cooled Diesel Engine

Petter PAZ1 Single Cylinder Air Cooled Diesel Engine

Lister Petter PH1 and PH2 Single and Twin Cylinder Air Cooled Diesel Engines

Petter PH1 Single Cylinder Air Cooled Diesel Engine

Petter PH1M Single Cylinder Air Cooled Marine Propulsion Engine

Petter PH1WM Single Cylinder Water Cooled Marine Propulsion Engine

Petter PH2 Twin Cylinder Air Cooled Diesel Engine

Petter PH2M Twin Cylinder Air Cooled Marine Propulsion Engine

Petter PH2W Twin Cylinder Water Cooled Diesel Engine

Petter PH2WM Twin Cylinder Water Cooled Marine Propulsion Engine

Petter PJ1 Single Cylinder Air Cooled Diesel Engine

Petter PJ1M Single Cylinder Air Cooled Marine Propulsion Engine

Petter PJ1WM Single Cylinder Air Cooled Marine Propulsion Engine

Petter PJ2 Twin Cylinder Air Cooled Diesel Engine

Petter PJ2 (late) Twin Cylinder Air Cooled Diesel Engine

Petter Ava1 Manual Pdf

Petter PJ2M Twin Cylinder Air Cooled Marine Propulsion Engine

Petter PJ2WM Twin Cylinder Water Cooled Marine Propulsion Engine

Petter PJ3 Three Cylinder Air Cooled Diesel Engine

Petter PJ3M Three Cylinder Air Cooled Marine Propulsion Engine

Petter PJ3WM Three Cylinder Water Cooled Marine Propulsion Engine

Petter PJ4 Four Cylinder Air Cooled Diesel Engine

Petter PJ4M Four Cylinder Marine Propulsion Engine

Petter PJ4WM Four Cylinder Marine Propulsion Engine

Lister SL3 Three Cylinder Diesel Engine

Lister SL3M Three Cylinder Marine Propulsion Engine with Lister LH150 Hydraulic Gearbox

Lister SL4 Four Cylinder Air Cooled Diesel Engine

Lister SR1 Single Cylinder Diesel Engine

Lister LR2 and SR2 Twin Cylinder Air Cooled Diesel Engine

Lister LR2M and SR2M Twin Cylinder Marine Propulsion Engine with Lister LM100 Mechanical Gearbox

Lister SR3 Three Cylinder Air Cooled Diesel Engine

Lister SR3M Three Cylinder Air Cooled Marine Propulsion Engine with Lister LH150 Hydraulic Gearbox

Petter

Lister ST1, ST2 and ST3 Range of Air Cooled Diesel Engines (Reverse Rotation Shown)

Lister ST2 Twin Cylinder Air Cooled Diesel Engine

Lister ST2 Start-o-Matic Generator

Lister ST2M Twin Cylinder Air Cooled Marine Propulsion Engine with Borg Warner Gearbox

Lister ST2M Twin Cylinder Air Cooled Marine Propulsion Engine with Hurth Gearbox

Lister STW2M Twin Cylinder Water Cooled Marine Propulsion Engine with Hurth Gearbox

Lister STW3M Three Cylinder Water Cooled Marine Propulsion Engine with Lister LH150 Hydraulic Gearbox

Lister STW3M Three Cylinder Water Cooled Marine Propulsion Engine with Hurth Gearbox

Lister TL2 and TL3 Range of Air Cooled Diesel Engines

Lister TS1, TR1, TS2, TR2, TS3 and TR3 Range of Air Cooled Diesel Engines

Lister Petter TS2M Twin Cylinder Air Cooled Marine Propulsion Engine with Hurth Gearbox

Petter Ava1 Manuale

Lister Petter TS3M Three Cylinder Air Cooled Marine Propulsion Engine with PRM Gearbox

Petter Ava1 Workshop Manual

Lister TX2 and TX3 Range of Air Cooled Diesel Engines

Contact: Email mail@realdiesels.co.uk Telephone +44(0)7415426368

Petter Ava1 Manual Transmission

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