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Lister Petter
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TR1
Lister Petter TR1 Workshop Manual
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TS, TR, TX
W
orkshop Manual
Edition 12: May 2005
Publication P027-08221
2
Table of Contents
Table of Contents
3
Manual Contents
3
Introduction
4
If Problems Occur
4
Using this Workshop Manual
4
Caution and Warning Symbols
4
Handling Fluids Safely
5
Personal Safety
5
Personal Protective Clothing and Equipment
5
Section 01. General Information
5
High Pressure Fluids
6
Electrical System Considerations
6
Alternator/Charge Windings Precautions
6
Starter Battery Precautions
6
Fuel System Precautions
7
Precautions for Oil, Filters and Elements
7
Safety Symbols
8
General Information
8
Engine Features
9
Engine Identification
10
Nomenclature
10
Engine Serial Number
10
Battery Details
11
Preparing a Battery for Use
11
Connecting Batteries
11
Connecting a Slave Battery
11
Battery Charging
12
Ambient Temperature Range
12
Battery Cold Cranking Performance
12
Preliminary Instructions
13
Dismantling and Rebuilding
13
Section 02. Engine Servicing and Adjustments
13
The Air Cleaner
14
Inlet Manifold Loading
14
The Cyclonic Air Cleaner
14
The Cold Start Aid
15
TS and TR Engines
15
TX Engines
15
Removing the Manifolds-TS/TR
16
Refitting the Manifolds-TS/TR
16
Removing the Manifolds-TX
16
Refitting the Manifolds-TX
16
The Cylinder Cooling Fin
17
The Air Baffles
17
Removing the Air Cowling-TX
17
The Axial Fan-TX
18
Drive Belt Tension
18
Removing the Fan
18
Axial Fan Drive Guard-TX
18
The Cylinder Head Cover
19
The Crankcase Breather
19
Removing the Cylinder Head Cover
19
Refitting the Cylinder Head Cover
19
Removal of a Cylinder Head
20
Refitting a Cylinder Head
20
Cylinder Head Clearance
21
Refitting the Stub Shaft
22
The Valve Rockers-TX
22
Removing Stub Shafts
22
The Valve Rocker Stub Shafts-TS/TR
22
Removing the Valves
23
Refitting the Valves
23
Valve Guides-TS/TR
23
Valve Guides-TX
23
Refitting Valve Guides
24
The Valve Seats
24
Valve Recess and Seat Cutting
24
Adjusting the Valve Clearance
25
Removing the Decompressor
25
Decompressor Adjustment
25
Refitting the Pulley
26
Removing the Pulley
26
The Crankshaft Pulley-TX
26
The Gear End Cover
27
Removing the End Cover-TX & TS/TR
27
Refitting the End Cover
27
The End Cover Oil Seal
27
Tank Maintenance
28
Removing the Fuel Tank-TS/TR
28
Replacing the Fuel Tank-TS/TR
28
Removing and Replacing the Fuel Tank-TX
28
The Fuel Tank Filter
29
The Fuel Filter-TS/TR2, 3
29
The Cartridge Agglomerator
29
Priming the Fuel System
29
The Fuel Lift Pump
30
Removing an Injector-TX
31
Removing an Injector-TS/TR
31
The Fuel Injector
31
Cleaning an Injector
32
Setting the Injector
32
Injector Back Pressure
32
Replacing an Injector
32
Removing the Fuel Pumps
33
Fuel Pump Maintenance
33
Timing Shims
33
Refitting the Fuel Pumps
34
Fuel Pump Timing
35
Spill Timing
35
Fuel Pump Timing Gauge
36
Fuel Pump Timing Tables
36
Early TS/TR
36
Later Engines-TS/TR and All TX
36
Governor Modifications
37
The Governor Linkage
37
Governing Ranges to BS5514
38
Governor Combination Code
38
Dismantling the Governor
39
Assembling the Governor
39
Changing Governor Weights
39
Governor 'E' Setting
40
Governor 'Q' Setting
40
Governor 'A' Setting
41
Governor 'G' Setting
41
Limited Excess Fuel Trip-TX
42
Adjusting the Trip
42
Governor 'G' Setting and Timing Tables
43
Fixed Speed Adjustment
45
Variable Speed Adjustment
45
The Speed Control Lever
46
Removing the Assembly
46
The Engine Control
46
The Fuel Pump Tappet
47
Removing a Tappet
47
Replacing a Tappet
47
Removing the Camshaft
48
Inspecting the Camshaft
48
Replacing the Camshaft
48
Camshaft Endfloat
48
The Camshaft Gearwheel
49
Removing the Gearwheel
49
Refitting the Gearwheel
49
Changing the Camshaft Ball Race
49
Centre Bush Removal and Replacement
50
Flywheel End Bush Replacement
50
Flywheel End Bush Removal
50
The Camshaft Bushes
50
Centre Bush Removal
51
Centre Bush Replacement
51
Cylinder Barrel Removal
52
Cylinder Barrel Replacement
52
The Piston and Connecting Rod
53
The Piston Rings
53
Removing a Piston
53
Refitting a Piston
53
Flywheel Removal
54
Refitting the Flywheel
54
Flywheel Housing-TX
55
Removing the Flywheel Housing
55
Removing the Fanshroud
55
The Fanshroud-TS/TR
55
Removing the Main Bearing Housing
56
Refitting the Main Bearing Housing
56
The Main Bearing Oil Lip Seal
56
Crankshaft Removal
57
Servicing the Crankshaft
57
Refitting the Crankshaft
58
Crankshaft End Float
59
Checking Bearing Clearance
59
Crankshaft Main Bearings
60
Gear End Main Bearing Removal
60
Gear End Main Bearing Replacement
60
Flywheel End Main Bearing Removal and Replacement
60
Intermediate Main Bearing
61
Flywheel End Main Bearing Removal/Replacement
61
Gear End Drives
62
Crankshaft Extension Spanner 317-50060
62
Changing the Oil Filter
63
The Oil Dipstick
63
Draining and Filling the Sump
64
Oil Sump Capacity
64
Removing the Sump
64
Replacing the Oil Sump
64
The Oil Strainer
65
Removing the Oil Pump
65
Refitting the Oil Pump
65
The End Cover Lip Seal
66
The Main Bearing Housing Lip Seal
66
The Rotary Oil Seal
66
The Screw Type Seal
66
Past and Current US API Grade Oils
67
European Oil Specifications
67
The Oil Classification System
67
Engine Fluids-Lubricating Oil
67
Section 03. Engine Fluids
67
The Oil Specification
68
Oil Viscosity
69
Engine Fluids-Fuel
70
The Fuel Specification
70
Low Temperature Fuels
70
Starting Handle Precautions
71
Automatic Excess Fuel Device
71
Cold Starting Aid-TS/TR
71
Section 04. Operating Instructions
71
Hand Starting
72
Electric Starting
73
Stopping the Engine
74
The Use of Genuine Parts
75
Section 05. Routine Maintenance
75
Routine Maintenance-Schedule Hours
76
Spanner Torque Settings
77
Jointing Compounds
78
Dimensions of Wearing Parts
79
Cylinder Bore Wear
79
Piston Ring Wear
79
Oversize and Undersize Items
79
TS, TR Wearing Parts
80
TX Wearing Parts
82
Long Term Storage
84
Preparing the Engine for Storage
84
Returning the Engine to Service
84
Section 06. Troubleshooting
85
Troubleshooting-Mechanical and Electrical
86
Troubleshooting Tables
86
Battery Charge Indicator Light
89
Syncro Charge Windings
89
Fault Finding
89
Section 07. Flywheel Charge Windings
89
Syncro Fault Finding Flow Charts
90
Charge System Overcharging
90
Charge System Warning Lamp Malfunction
90
Starter Motor, Battery and Charge System
91
Charge System-No Charge
91
Nicsa Charge Windings
92
Stator Winding Resistance at 20 C (68 F)
92
Stator Winding AC Open Circuit Voltages at 20 C (68 F)
92
Output Charge Rate-Voltage Held at 12.5 Volts
92
Charge System-Low Charge
95
Section 08. Electrical Wiring Diagrams
97
Engine Mechanical Data-TS
105
Injector Setting
105
Crankcase Vacuum
105
Section 09. Technical Data
105
Engine Mechanical Data-TR
106
Engine Mechanical Data-TX
107
Builds-TS
108
Builds-TR
109
Builds-TX
110
Formulae
111
Temperature
111
Section 10. Conversion Factors
111
Section 11. Index
115
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Lister Petter TR1 Specifications
General
Engine Model
TR1
Cylinders
1
Cooling System
Air-cooled
Fuel System
Direct injection
Governor Type
Mechanical
Displacement
0.5 L
Bore
86 mm
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