Lister Petter TS1 - User Manual

TS, TR, TX
Workshop Manual
Edition 12: May 2005 Publication P027-08221

Summary

Introduction

Caution and Warning Symbols

Explains symbols used to denote hazards and important notes.

Section 01 General Information

01.1 SAFETY PRECAUTIONS AND SAFE WORKING PRACTICES

General safety and working practices for engine operation and maintenance.

Safe Maintenance Considerations

Starter Battery Precautions

Fuel System Precautions

Precautions for Oil, Filters and Elements

01.2 SAFETY SYMBOLS

Identification and explanation of ISO 8999 safety symbols used by Lister Petter.

01.4 ENGINE IDENTIFICATION

01.5 BATTERY DETAILS

Section 02 Engine Servicing and Adjustments

02.1 PRELIMINARY INSTRUCTIONS

Essential safety warnings and procedures before starting engine servicing.

02.3 THE COLD START AID

02.11 THE CYLINDER HEAD

Detailed instructions for removing and refitting the cylinder head, including torque settings.

02.12 CYLINDER HEAD CLEARANCE

Procedure for measuring and adjusting cylinder head clearance using lead wire.

02.13 THE VALVE ROCKER STUB SHAFTS - TS;TR

02.14 THE VALVE ROCKERS - TX

02.15 THE VALVES

Step-by-step guide for removing and refitting engine valves.

02.16 THE VALVE GUIDES

02.17 THE VALVE SEATS

02.18 VALVE CLEARANCE

Method for measuring and adjusting valve clearances when the engine is cold.

02.19 THE DECOMPRESSOR

02.21 THE GEAR END COVER

02.23 THE FUEL FILTER

02.24 PRIMING THE FUEL SYSTEM

02.26 THE FUEL INJECTOR

Procedures for removing and refitting fuel injectors for TS/TR and TX engines.

Replacing an Injector

Steps for replacing fuel injectors, including sealing washers and torque settings.

02.27 THE FUEL PUMP

Instructions for removing and refitting fuel pumps, including timing shims.

Refitting the Fuel Pumps

02.28 FUEL PUMP TIMING

Method for checking and adjusting fuel pump timing using the spill timing technique.

Fuel Pump Timing Gauge

Fuel Pump Timing Tables

02.30 THE GOVERNOR

Table of governing ranges and combinations for different engine builds.

Dismantling the Governor

Assembling the Governor

02.31 SETTING THE GOVERNOR

Procedures for setting governor 'E' and 'Q' parameters.

Governor A Setting

Method for setting the governor 'A' distance and adjusting fuel pump calibration marks.

Governor G Setting

Procedure for setting the governor 'G' parameter to ensure correct fuel delivery.

Limited Excess Fuel Trip - TX

02.32 GOVERNOR G SETTING AND TIMING TABLES

Continuation of tables for TX engine 'G' settings and timing values.

02.33 SPEED ADJUSTMENT

Procedures for adjusting fixed and variable speed controls to set engine RPM.

02.34 THE ENGINE CONTROLS

02.35 THE FUEL PUMP TAPPET

02.36 THE CAMSHAFT

Procedures for removing, inspecting, and replacing the camshaft.

Camshaft Endfloat

02.37 THE CAMSHAFT GEARWHEEL

02.38 THE CAMSHAFT BUSHES

02.39 THE CYLINDER BARREL

Steps for removing and replacing the cylinder barrel, including piston and connecting rod assembly.

02.40 THE PISTON AND CONNECTING ROD

Instructions for removing and refitting pistons and connecting rods, including ring fitting.

02.41 THE FLYWHEEL

Procedures for removing and refitting the flywheel, including locking tools and torque specs.

02.43 MAIN BEARING HOUSING

02.44 THE CRANKSHAFT

Detailed instructions for removing and refitting the crankshaft and its components.

Servicing the Crankshaft

Refitting the Crankshaft

Steps for refitting the crankshaft, including bearing shells and torque settings.

02.45 CRANKSHAFT END FLOAT

Method for measuring and adjusting crankshaft end float using a dial test indicator.

02.46 CHECKING BEARING CLEARANCE

Procedure for checking main bearing clearance using Plastigauge.

02.47 CRANKSHAFT MAIN BEARINGS

Detailed instructions for removing and replacing crankshaft main bearings using special tools.

Gear End Main Bearing Replacement

Flywheel End Main Bearing Removal;Replacement

02.48 GEAR END DRIVES

02.49 THE OIL FILTER

Steps for changing the engine oil filter.

02.51 THE OIL SUMP

02.52 THE OIL STRAINER AND PUMP

02.53 THE OIL SEALS

Section 03 Engine Fluids

03.1 ENGINE FLUIDS - lubricating oil

Classification and specifications for lubricating oils suitable for Lister Petter engines.

The Oil Specification

03.2 ENGINE FLUIDS - fuel

Fuel specifications and recommendations for Lister Petter diesel engines.

Section 04 Operating Instructions

04.1 PRELIMINARY INSTRUCTIONS

General safety warnings and advice before operating the engine.

04.2 HAND STARTING

Step-by-step guide for starting the engine manually using the starting handle.

04.3 ELECTRIC STARTING

Procedures for starting the engine using the electric start system.

04.4 STOPPING THE ENGINE

Instructions on how to safely stop the engine.

Section 05 Routine Maintenance

05.1 PRELIMINARY INSTRUCTIONS

Essential safety warnings and general guidance for performing routine maintenance.

05.2 ROUTINE MAINTENANCE - SCHEDULE HOURS

Schedule of maintenance tasks based on operating hours (Daily, 125h, 250h, etc.).

05.03 SPANNER TORQUE SETTINGS

Table of recommended torque settings for various fasteners and components.

05.5 DIMENSIONS OF WEARING PARTS

Guidelines for measuring wear on engine components and determining when replacement is needed.

TS, TR Wearing Parts

Detailed dimensions for TS/TR engine components including camshaft, valves, and bearings.

TX Wearing Parts

05.5 LONG TERM STORAGE

Section 06 Troubleshooting

06.1 PRELIMINARY INFORMATION

General advice and considerations before troubleshooting engine problems.

06.03 TROUBLESHOOTING TABLES

Tables listing common engine problems and their corresponding correction methods.

Engine Stops

Lack or Loss of Power

Overheating

High Fuel Consumption

Undercharging

Overcharging

Battery will not Charge

Starter Motor does not Operate

Section 07 Flywheel Charge Windings

07.1 CHARGE WINDINGS

Syncro Fault Finding Flow Charts

Flow charts for diagnosing battery and starter motor issues related to Syncro charge systems.

07.3 NICSA CHARGE WINDINGS

Nicsa Fault Finding Flow Charts

Flow charts for diagnosing Nicsa charge system faults like warning lamp malfunction.

Nicsa Fault Finding Flow Chart

Flow chart for diagnosing Nicsa charge system faults related to low charge.

Section 08 Electrical Wiring Diagrams

08.01 WIRING DIAGRAMS

General information on cable specifications, sizes, and identification keys for wiring diagrams.

Keyswitch Start with Syncro Charge Windings. (TS;TR)

Keyswitch Start with Nicsa Charge Windings. (TS;TR)

Syncro Charge Windings Less Starter. (TS;TR)

Nicsa Charge Windings Less Starter. (TS;TR)

Start Panel with Fuel Control Solenoid - Syncro Charge Windings. (TS;TR)

Start Panel with Fuel Control Solenoid - Nicsa Charge Windings. (TS;TR)

Start Panel with Fuel Control Solenoid and Protection Devices - Syncro Charge Windings. (TS;TR)

Start Panel with Fuel Control Solenoid and Protection Devices - Nicsa Charge Windings. (TS;TR)

Electric Start with Panel - Nicsa Charge Windings. (TS;TR)

Electric Start with Panel - Belt Driven Alternator (TX)

Start Panel with Fuel Control Solenoid - Belt Driven Alternator (TX)

Start Panel with Fuel Control Solenoid and Protection Devices - Belt Driven Alternator (TX)

Section 09 Technical Data

09.1 ENGINE MECHANICAL DATA - TS

Mechanical specifications for TS engines including bore, stroke, compression, and speeds.

09.2 ENGINE MECHANICAL DATA - TR

Mechanical specifications for TR engines including bore, stroke, compression, and speeds.

09.3 ENGINE MECHANICAL DATA - TX

Mechanical specifications for TX engines including bore, stroke, compression, and speeds.

09.4 BUILDS - TS

09.5 BUILDS - TR

09.6 BUILDS - TX

Lister Petter TS1 Specifications

General

Cylinders	1
Cooling System	Air-cooled
Fuel Type	Diesel
Fuel System	Direct Injection
Lubrication System	Forced feed
Starting System	Electric start