Power Unit
D9531s Davey Paxman 6YJXL power unit (6-cyl 4-stroke, 650BHP @ 1500rpm) had many worn out components, although spares are available as the 6YJXL also has marine usages. In late 2003 a refurbished, zero-hours 6YJXL was located in Holland. This was secured for £10k less than the cost of replacent parts required.

It is very likely this power unit came from classmate D9505 which used to work on Zeebrugge docks and was scrapped about a year before we aquired the Power unit. The PU had been refurbished and installed into marine vessel but was reclaimed when the new owner failed to make payment. When we got it, the wiring on the power unit was found to be in a class 14 configuration so we assume it must be ex-D9505.

Some minor adjustments were needed but due to it's 'Zero-hours' condtion no overhaul was necessary saving 6-12 months work and leaving D9531's former power unit as a spares pool. Once pressure tested, repainted, heat exchanger and new Oil Filters fitted, the unit went into the loco in August 2008.

New fuel pumps were aquired and fitted along with new flexible leak off pipework to complete the fuel system. A spare exhaust stack was sourced from Peak Rail and, after minor adjustments, fitted as of January 2011. The power unit was successfully started on the 30th of April 2011.

Radiators, Exhausters etc
The cooler group was flushed out, repainted and radiator elements refitted, SERCK (radiator fan) system overhauled and, sitting underneath all this, the fuel lift pump was also refurbished and repainted.

The transmission heat-exhanger was stripped down and rebuilt, all tubes were cleaned then a water test and a repaint before refitting. The engine oil priming pump was stripped, cleaned, anti-tracked, painted, tested and refitted with new flexible pipe for the oil system installed along with modifications to, or new, unions etc where required. Matching refurbished vacuum exhausters, ex-class 47, are installed, with the necessary framework acquired from the Nene Valley Railway. These sit above the transmission heat-exchager.

All new silicone pipe has been cut for the flexible water connections along with new jubilee clips some being welded to suit. New bleed pipes installed from the water header with modifications made as required. Some 'fine tuning' was required to line up the large water pipes in places! The coolant level switch has been removed and replaced with a standard mobery float, replacing the original mercury type.

Sideframes were cleaned, painted and refitted. All conduit and pipework thoroughly cleaned and repainted (old paintwork removed, bare metal exposed, primed, undercoated and glossed) with new gaskets manufactured then refitted, including the fuel and water header tanks, associated pipework and brackets.

The nose roof was cleaned, painted and permanently refitted in February 2011 along with the exhaust and water header tank cowl. Refurbished air vents with new gaskets have been installed and the remaining hatches and covers will be replaced as the loco nears completion.