Saturday 16th July
Attendance: 6
The first working party on D9531 for some time, all present were keen to make a start.
Most of Jason and Adam's day was spent on the injector and fuel pump leak off pipe work, easier said than done! Pipes needed to be found and then matched, jigsaw style, to where they live. Fittings needed changing round and finding, with new ones required in places too.
Adam sorting injector leak off pipework | Fuel pump leak off completed |
Chris got on with removing the engine governor, the aim being to replace it with D9531's original power unit governor. Suitable tooling had to be found and borrowed, but after a bit of a slog the governor was liberated. It was thought that the governor on the replacement power unit was a fixed speed type, with a torque governor required. However, once out, Alan Lee inspected the unit and found that it actually is a torque governor and can be used after all, needing just a little TLC and fine-tuning in due course. D9531's original governor was in dire need of attention so this is a very welcome discovery, saving a costly governor overhaul. The unit was given a good clean out and had some fittings swapped over ready for re-installing.
Chris then moved on to figuring out an alternative for the power unit sump drain. It was discovered that the hole was threaded, so a fitting was found to screw into the hole, this will then be taken to a suitable supplier to get a lockable drain tap with the correct size fitting.
Alan Lee & Graham Mortimore were busy cutting, cleaning and fitting the 6 main heavy duty power cables to the loco. Each was measured, cut, cleaned and the ends marked. The cables run from the generator, battery boxes, and starter motor back to the battery isolating switch and control cubicle. The ends will be crimped and terminated at a later date.
Split pin fitted to brake rigging | Graham disconnecting the oil-priming pump |
Dave Mylett got on with the task of fitting the pins to the 6 main brake hangers, sounds easy, but each pin needed grinding down to suit each hole as they were very much oversize! Once done, Dave went through the bottom end splitting all the new pins that had been fitted.
Adam, Jason and Graham also removed the oil-priming pump. It was fitted some years ago, but has been open to the elements so it was decided to remove it. The pump will be serviced and cleaned out off-site and returned for re-fitting later in the year.
One other task for the day was to remove the exhaust stack from the turbo and is had a nasty crack in it. We attempted to fit a replacement, but the holes in the flange were not big enough and required opening out. As time was knocking on it was decided it would be a task for tomorrow.
Sunday 17th July
Attendance: 5
Jason continued work on the exhaust stack, drilling out the holes on the flange and re-fitting the exhaust to the turbo, he then set about fitting the last leak off pipe to the left hand side injector rail. This meant searching for fittings up at Castlecroft, which took up a lot of his time. Still he triumphed and the last leak off was fitted meaning the fuel system pipe work is now complete.
Old cracked exhaust manifold | Opening out the holes on the replacement exhaust manifold |
Carl Holt & Adam Booth set about the task of fitting the overhauled fuel pumps, starting on the right hand side, diconnecting all the pipe work and then marking the coupling for timing purposes, and removing the old pump. New and old pumps were layed next to each other on the bench, the drive and drive plate swapped over ensuring all marks were the same. The new pump was then fitted and had the drive and associated pipe work connected. As Carl had to depart early, only the one side was completed, the left side will be swapped in the near future. Once Carl fits the other fuel pump, the fuel system can be bled up ready for an eventual start up.
New and Old Fuel pumps | New fuel pump fitted on right hand side |
Chris Baily set about fitting the governor to the engine, an oil pipe had to be slightly adjusted due to a fitting that had changed. The run solenoid still requires wring in, but will be done when there is suitable tooling and equipment available.
Governor refitted | Cab Doors rescued |
Chris and James had a search through various containers at Baron St for the missing brake rigging and any other class 14 related parts. Unfortunately nothing of what we needed was found, but other parts were found and moved back to paddy for safekeeping. Next stop was Castlecroft to continue the search, again with no success although the cab doors were brought up to Baron St. The last place to search is the secure store in Bolton, which will be done in the near future.
Towards the end of the day Adam and Jason cleared out various items that had gathered over the years in D9531's cab, moving them across to the storage areas in 'Paddy'.
Tools were packed away and we called it a day and a very productive working weekend on D9531.
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