April 19th-29th 2011

As mentioned at the end of the previous report, April 19th was the day D9531 became electrically live. Alan Lee had connected the batteries and loco so that sequence testing of the various systems could begin. During these tests the starter motor was found to have an earth fault on the negative side. Malcolm Kirkwood removed it from the loco, stripped it down, identified and rectified the problem.

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Saturday April 30th 2011
Attendance: 10

The big day we had all been working towards - start up of the power unit. An attempt had been pencilled in for 3.30pm although there were a number of outstanding tasks to complete first. With the weather fine, 'Ernest' was dragged out into the sun. Alan and Matt Lindley continued electrical sequence testing and Chris stripped the fuel racks down and figured out how to set them up.

D9531 outside basking in the sun	Chris B setting the fuel racks

Jason and Graham were tasked with lifting out the Air tanks with the Manitou, Adam filled the coolant system. Jim, Kris and Dave busied themselves making adapter plates and gaskets for the air intake bellow and Rob fashioned a bar to fit in the direction quadrant. The loco was a hive of activity!

Jason guides an air tank off the loco	Adam filling the water header tank

Once the air tanks were out Jason then set about prime filling the fuel pumps with oil as these were brand new from overhaul and dry. Graham and Alan repaired the terminal bar on the 110v generator and Matt busied himself checking the exhausters over. Dave and Rob cleaned up threads and freed off nuts on the various fuel rack items allowing Chris to fit them and begin setting the system up. Jim and Kris fitted the new air intake bellow and Adam fitted a tap handle to the main fuel shut off.

Repaired terminal bar on the 110v generator	D9531 is shunted to help free up the Final Drive

Attempts were then made to get the final drive into a direction ready for starting, but to no avail as the main reversing shaft was stuck through lack of use, using bars, wedges and Brute force Rob finally got it moving and we were able to get the final drive in a direction - the loco was then taken on a short shunt to help free the drive up.

Fuel was bled up to the pumps and, with Alan happy to go for a cranking test, the fuel racks were held shut and the start button pressed. The oil pump ran and then the engine began to crank. After a few minor checks we were ready to go for a start.

With everyone in position, the button was pressed, this time though things did not go to plan; the starter motor engaged but didn't crank at full speed and the start panel started smoking. A halt was quickly called and everything allowed to cool while investigations were made. It was discovered that the 2nd stage of the starter motor was not getting detected properly so was not allowing full power to the starter motor.

With everything cooled off, we tried again, only this time Alan prodded in the contactor .. the engine cranked, cylinders began to pick up and D9531 burst into life!

Another video can be seen on Youtube

The loco ran up ok but the governor was not taking hold, so Alan had to rack the engine to keep it running, eventually we allowed it to shut down then investigated. Oil wasn't getting up to the governor, so we decided to try and blow oil up the pipe work with using a a compressed air gun, through the reservoir bowl. This was successful with evidence of oil at the governor. The oil was topped up and a few other checks made before firing the power unit up again - this time after a few seconds, the governor took hold and began regulating the engine.

Everyone was amazed at how clean the engine was running and, although idling a little high, it sounded very nice. No evidence of any oil/fuel/coolant leaks was found and everything seemed happy. Alan checked over the electrical systems to ensure the batteries were receiving a charge and he also switched in the 2 exhausters which ran perfectly. The fan was then manually wound in to see if the hydrostatic oil system was ok and the fan duly started spinning.

'Ernest' was allowed to run for some time and heat up whilst checks were made. With everyone happy D9531 was later shunted back into the loco works by 08479. Smiles all-round!

Apart from the fault with the starting system, which we know how to resolve and the engine idling to high which will need the governor setting up properly, the loco did everything it should and did the team proud.

Next on the agenda is to complete the Air and Braking systems and also begin the shiny new paint job. D9531 will be moving from the works to the C & W depot for these next stages.