d5401.co.uk

Sorry, sorry sorry.... I promised that I would keep this webpage updated nearly weekly and for a variety of reasons that hasn't happened. But anyway a long overdue progress report.

Excellent progress has been made over the last four weeks since the Turcbocharger & Intercooler have been removed. The load regulator has been "plugged" and lifted on to the floor awaiting removal for a service at a later stage. The main generator has been electrically disconnected and each wired marked up and photos taken to ensure its put back together correctly, also the generator has had its insulation tested and as expected its low but not dead by any measure.

Saturday 16th October was a another good day, the time was spent getting the deflection readings from Cylinder No6 and recording the results. The labryinth seal removed and stored, the large coupling bolts undone and stored, the homemade designed and built armature support band has been fitted, all the carbon brushes removed and stored. Even with all that done time was found to start unbolting the side bolts and surprisingly they unbolted quite easily, two are remaining but these will be more difficult due to heavy corrosion. These two bolts will be replaced and another surprise was a BR bodge on the adjustment screws which means another tool will have to be made so these can be unbolted. Fingers crossed another days work and the generator will be ready to lift out.

As Can be seen from the photos above good progress, There is now a healthy pile of stored items that will need cleaning and given a fresh coat of rail grey at somepoint before its all put back together.

Wednesday 24th November

Since the last update progress has still been made but not alot worthy of taking photos, the power unit craddle side two remaining bolts were removed after some effort to un-seize them. Next on the list was the "intercooler side" four adjustment screws to loosen off, These proved to be considerably more difficult to loosen than expected, the gas torch was summonded and eventually with some heat and rocking motion with spanners/socket sets and so on they eventually gave out. The next hurdle to overcome were the fitted bolts on top of the craddle like the adjustment screws they weren't going to give in without a fight, the gas torch was used again and with jacks, sledgehammers, shouting and alot of effort they both refused to move.... so left with no other option the tops were burned off and punched out, replacement bolts will be made when the generator is returned and aligned.

So after all the above the generator was jacked off the crankshaft using two 1" bolts about 10mm and so the only thing holding the generator in situ was gavity. Tuesday 23rd November was the day selected to lift the generator carass out of D5401 and considering the problems encounted before with seized components it was expected something would not to go to plan.

The day was clear sky, dry, cold and low wind, the locomotive was positioned near the GCR small 12ton crane on the shed area with the fibreglass roof removed. Next chains were secured to the generator and with some small effort the generator lifted away from its resting place for the 28 years with more ease than expected. Once removed and resting on wooden packing on the floor next to the locomotive awaiting the booked lorry to arrive. The locomotives fibreglass roof was refitted, secured with the tarpulin tightened down again and the locomotive shunted back to the siding it came from earlier that morning. After a brew the lorry arrived and the generator was loaded and secured and taken away to Henor Electricals where an overhaul will take place over the coming weeks.

Now there is a big hole left in the locomotive where the generator once lived which is very oily and messy, no doubt time will be spent degreasing and painting before its return in the new year.

Tuesday 18th January 2011

Now the Xmas period is over and for the time being the bitterly cold weather has left us, I have been able to visit D5401 and carry on with the deep cleaning of the power unit craddle and generally preparing the area for a fresh lick of rail grey paint ready for the return of the overhauled generator, not exactly something worth taking a photo of at present as it doesn't look any different.

One of the left hand side adjustment screws didn't want to unscrew when the generator was removed so now there was space it was screwed in until it was free, it took some doing and an inspection found half of the thread was missing, a spare adjustment screw has been obtained and to help matters a 2" BSP tap will be run through all the threads shortly to aid re-fitting.

A couple of visits to Bowers Electricals to view progress just before Xmas 2010 and today have seen considerable work already undertaken, the armature was showing pretty healthy readings after cleaning and stoving, the comms still require skimming and after inspection by both parties a new banding will be fitted as the old ones are showing signs of age. The carcass took a bit of work more indepth cleaning and stoving was required but the readings are good and now it awaits its turn for minor glass resin straps and some tidying work. The Main generator brush ring has been cleaning, PTFE insulators installed with the brushboxes to fit shortly. The Aux genny brush ring is still to do.

Wednesday 2nd March 2011

The overhaul of the generator was completed by mid February and with the comestic work also done in the engine room a date was set for the generator to be returned to the locomotive on Monday 21st February 2011. A bloody wet day with constant showers and cold temperatures (could of asked for better conditions!!!!) The GCR 12ton crane was once again employed for this lift and with some readjustment at times the generator was successfully lifted back into the loco by lunchtime and the roof refitted to protect the newly installed generator against the rain. Now starts the long drawn out saga of re-aligning the generator along with the physical reconnecting and electrical connections to be done.

Realigning a generator on a Sulzer power unit has been be correct and the deflection readings MUST be within 2 thou or 0.15mm so any vibrations won't cause excessive stress that can eventually cause cracks in the crankshaft. So the deflections must be spot on or you stand to destroy the power unit and the generator set, needless to say this isn't understated by ourselves and we are going to great lengths to ensure we get this right first time as a result realigning is taking considerably longer than I had initially expected. This part of the rebuilding process still is not finished and may take a few more working days of hard labour and calculations before we are satisfied the job is done as per the manual. Once we are happy the deflection readings are as per the manual/old readings before dismantling last year we can replace the equipment that ususually sits onto of the generator at a later stage.

As you can see below the top row of pictures shows the completed generator overhaul at Bowers prior to delivery back to the GCR and the comestically cleaned and painted engine room area. The bottom row of pics shows the class 27 on the shed area at Loughborough and after the generator is refitted and the long task of re-aligning and refitting components has started with two brand new fitted bolts made also.

Saturday 13th August 2011

The overhauled generator is now aligned and finally tightened down, the turbocharger and intercooler have since been refitted along with all the pipework (photo not seen) a final go around with the paint brush to make things look clean and tidy.

The Class 27 was finally started on August 7th 2011 with it being a success, photos will follow of the test run booked to take place in late August. Below are a couple of photos taken during the few months since the above update. A more detailed account of the last few months are on the lastest news page

Northampton Type 2 Group

Generator Overhaul

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Northampton Type 2 Group

D5401 (27056,27112) has been running continously pretty much since it was preserved in early 1988.

Clearly British Railway discarded the Class 27 fleet due to budget cut backs and basically the fleet were very worn out for high speed running and intense use. The locomotives were mostly sent to the scrap yards but a few were saved for preservation.

27056 was one of those locomotives and electrical machines and mechanical parts do eventually wear out and need overhauling or replacing to keep the locomotive running.

It is the turn of the Main Generator on D5401 (27056,27112) to receive some professional attention to ensure reliable service for a good number of years to come.

Both the Turbocharger and intercooler have been placed in store and further component removal is needed at a later date before the generator can be disconnected ready for lifting.

Above shows the picture taken during the lift and the flywheel of the generator before uncoupling from the crankshaft