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Standard Operating Procedure

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The service & repair process may be carried out by different people so the club have developed a Standard Operating Procedure to ensure that every service is carried out to the same professional standard. This lists all the service actions that will be carried out on each individual loco.

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Initial inspection:

External inspection of the loco and tender bodies for missing parts, damage and cleanliness.

Internal inspection of the working parts for missing parts, damage and cleanliness.

 

If runnable steam up the loco on a test stand with the body off.

After pressure is attained run the loco, allow it to get hot then check the following:

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1.    The timing condition at the slowest running speed – forward and reverse.

2.    Do the driving wheels stall momentarily when the relief valve lifts.

3.    The whistle operation.

4.    Speed up the loco and stop the driving wheels with the regulator open to check for steam leakage past the               rotary valve.

5.    Stop the loco on the red light, do the driving wheels continue to run.

6.    Lights operation through the green and red zones.

7.    The regulator motor does not stall – using the main controller or the Live Drive.

 

Make adjustments and refurbishments of each of the above where necessary.

 

Service:​

1.    Generally clean off excess oil around the loco mechanism if necessary.

2.    Check the visible seals condition; oil and water fillers.

3.    Remove the rotary valve housing and check the condition of the valve and thrust pad.

4.    Change rotary valve housing gasket if necessary.

5.    Check the condition of the regulator valve faces, change the super heater gasket if necessary.

6.    Change the piston seals.

7.    Tightness of all screws, common faults here are as follows:

1. The screws under the front bogie on the A3's that secure the steam chest and rotary valve housing to                 the chassis, two screws.

2. The lights board and wiper on the A4's + clean the wiper and board.

8.    Replace the magnets on the regulator motor.

9.    Oil the regulator motor bearings.

10.  Check the carbon brush holders are secure.

11.  Check the alignment of the exhaust ports on the top of the relief valve.

12.  Check the general condition of the PCB. Look for broken wires, dry joints and corrosion on the soldered joints.          On the A4's check the common connection that terminates onto one of the screws at the base of the relief                valve.

13.  Check the tender/loco connecting cable plug/socket for discoloration by overheating.

14.  Check the condition of the wires and insulation connecting the lights board.

15.  Lubricate the reduction gearbox parts and bearings, particularly the two worms and wheels.

16.  Loosen the screw for the final drive crown wheel and lubricate.

17.  Check the timing adjuster mechanism that it has not loosened from the main timing shaft.

18.  Check the front and rear bogies that the wheels rotate freely. Clean if necessary.

19.  Clean all the connecting rods and crank pins and re-lubricate.

20.  Check the connecting rods are not bent or interfering anywhere.

21.  On the underside of the loco remove the plastic cover on the chassis and check the tightness of the

        differential gearbox screws.

22.  Oil the driving wheel axles and bearings.

23.  Check the tightness of the driving wheel nuts, rotate the wheels and check any misalignment or run out.

24.  Remove the tender wheels and check the condition of the bearings for free movement. Thoroughly clean the            wheel sets in solvent.

25.  Remove the power collectors and polish the contact areas.

 

Final running checks:

1.    On the test stand carry out the checks as per those of the initial inspection, 1 to 7.

2.    With body on and the loco up to maximum temperature check the regulator motor operation with both the             main controller and the Live Drive.

3.    On the test layout run the loco under load until satisfied that the loco runs as required.

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