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D2069 Class 03 Shunter

Class 03 No.D2069 at Doncaster Works Open Day 26th July 2003.New 19th September 1959 and under TOPS became 03069 in October 1973.Sold to Vic Berry of Leicester 4th January 1984 for use in their scrapyard.Sold for preservation on closure of the yard 1st August 1991 to the Gloucester and Warwickshire Railway at Toddington.

Class 03 No.D2069 at Doncaster Works Open Day 26th July 2003.

Class 03 diesel shunters were once British Rail’s (BR) most successful 0-6-0 diesel-mechanical shunters and very common in yards all over the country due to their lightweight and short wheel base making them ideal for tight radius curves. 230 were built in the Doncaster and Swindon locomotive works between 1957 and 1962. Later as the need for these shunters diminished on the railway network, many continued useful working lives in Industry. Today almost all of these shunters can be found at heritage railways with at least 56 examples surviving into preservation.

 

Class03_D2069_SharpnessShed

 

 

D2069 was finished on the 19th September 1959 and under TOPS became 03069 in October 1973. It was sold to Vic Berry of Leicester 4th January 1984 for use in their scrapyard, then later sold into preservation, on closure of the yard 1st August 1991 to the Gloucester and Warwickshire Railway at Toddington.

 

 

 

 

Overhaul Progress

Follow the work of the Diesel Team, led by Stuart Piddy as they overhaul D2069. The team usually meet up on a Wednesday and Friday with some work also done on the Saturday.

 

March 2017

The first day of March heralded a momentous day for the 03 shunter as it was the first day it moved under it’s own power for at least 7 years. After being towed out of the shed and the usual last minute tweaks, the engine was started and this time it ran much better as the video shows. Later after sufficient air pressure had been created the loco moved back & forth a little and back into the shed.

03 engine trail 1st march 2017

Last minute tweaks before start up

 

 

 

February 2017

The refurbished fuel pump was returned and re-fitted back on the engine. The rest of the engine was put back together ready for another trail run.

Work continued on replacing parts of the rotten cab. This month the bracket that ran along the back of the cab was replaced by cutting away a section of the cab side and a new angle bracket welded in place. All that remains is for the cab side to be replaced.

Refitted Fuel Pump Feb17

Refurbished and refitted fuel pump

03 New Angle support Feb17

Rear of cab support bracket replaced

 

 

 

 

 

 

 

 

 

January 2017

Whilst the fuel pump is away for refurbishment, attention has turned back to the loco cab side. The bottom of the cab was rotten and so were the supports behind them. The rotten bits have been cut out, new supports welded into place and a new sheet metal skin welded over the top.

CabSideReceivingAttension

NewCabSide

 

 

 

 

 

 

 

 

December 2016

Part of the engine and fuel system have been stripped to investigate the cause of the poor running. It has been decided that the fuel pump may be the main problem and so has been disassembled and sent away for refurbishment.

DismantledFuelPump

Fuel Pump Assembly

AirFilters

Air Filters

 

In the mean time, some of the rest of the team have been looking at the cab controls, in particular the air system, which as well as being used for the loco air brakes is also used to control various actuators such as the direction and gears. The air system was know to have a few faults so using an external compressor to provide the air supply the following problems were fixed:

  • The Deadmans pedal (DSD) which had a seized vale core was fixed.
  • Low main reservoir air problem was down to a jammed open blow down valve.
  • Lack of Control Air was due to the low reservoir air. Once this issue had been fixed enough pressure was raised in the main reservoir to allow the control air to come up.
  • The gear selector and direction lever were also adjusted to improve their operation

 

 

November 2016

The new silencer has been finished and mounted back on the loco. It just needs to be connected back to the engine and exhaust pipe. In the mean time new water filler pipes that feed the large radiator on the front of the shunter have been fabricated and welded into place.

NewSilencerFitted

New silencer fitted back on loco

WaterFillers

Newly fabricated water filler pipes

 

 

 

 

 

 

 

 

 

October 2016

After the problems encountered with the trial engine start up the team have decided to renew the fuel injectors but also to investigate other areas of the fuel system including the fuel pump & air filter.

In the mean time work continues in other areas. One problem is the original silencer is well past it’s best so Vince has started to construct a new one from scratch, cutting and bending a tube of sheet steel which is waiting to be welded along the seem. Sitting on the end of the bench is the salvaged filter, which will be reused.

NewSilencer

New silencer under construction

 

 

 

 

 

 

 

 

 

September 2016

This month saw the engine rebuilt completed and on the 28th Sept the 03 shunter was moved out of the shed for a trial start up. The engine was found to be very smokey and not running on all 6 cylinders, which might be linked to the injectors but further investigation is required.

03_2069_outside

D2069 moved outside for a trail start

03_2069_outsideforfirststartup_28sept2016

Trail stating in progress

 

 

 

 

 

 

 

 

 

 

A short video showing how rough the engine is running can be seen below


August 2016

Good progress has been made this month with the engine rebuilt coming together. The pistons have now all been refitted along with the valves and cylinder heads. Once all the piping up work is complete with fuel lines and exhaust the engine will be ready to be started.

03_paultucker_Aug2016

Paul Tucker reassembling the engine

03_valveheadsreinstalled_aug2016

The engine’s pistons, valves and cylinder heads are all refurbished and reinstalled.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

July 2016

Work to rebuilt the engine progresses with refurbished parts being reassembled when ready.

03_enginerebuilt_july2016

Refurbished parts of the engine slowing being reassembled

 

 

 

 

 

 

 

 

 

June 2016

This month saw further work at striping the 03’s Gardner 8 cylinder 4-stoke 204bhp engine, to clean and refurbish the parts damaged by water in the sump.

03_mattthomas

Matt Thomas, stripping D2069’s engine.

 

03_peterwhite_refurbishingpistons_june

Peter White refurbishing the pistons

 

 

 

 

 

 

 

 

 

 

 

 

 

May 2016

A thorough check of the engine was made before the shunter was due to be started but unfortunately upon removing the crankcase water was found in the sump. Further investigation has shown this has damaged some of the engine components and so the engine is now going to be stripped, cleaned and refurbished. Naturally this is a bit disappointing but the team are determined to repair the damage and return the shunter back to operation.

03

D2069’s engine

 

 

 

 

 

 

 

 

 

 

 

April 2016

Work has started on refurbishing D2069 with some of the framework still to be repaired or replaced and the engine to be checked over before starting. New batteries have been ordered and the water system filled ready for final checks before starting.