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Shaun McMahon has sent this long list of modifications to the
first FCAF Garratt (2), which for the most part were carried forward into the
construction of the second Garratt delivered in 2006.
STAGE 1 - 2001/2002.
1. Replaced boiler.
2. Modified position of boiler.
3. Foam height meter.
4. Installed fusible plug.
5. Fitted second water gauge to backhead.
6. Improved ergonomics.
7. New live steam pipes - enlarged section, streamlined.
8. New exhaust steam pipes - enlarged section, streamlined.
9. New live steam branch pipes (Y piece).
10. New exhaust steam branch pipes (Y piece).
11. Lempor exhaust manifold.
12. De laval blower.
13. Lempor chimney.
14. Modified cab structure.
15. Replaced wheelsets.
16. Replaced axles.
17. Replaced axleboxes.
18. Replaced axlebox roller bearings.
19. Replaced rod end roller bearings.
20. New design of drive crank - replaced.
21. Replaced crank pins.
22. New design of eccentric crank - replaced.
23. Replaced eccentric crank pin.
24. Modified eccentric rod ends to housed roller bearings.
25. Fitted proportionally fed and extended mechanical lubrication system.
26. Insulated cylinders and valve chests.
27. Insulated live steam pipes.
28. Insulated exhaust steam pipes.
29. Insulated between the frames box section.
30. Replaced piston rings.
31. Replaced valve rings.
32. New fuel tank.
33. Modified front and rear water tanks - greater capacity.
34. Electric lighting - headlamps, motion, cab, injector.
35. Pedal operated, bi directional air-sanding gear.
36. New burner.
37. New panplate.
38. Brick arch and refractory.
39. Burner atomising steam superheated.
40. Steam sampling system.
41. Improved climbing handles and steps.
42. Modified smokebox door.
43. Test instrumentation.
44. Flange lubricator system.
45. Rail cleaning jets.
46. New injectors x 2.
47. Balancing of reciprocating components.
48. Modifications to air pump - insulation.
49. Carried out sealing repairs to cylinders so as to cure leakage.
STAGE 1 OUTSTANDING WORK - TO BE INCLUDED IN 2003 WINTER MAINTENANCE SCHEDULE.
1. New fixed pilots as per Camila design 2001.
2. Extended drawbars to suit 1.
3. New snowplough x 2.
4. Fitting of Rio Turbio screw reverser.
5. Modify RH cab side so as to accommodate 4.
6. Final modifications to combustion system as required from testing period 2002/2003.
7. Valve gear overhaul.
8. Repaint in new livery.
AREAS OF DOUBT AS FAR AS RELIABILITY IS CONCERNED.
1. Valve bodies - showing signs of break up.
2. Pistons - as for 1.
3. Connecting and coupling rods - origin of design not known, material not confirmed, crystalline state of material not known.
4. Valve gear - as for 3.
5. Unit pivots - design does not conform to any standard, break up of centres and bearing housing evident at present strip down.
6. Strength of locomotive cradle due to lack of original design information. Material not confirmed.
7. Robustness and alignment of power unit frames.
8. Bracing of unit frames by current stretchers does not conform to any laid down code of practice therefore gives cause for concern.
9. Cylinder and valve chest bodies showed signs of decomposition under normal welding repairs to cure steam leaks, leads to suspicion as to the selection of original material.
10. Firebox square corners.
The work carried out at stage 1 should allow us to obtain some 22,000 km from the current driving wheels before they begin to break up in the same way as the originals did. This allows us some 3 operating years in order to finalise all design work for the stage 2 modifications and even time to prepare the components for fitting with the engine remaining in traffic rather than manufacturing and fitting as has been the case up to date. Likewise it would be convenient to use the allocated time in order to design the new components for Camilla stage 2 work and the new locomotive LVM 803 so that manufacturing can also take place in parallel at designated factories and workshops so as to reduce costs.
STAGE 2 - 2005.
1. Modified boiler in order to increase efficiency by high degree of superheat. Use existing barrel in order to reduce cost, replacing firebox with round corner Belpaire type, tubeplates and adding a superheater along with superheater booster and roughened smoke tubes.
2. Additional firebox, barrel and smokebox lagging so as to further increase efficiency.
3. Feed water heater - fit in front of chimney, extend smokebox so as to accommodate such.
4. Feed water pump.
5. New design of unit pivot based upon known designs in daily service.
6. Modified suspension - compensated.
7. New design of piston.
8. New design of multi ring, lightweight, articulated piston valve.
9. Cylinder rebore.
10. New valve liners - modified.
11. New cylinder and valve bodies to be fitted if material testing of originals reveals sub standard material was used during manufacture. Opportunity to be taken to redesign valve chest (larger volume).
12. Fitting of new adjustable shoes and wedges to axleboxes.
13. Modify and rebuild brake gear.
14. Modify handbrake arrangement.
15. Fit steam brake.
16. Redesign and manufacture new driving wheelsets, these should allow for proper tyring standards and integral balancing.
17. Redesign motion and valves so as to incorporate lightweight reciprocating parts of correct section and geometric accuracy.
18. Check and revise as required the alignment of the power unit frames.
19. Reinforce power unit frames as required.
20. Structural modifications to engine cradle as required.
21. Modifications to exhaust system as a result of altering the gas flow cross sectional area in 1.
S.T. McMahon
Technical Manager
Tranex Turismo S.A.
13th August 2002.
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