Time for generators

[ajaffa1]

Hi guys and Gals, it`s been a few days since I posted any progress, sorry, I`ve been waiting for parts deliveries. Incredibly I have received new oil seals shipped from the UK faster than parts I ordered at the same time from within Australia, where I live. The crankcase and gear end seals have been fitted and the flywheel has been re-fitted and painted. The Lucas starter motor has been stripped, serviced and re-fitted, no apparent wear on the commutator ring confirms that this engine has done little or no work.
Cleaned up and painted the Lucas dynamo today, I don`t think I have played with a dynamo since the 1970s but it looks OK and tests OK with a multimeter.
Stripped and painted some of the engine shrouds today, looking forward to getting the motor finished and moving on to the generator head and wiring.
Parts should arrive next week. A few pics attached for those too lazy to read.

Bob

[dax021]

Looking great.  Can't wait to see it running

[ajaffa1]

G`day folks, finally some of the parts I ordered are starting to be delivered. Today the replacement seals for the push rod tubes arrived, the push rod tubes have now all been fitted, What a pr1ck of a job, the internal springs are very powerful and at full compression only allow about 3 mm of clearance, sore arms and skinned knuckles!
All of the engine shrouds have been painted and fitted, another pr1ck of a job. the shrouds have clearly been bashed about over the years so none of the holes would line up with the threads in the engine. I`m glad there is no swear jar around here or I`d not be able to buy a beer for months! 
So the beast is finally coming together, in the morning I will fit the inlet and exhaust manifolds and refit the oil feed lines. Still waiting on parts for injector pumps, should be here next week.
Some pics attached for you diesel junkies:

[ajaffa1]

G`day folks, I didn`t get as far as I would have liked today but the pushrods are back in place and the rocker assemblies have been fitted and torqued down, tappet clearances set at 0.1 mm (0.004"). this is a much smaller clearance than I am used to but it`s what is says in the manual.
The inlet manifold is back in place along with the high pressure fuel injector lines and the lower pressure oil feed lines to the rocker assemblies.
The dynamo has been refitted and the drive belt tensioned. The new air filter has also been fitted but I forgot to take photos of the assembly.
So, I`ve just got to fit the exhaust manifold and then wait for the injector pump parts to arrive.
A few pics attached.

Bob

[ajaffa1]

G`Day folks. not much progress today because it is Anzac Day. equivalent to Remembrance day in the UK and Veterans day in the US. Time to lay down the tools and remember that the freedoms we enjoy were bought with the lives of a great many brave young people from all over the world.
I did manage to fit the new oil filter and its assembly. I am encouraged to find that the filter I took out had a 1978 date stamped on it suggesting that this unit, made in 1976, has had a least one service in it`s life. I am very disappointed by the quality of replacement oil filters. compare the 1978 unit with the sh1t replacement made in China or India! I`m sure it will work but what a drop in quality over the last 40+ years, so much for Globalisation!
I also finished up fitting the oil feed lines. A few pics attached.

Bob

[ajaffa1]

G`Day everyone. The fuel tank has been flushed and stripped back to bare metal, etch primed and painted. The pipe fittings have all been sealed in place with a liquid thread sealer, I do not believe that PTFE thread tape should ever be used on fuel lines.
The tank has now been fitted with some thin rubber strips between the tank and the tank straps to prevent chafing.
I`ve now got to try to rebuild the wiring loom. The dynamo voltage regulator was full of dust because the cover was loose. It has cleaned up well and looks to be serviceable, just cleaned the points with fine emery paper.
Some pics attached.

Bob

[ajaffa1]

G`Day folks. Not much to report today, I`ve started building the beast a new wiring loom.  The old one was badly made and all the insulation had perished and cracked.This is going to be a bit of a mission because this unit has every imaginable sensor and all wired up to a fuel control solenoid to shut it down if it gets too hot, oil pressure drops and etc.
Just a couple of pics.

Bob

[ajaffa1]

G`Day, the wiring for the engine side of things is completed and looks OK, not the right time of year for this type of work, too cold to be sitting on a milk crate for many hours.
Pics attached.

Bob

[dieselspanner]

Looks like you're getting there, keep it up!

Cheers
Stef

[ajaffa1]

Hi Stef, thanks for the support. How are things going up in the mountains? You will be coming into summer time there, We are just going into winter so the wood burner is lit and we have just changed from salads & fish to meat and 3 veg, Can`t beat heavy greasy food and stews when the weather gets cold, bugger the Doctors health advice! 
A bit of a way to go on this old Petter, I hope to have it generating by June. Still got to tackle the generator head.

So today I stripped and cleaned up the injector pumps and linkages, I`m not going to strip out the elements from these as I see no need, this unit has less than 100 hours on the clock so they should be fine. They have been flushed out with carby cleaner, followed by petrol and finally clean diesel. Just waiting on replacement rubber gaiters for the racks
A few pics attached.

Bob

[ajaffa1]

G`Day folks, I`m still waiting for bits to be delivered so I can`t move forward with the Petter PJ2.
So, today I decided to strip the 3 phase generator head. This head has four slip rings and is wired as a Y with 3 single phase 240 volt supplies on each branch of the y, rated at around 20 Amps for each leg. Alternatively I can draw 3 phase power at 415 volts off the three outer legs. Early inspection shows no wear in the bearings or on the slip rings/carbon brushes. This tool has sat in a farmers field for the last ten years, so there is a lot of rust and detritus so it will be cleaned and repainted. the field coils will be cleaned and soaked in polyurethane varnish as will the transformer assembly that feeds the field coils.
A few pics showing dismantled components.

Bob

[ajaffa1]

G`Day everyone. The rubber gaiters/boots for my fuel injector pumps arrived today. Hat off to Stationary Engine Parts in the UK and also the Royal mail delivery system, these parts travelled around 12,000 miles in ten days. Parts ordered from Sydney , Australia at the same time have still not arrived! So the gaiters have been fitted, slippery little buggers to fit, they need to be oiled to get them to slide into place but then the oil makes it almost impossible to hold onto them and manipulate them into place. Took about a half hour each, with much swearing.
The injector pumps are now assembled and ready for installation tomorrow.
some of the generator head casings have been stripped and painted, I will be continuing with the gen head in the morning.
Some pics attached.

Bob

[ajaffa1]

G `Day People. Not much progress today but I did manage to clean the mating faces and fit the fuel injection pumps and fuel control solenoid. Pics attached.

Bob

[broncodriver99]

Coming along nicely. Excellent work.

[ajaffa1]

Thanks Broncodriver, progress is slow but steady, got nothing done yesterday because my Wife decided to rearrange our house. Spent the day moving furniture, with the help of a friend. Too old to be a furniture removalist, can hardly move today! 

Some progress made regardless of my being stiff as a board. Armature cleaned and now has 2 new coats of polyurethane, cooling fan has been etch primed and painted. Electrical continuity has been checked on the windings and everything looks OK.

The four field winding coils have been cleaned and rust removed. They are now re-installed in their casing and the cabling soldered back together with heat shrink to cover the joints.  This assembly has had a new coat of polyurethane and will receive a second coat in the morning. There is electrical continuity through the field windings.

I`ve started work on cleaning up the 3 phase transformers and bridge rectifier that feeds the field windings. The bridge rectifier is made up of 6 diodes bolted to two separate aluminium heatsinks. The diodes all test OK. In the morning I will check the electrical continuity of the transformer windings.

Few pics attached.

Bob