Lister 5/1 Diesel

Ruston-Hornsby 1ZHR

Rebuilding the Ruston - Page 5


Started to get the frame assembled loosely with the water and fuel tanks, battery tray and the Start-O-Matic alternator all sat on the frame.

Then we took the Ruston itself to bits, ready for a hoist onto the frame tomorrow. I may have mentioned this before, but the HR series engines in the smaller sizes are as wide as they are long, the crankshafts overhand the sides by a huge anount.

Bearings haven't been photographed since we went digital some 8 or so years ago, so I took some shots of the bearing shells, which are almost unmarked.



Brought in the larger F717 camera this morning as the Mavica FD100 hasn't got a strong enough flash for distance shots indoors.

First Picture shows the frame with Simon's tank that he kindly donated, the fuel tank that came from Nuenen in 2009 and the battery tray underneath. The batteries are quite big and long, it is a 24V starting system on the Lister Start-O-Matic.

Picture No2 is the alternator with new control box (empty) resting on top. The layshaft bearing blocks and pulley are also there, and the multi-rib engine pulley with the blue spokes is just visible on the left.

Picture No3 is the other side of the alternator, note that I haven't painted the front!

Picture No4 is the Ruston crankshaft, sitting on the floor. Those ends are 2-5/8" diameter, and the eccentric is for the Dobbie McInnes Indicator, you can see the other part in the shot of the main engine bed that I posted yesterday.


08/07/2009 Continued

Got the main part of the engine inside on the crane, lifted it OK on the 1/2 ton setting on the jib but there was a noticeable slight bend! PU8 short engine on the right, and the maroon engine on the left is the Onan W3S that has a piston soaking in oil at present to get the rings freed off.

Once inside, we were able to manouevre the crane round the back of the trolley frame and lift the Ruston over the top of the alternator.

There's a bit of a problem with the connection for the Indicator, as that passes under the frame for the tanks and batteries, so a new connection will have to be made there. The injector leak-off union will similarly have to be shortened and made as a right-angle.

The layshaft bearings and pulley will be underneath the frame, not enough room within the length of the frame to get it all in, and the belt length is better than if it were to be squeezed in on top.


08/07/2009 Continued

Had a session on sorting out the injector leak-off connection this evening.

The existing Ruston injector has a very large connection for something which does not even leak fuel yet, the engine is not old enough!

With the two 12V 105AH batteries in place, there was no room for the very long spigot, so I got another spigot from a Ruston injector that was different but had the same part fitted, and modified it.

The original top part was sawn off and the end refaced in the lathe. A clearance drill for a deep socket body was then drilled down, and then a slot drill in the tailstock chuck gave a flat bottom to the hole.

The original through hole was opened up to 5mm and tapped M6. Once done the little brass spigot was fitted with its copper washer using an 8mm A/F socket. Once back on the injector, there is plenty of room to fit a small rubber pipe and lead it up to the top of the tank to the fuel return connection.

Pictures below show the two spigots side by side, then a shot of them with the brass connector unscrewed, then a shot 'down the barrel' and finally a picture of the fitting back in place on the engine.

The last picture shows the two batteries in the tray. The connection for the indicator and the starting fuse will be addressed later....


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