roundhouse Darjeeling 'D' Class Garratt User guide

Darjeeling ‘D’ Class Garratt
Owners Handbook

Operating Instructions
IMPORTANT: Read these instructions carefully before operating
the locomotive
The following items are required for running this engine and are not
included with the model.
Fuel Butane gas. See ’Gas System’ section.
Water See 'Filling the boiler' section.
General Lubricating oil See 'Lubrication' section.
SAFETY PRECAUTIONS
This is a working model locomotive using steam under pressure
and highly flammable fuel. Provided it is operated with reasonable
care and attention, no problems should arise.
It is intended for use out of doors and must only be operated in a
well-ventilated area.
Whilst the locomotive is in use, hot gasses are exhausted up the
chimney and excess steam frequently blows off through the safety
valve even when stationary, so operator and spectators should not
bend over the model.
As you will appreciate, this is not a toy and is therefore unsuitable
for young unsupervised children.
Follow manufacturer’s recommendations regarding the safe
storage of Butane gas canisters.
Some areas of the model will get quite hot whilst it is operating, so
a pair of gloves is provided in the tool kit for your protection.
Always have to hand either a fire extinguisher or wet cloth when
operating the model.
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CONTENTS
Tool kit Page 4
Running in Page 4
Handling & transporting Page 4
Access to controls Page 5
Identification of parts of the locomotive Page 6
Preparing for operation Page 7
1. Filling the gas tank Page 7
2. Filling the boiler Page 8
3. Lubrication Page 10
4. Lighting the burner Page 11
Running the locomotive Page 12
Batteries Page 13
Radio control system Page 13
Water top-up system Page 14
Trouble shooting & maintenance Page 16
Storage between operating sessions Page 16
Steam leaks Page 16
Water top-up system Page 17
Steam regulator not shutting Page 17
Radio control Page 17
Gas system Page 17
Gas jet removal Page 18
Gas regulator maintenance Page 19
Boiler and gas tank certificate, Pages 21 & 22
(EC Declaration Of Conformity).

TOOL KIT
The following items are included with your locomotive:
One 60ml bottle of special steam oil for use in the lubricator.
One 60ml syringe with plastic tube for filling the boiler with water.
One water top up pump bottle and ‘swan neck’.
One set of spare washers and ‘O’ rings.
Two spare gas jets.
One pair of protective gloves.
One cleaning duster.
One wheel back to back gauge and Allen key.
One Allen key for cylinder socket cap screws.
RUNNING IN
All locomotives are test run before leaving the factory, but when new, will
require several hours of running in to overcome initial tightness and allow
valves etc. to 'bed in' completely. Also, the loco will waste a proportion of
it's water and steam until 'run in' due to leaking slide valves, a tendency
to prime more, and simply overcoming the initial tightness of the moving
parts. As the model heats up and cools down each time you raise steam,
screws and nuts have a tendency to stretch and loosen a little, which
means that you will need to make regular checks and 'nip up' any that
become loose.
HANDLING & TRANSPORTING
As this is a large articulated locomotive,
lifting and moving it around when not on the
track should be done with great care to
avoid damage. To aid in this, the model is
supplied with a specially designed carrying
cradle. Once the two shipping screws have
been removed (see separate instruction
sheet) the model can be rolled on or off the
cradle base as follows. Stand the cradle on
the track with the centre of the base lined up
with the centre of the track and lower the
two sides down flat.
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Holding the loco by the front and
rear footplates, roll it off onto the
track, lining up the wheels as they
exit the cradle base. Because the
loco wheels sit in cut-outs in the
base, it is necessary to lift the
model very slightly as it is
wheeled along. Once the wheels
are clear of the cut-outs, they will
roll along the base. Hold the
cradle base while rolling the loco
along to prevent it from sliding. Do
not lift the model by holding the sides of the bunkers, always hold the
footplates.
Getting the loco into the
cradle is simply a
reverse of the previous
procedure
ACCESS TO THE CONTROLS
For normal operation, all main controls are accessible without the need to
remove any part of the locomotive; however, for ease of servicing, the
cab roof can be removed by sliding backwards, and then lifting off.
The gas regulator is located in the right hand front corner of the rear
bunker.
The displacement lubricator is positioned inside the cab, at the rear left
hand side.
The gas filler valve and gas tank are situated in the rear bunker,
underneath a dummy coal load. There is a hole in the Dummy coal load
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IDENTIFICATION OF LOCOMOTIVE MAIN CONTROLS
Displacement
Lubricator
Filler Cap
Gas
Filler
Valve
Water
top up
valve Gas
Regulator
Pressure
Gauge
Water
Gauge
Rear Bunker
With cab roof and dummy
coal removed
Front Bunker
With cover and steam dome
removed.
Steam
Regulator
Displacement
Lubricator
Drain Screw
Gas Jet
Holder
Union
Nuts
Battery Holder
for ‘AAA’
Batteries
R/C switch Safety Valve

to allow access to the Gas Filler Valve. The coal load can be removed by
simply lifting it upwards.
The switch for the locomotive R/C equipment is on the rear of the front
bunker, just in front of the smoke box door..
The radio control equipment fitted to the locomotive is powered by 4 x
AAA batteries. The battery box is accessed by lifting off the top of the
front bunker.
PREPARING FOR OPERATION
The locomotive must be serviced before being operated. It is important to
perform all of the following operations.
NOTE, check that the batteries in both the R/C transmitter and the
locomotive are in good condition before attempting to operate the model -
see the Radio Control section later on.
1) FILLING THE GAS TANK
The filling of the gas tank should only be carried out in a well-ventilated
area, where there are no naked lights or other lighted locomotives close
by. Ordinary Butane or Iso-butane gas (as used in gas cigarette lighters)
is the preferred fuel, though for economy, the larger canisters as used for
blowlamps or camping stoves etc. are better. The larger canisters have
an EN417 threaded self sealing valve on top and require a special
adapter to couple up to the filler valve on the locomotive. A Gas Filler
Adapter is obtainable from your local garden railway supplier or direct
from ROUNDHOUSE. Mixed gasses are also available and may be used
if ordinary butane or iso-butane are not available, but see the ‘Gas
System’ section for more information on this subject.
Before attempting to fill the gas tank, make sure that the gas control valve
is closed by turning it clockwise and that there are no other operating
locomotives or naked flames nearby.
The filler valve for the gas tank is in the rear bunker and is accessed
through a hole in the dummy coal load. Ensure that the gas canister is
fitted with a correct adapter, then invert it and place its nozzle over the
gas filler valve. Support the locomotive from underneath in the area of the
tank, and press the canister down. The gas will be heard hissing as it
enters the tank and a small amount will escape around the valve. This is
quite normal and is the tank venting as the liquid enters. After about 30
seconds liquid gas will emerge from the valve showing that the tank is
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full. Remove the canister immediately. Filling times will vary depending
on the temperature of the locomotive and are for guidance only.
2) FILLING THE BOILER
There are two methods of filling the boiler
1/ Quick filling when cold.
The brass dome in the centre of the boiler can be lifted off to allow
access to the safety valve. This can simply be unscrewed and the boiler
filled using the syringe and tube provided.
The dome is a substantial and heavy item, being machined from solid
brass. Take care not to drop it onto the locomotive, as the weight of it
may damage the model. Care is especially needed if the locomotive is, or
has been in steam, as the dome will be hot and will retain its heat for a
considerable time.
Remove the safety valve and using the 60 ml syringe and plastic tube
supplied, fill the boiler right to the top with clean water. Distilled water is
recommended if available. As an alternative, clean tap water can be used
in soft water areas. Also, rain water or water from a dehumidifier can be
used provided that it is adequately filtered through a coffee or wine
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making filter to remove any particles or debris in the water.
Do not use deionised water as this may cause long term damage to the
boiler and fittings.
There has to be a space above the water to allow steam to be raised so,
insert the end of the plastic pipe into the boiler and withdraw 30 ml of
water with the syringe. Replace the safety valve finger tight, and then
place the dome back over it.
2/ Pump bottle when hot or cold.
In the right hand side of the cab is a top-up-valve. Fill the plastic pump
bottle with clean water and push the end of the plastic tube into the
socket in the top up valve.
The socket has a slight taper in it, and a little downward pressure on the
tube will ensure a good seal.
To assist locating the plastic tube into the top up valve, a copper ‘swan
neck’ is fitted that holds the plastic at the correct angle to enter the valve.
Pump the handle on the bottle to inject water into the boiler whilst

maintaining this downward pressure. Keep pumping until the water level
in the water gauge is almost at the top of the glass.
Remove the plastic tube. Note that a small amount of water will remain in
the top of the valve but will evaporate away as the valve heats up.
3) LUBRICATION
Regular lubrication of all working parts is important and should be carried
out before each operating session. There are two types of lubrication
required: The external moving linkages and bearings are lubricated with a
medium oil such as motor engine oil, and the internal steam mechanisms
such as cylinders, pistons and valves are lubricated with a special steam
oil. Infrequent external lubrication will allow parts to run dry, and over
oiling can form pools around operating parts that attract dirt and grit. If too
thin an oil is used it will evaporate very quickly as the loco gets hot –
leading to dry running. We recommend the use of a 20-50 motor oil for
external lubrication. When carrying out general lubrication, do not forget
the regulator spindles (see Trouble Shooting section for further details of
oiling the regulators).
Internal lubrication is achieved by steam oil that is mixed with the steam
in the displacement lubricator, housed in the rear, left-hand corner of the
cab. Unscrew and remove the knurled cap from the top of the lubricator.
Locate the knurled drain screw at the base of the lubricator and unscrew
it two or three turns, but do not remove it. Any water in the lubricator will
run out through the hole in the drain screw. When the water has finished
draining, tighten the drain screw and refill the lubricator from the top with
the steam oil supplied. Replace the cap. Take time filling the lubricator,
especially when cold, as the oil takes time to run down and may trap an
air bubble. Both cap and drain screw are fitted with ‘O’ rings and need
only be closed finger tight.
NOTE: Only special steam oil as supplied should be used in the
lubricator and under no circumstances should ordinary oil be substituted,
or damage may result.
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