Wilesco Steam Roller D375 User manual

Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Overview
Stage 1, Front Part Stage 6, Boiler Assembly Operating instructions
Stage 2, Burner Chamber Rear Stage 7, Burner, Front Connection Functioning of the original engine
Stage 3, Burner Chamber Front Stage 8, Steering Mechanism The Energy Transformation
Stage 4, Flywheel Shaft Stage 9, Rear Rollers History
Stage 5, Cylinder Stage 10, Roof and Chimney Accessories
Special Notes on the Assembly
1. The assembly takes approx. 3-4 hours. Please allow sufficient time in order to avoid too many
interruptions.
2. This is a valuable, demanding model. The assembly requires quiet, concentration and manual
dexterity.
3. These instructions are applicable to both the steam engine as well as the traction engine. Please
refer to the relevant text/picture.
4. The assembly should be carried out on a clean even table, so that no parts are lost.
5. All parts have been checked several times and fit into each other. If something does not fit, do not
use force but study the assembly instructions/illustrations again.
6. Before operating the steam engine, please read and observe the operating instructions carefully.
7. After longer periods of operation, individual screws might need tightening.
Note: Brass and black/brass models. The brass parts are treated with a clear lacquer to prevent tarnishing.
After usage and to prevent tarnishing, apply a further coat of clear lacquer.
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany

Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Stage 1, Front Part Steam Roller
Illustration 1
1 2 x front rollers
2 1 x saddle cam
3 1 x saddle
4 4 x slot bolts M3x4mm
5 4 x hexagonal nuts M3
6 1 x roller bracket
7 6 x washers 8/4.5mm
8 1 x front axle diameter 4x116mm
9 1 x scraper harness
10 2 x spacers, red diameter 6x24mm
11 4 x slot bolts M2x6mm
12 4 x hexagonal nuts M2
Illustration 2
Push the two front rollers (1) onto the front axle (8).
The pressing nearer the roller-edge faxes
outwards. Push on both sides of the front axle (8)
washers (7) then a red spacer (10). Assembly of
front axle with rollers in the wheel bracket (6). The
play between wheel bracket and the front rollers is
adjusted by means of washers (7) so that the front
rollers move easily.
Illustration 3
Fit the scraper harness (9) with 2 slot bolts (11)
m2x4mm and nuts (12), each side. Insert screws
from either top or bottom and tighten well.
Illustration 4
The saddle cam (2) is fitted with 4 slot bolts (4)
M3x4mm and nuts (5) onto the saddle (3).
This front part is put to one side and connected
with the boiler in stage 8.
Stage 1, Front Part Traction Engine

Illustration 1a
16 1 x wheel assembly traction engine
17 1 x front axle ?4 x 104 mm
7 4 x washers 8/4.5mm
18 2 x front wheels
19 2 x wheel locking caps ?4 mm
The front axle (17) is pushed trough the wheel
assembly (16). The washers are fitted to both sides
Illustration 2a
One front wheel (18) is fitted to the axle/wheel
assembly and is then placed onto the table in such
a manner that the front axle is in the vertical
position and the wheel is on the table. The other
wheel (18) is then fitted. The locking cap (19) is
pushed onto the free end of the front axle. Invert
the front assembly part and fit the second cap. This
front part is put to one side and fitted to the boiler in
stage 8.
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany

Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Stage 2, Burner chamber, rear
Illustration 5
20 1x burner chamber cover
21 1x control cabin
22 1x steering shaft bracket
23 1x clutch lever
24 1x tow bar
5 10x hexagonal nuts M3
4 8x slot bolts M3x4mm
25 2x slot bolts M3x6mm
26 1x burner chamber rear wall
Illustration 6
Fit the tow bar (24) to the control cabin (21) with 2
slot bolts (4) M3x4mm and nuts (5). The two slot
bolts (25) M3x6mm are inserted at the top of the
burner chamber cover (20) and secured with 2 nuts
(5). At a later stage the piston cylinder plate is fitted
to these screws.
The rear wall of the burner chamber (26) is fitted to
THAT end of the cover, which has the hole on top
for the steam whistle. Then the steering shaft
bracket (22) is fitted to the right hand side of the
cover and driver's cabin, with 2 slot bolts (4)
M3x4mm and nuts (5), using the second and fourth
hole from the bottom. The steering shaft bracket
has to be mounted between the rear wall of the
burner chamber and the control cabin (see
illustration 6). Secure the burner chamber rear wall
at the bottom.
Illustration 7
Insert on the left hand side the clutch lever (23) into
the second and fourth hole from the bottom with 2
slot bolts (4) M3x4mm and secure with 2 nuts (5).
On completion, all screws should be checked for
tightness.
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany
Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Stage 3, Burner chamber front

Illustration 8
30 1 x gangway bracket
31 1 x gear wheel, large
32 1 x burner chamber front wall
33 1 x collar screw M3
34 2 x washers diam. 6.7/3mm
5 11 x hexagonal nuts M3
4 10 x slot bolts M3x4mm
35 1 x worm bracket
Illustration 9
Fit large gear wheel (31) with collar screw (33) to
the outside of the burner chamber (20). Then fit 2
washers (34) and nut M3 (5) to the screw from the
inside of the burner chamber (20).
Tighten carefully with the combination spanner.
The gear wheel must move freely.
Illustration 10
Fit the worm bracket (35) with the opening facing
downwards (because of air circulation) to the
chamber front wall (32) with sides facing outwards,
tighten well. Place front wall of chamber into
position with 2 slot bolts (4) and nuts (5) and using
the second and third hole from the bottom fix
gangway bracket (30) through front cover onto
burner chamber.
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany

Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Stage 4, Flywheel shaft
Illustration 11
36 1 x machine plate
37 1 x flywheel
38 1 x pulley
39 1 x grub screw
40 1 x crank disk
41 1 x ex-centre plate
42 1 x collar screw Mw short
43 1 x spacer diam. 6x3mm
44 1 x slide rod
45 1 x brass cap
46 1 x washer 5.6/3mm
5 2 x hexagonal nuts M3
47 1 x hexagonal nut M4
7 4 x washers 8/4.5mm
48 1 x piston rod
49 1 x flywheel shaft
Illustration 12
This section must be assembled very carefully, as
the functioning of the steam engine is dependent
on it. The machine plate (36) is secured loosely
with the 2 nuts (5) onto the protruding screws of the
burner chamber cover. The fly wheel shaft (49) is
pushed through the bearings of the machine plate,
with the short thread on the right hand side. Fit 2
washers (7), the brass cap (45), and then a further
washer (7) to the left hand side of the shaft. Fit a
washer (7), ex-centre plate (41), and slide rod (44)
with bend towards the chamber and a further
washer (46) to the right hand side of the shaft.
Then screw the crank disc (40) onto the right hand
side of the shaft, using the middle threaded hole.
The piston rod (48) is attached to the crank disc by
means of the collar screw (42), with spacer (43)
fitted between piston rod (48) and crank disc (40).
Illustration 13
Now the flywheel (39) is pushed onto the left hand
side of the shaft with the pinion inwards. Screw
onto the thread a washer (7) and a nut (47) M4 so
that the shaft is slightly pulled inwards.
Tighten carefully all parts so that the crank disk is
firmly held in place.
IMPORTANT: The small pin of the ex-centre disk
(41) must move freely in the oval hole of the crank
Illustration 14
Tighten the M4 nut with the combination spanner
and move the flywheel along the shaft until the
pinion engages with the large gear wheel. Ensure
that the shaft is moving freely without the ex-centre
pin slipping from the oval hole in the crank disk.
Remove the nut M4 and the washer.

disk (40).
Illustration 15
Fit pulley (38) and tighten by means of the grub
screw (39).
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany

Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Stage 5, Cylinder
Illustration 16
54 1 x cylinder cap
55 1 x cylinder complete
56 1 x seal diameter 5.5/2.5mm
57 1 x slide valve
4 3 x slot bolts M3x4mm
58 1 x cylinder cover
59 1 x collar screw M2
12 1 x hexagonal nut M2
Illustration 17
Push the slide valve (57) into the cylinder (55).
Push on black cylinder casing (55) (nose
downwards). Place the slot bolts (4) through the
casing cap (54) fit seal (56) to inside of cap. Screw
on cap.
Illustration 18
Screw on cylinder with 2 screws (4) onto the
machine plate. Do not tighten as the steam pipe
must be inserted. Connect piston rod and piston
with the collar crew (59) and nut (12). Then connect
the slide rod to the slide valve with the slot bolt
(11).
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany

Assembly Instructions
Steam Roller D375, D376, D377 & Traction Engine D415, D416, D417
Stage 6, Boiler Assembly
Illustration 19
60 1 x steam supply valve
61 1 x boiler
62 1 x steam exhaust pipe
63 1 x steam whistle
64 1 x steam valve
65 1 x spring loaded safety valve
66 1 x oiler body
67 1 x oiler screw
68 1 x slot bolt M4 x 6mm
69 1 x seal diam. 10/6
70 4 x seals diam. 8/5
71 2 x seals diam. 7/4
56 3 x seals diam. 5.5/2.5
Illustration 20
The large seal (69) is placed onto the spring loaded
safety valve (65). This is screwed into the boiler.
The steam valve (64) is screwed into the boiler (61)
with 1 or 2 seals (70) so that the lever is pointing to
the left (as seen from the sight glass).
For safety reasons the boiler and the spring
loaded safety valve are already assembled. The
boiler has been pressure tested in the factory to 4.5
bars.
Illustration 21
Then the boiler is pushed into the burner chamber
(with the sight glass towards the control cabin) with
the valves pointing downwards. When the boiler
has been inserted into the chamber, it should be
turned, so that the valves point upwards.
The boiler is now fastened by the slot bolt (68)
The steam whistle (63) requires one ore two seals
(70) so that the lever is to the rear and can be
moved to the left or right. Do no over tighten.
Illustration 22
The small seals (56) are places into the opening of
the steam valve and lower cylinder. Then the steam
supply pipe (60) is screwed in. First of all tighten
slightly under the cylinder then at the steam valve.
Be carefully to screw-in correctly. Now tighten. Fit
the steam exhaust pipe (62) with seal (56) into the
cylinder and boiler, and tighten. Finally tighten the
cylinder with both slot bolts.

Illustration 23
Tighten the machine plate with the two nuts M3 and
the slot bolt (68). Boiler, cylinder, machine plate
and steam pipes are now fixed in position. The oiler
body (66) requires one seal (71) and is screwed
into the top of cylinder. Then the oiler cap (67) is
screwed in with a further seal (71).
Text & illustrations: Wilesco Wilhelm Schröder GmbH & Co., Germany