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PenBits Bachmann Class 66, Assembly Instructions Manual, Page: 3 / 61

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Summary of Contents for Bachmann Class 66

Page 1: ...ASSEMBLY INSTRUCTIONS PK018 SPRUNG BOGIE KIT BACHMANN CLASS 66 PenBits Model Railways www penbits co uk c o 12 Fieldside Long Wittenham ABINGDON Oxon OX14 4QB ...

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Page 3: ...ass 66 Bolster Bachmann Class 66 Modifying the Bogie Drive Dismantling the loco Dismantling the Bogie Modifying the Drive Train Mouldings Reassembly Bachmann Class 66 Preparing the Locomotive Fitting Wheelsets Bachmann 66 Springs Bogie Assembly and Rolling Test Bachmann 66 Cosmetic Sideframes Pickups and Power Bachmann 66 Final Assembly Replacing the Worm Drives Assembling the Bogies Checking Clea...

Page 4: ... kits are intended to be assembled by adult modellers with some workshop experience and awareness who are able to exercise due care and attention when handling the materials and carrying out the various operations involved Many of the metal components have sharp edges Chemical products used in assembly can be injurious through contact with skin or eyes ingestion or inhalation Some processes involv...

Page 5: ...f viewer Full printouts in booklet form can also be produced using third party services For more information visit our Printing the pdf Files page If you wish to print out sections of the HTML instructions they are formatted in standard HTML CSS but even so the print function in some browsers does a better job of rendering them than others We find that Print function of the Google Chrome browser p...

Page 6: ...e significant with the relatively thick materials that we use in the main structural parts of our kits than it is with the thinner materials typically used for detail parts The ideal degree of etching is indicated by the slots see above as manufactured being just slightly on the tight side of the easy sliding fit required The range of degree of etching which we deem to be acceptable is from a ligh...

Page 7: ... instructions for each component Soldering We use Carrs 145 wire solder with either Carrs Green Label liquid flux or La Co paste flux except where stated otherwise You will develop a technique that suits yourself and your iron but the following notes might help as a starting point Flux can be applied to the workpiece using a brush a pointed cocktail stick or for paste flux a syringe With liquid fl...

Page 8: ...r Catch it either between the jaws of the chuck if they are far enough apart or for smaller wire and armature diameters within the flutes of the drill Using a pair of pliers to apply tension rotate the lathe chuck by hand to wind the wire around the armature Pay heed to the direction of winding a surprising number of diesel bogies were fitted with left hand wound coil springs sometimes with a dupl...

Page 9: ...spring Slide back the tailstock and release the spring from the chuck Trim off the waste at the ends of the spring File the ends of the spring flat using the free end of the armature to support it Reset the armature in the chuck to the desired length of the spring General Notes 9 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 10: ...encing work Please follow the manufacturer s instructions for the dismantling of the locomotive Our instructions guide you in making modifications to components of the locomotive and fitting the kit The modifications the kit and the instructions have been tested by the kit designer and others to confirm that they are practical serviceable and when used as intended produce a working locomotive whos...

Page 11: ...elve axle bearings and test it in one of the subframe axle slots It should be a free sliding fit but if it s a bit loose don t worry It will more likely be a little tight in which case gently file the vertical sides of the bearing slot take off a little at a time equally from each side and try to keep the two sides vertical until the free sliding fit is achieved for the entire depth of the slot No...

Page 12: ...ed in all kits except for the Class 52 Test fit the bearings in the large central holes in the carriers The body of the bearing excluding the flange should pass through the hole If necessary gently relieve the holes with a round needle file working evenly around the edges until the bearings pass through The folds in the bearing carrier frames are best made in bending bars or between any two trued ...

Page 13: ...pringy one works OK If anything overfold beyond 90 just slightly Make Fold 3 to approximately 45 Note that this fold is along the line of the tags at the base of each carrier forming part of the frame assembly jig and is not a part of the finished carriers This is a view of the folded carrier frames Fold 3 has been made to 90 in this case but anything over about 45 will do The photo shows outside ...

Page 14: ...ts carrier by a very small amount not quite as much as in the sketch and the faces of the carriers should be parallel with the end faces of the bearings Using a cocktail stick apply a small amount of flux around the join between the protruding part of each bearing and the face of its carrier Holding a bearing in place with a heat insulating instrument to make sure it doesn t move bring the iron wi...

Page 15: ...d On the inner carriers the ones without a hole in their back face apply a small amount of flux cocktail stick to the folds and butt joints around the top of the carrier and flash in some solder to reinforce the folds and form a fillet between the lower edges of the ears and the top of the carrier body Clean off any solder which adheres to the outer faces of the ears Ensure the holes in the ears r...

Page 16: ... carrier tops The fit along the line of the axle i e of the subframe plate between the bearing flange on one side and the inner facing edges of the carrier on the other should be quite loose to accommodate tilting of the axle Check that all traces of the tag are removed from the edge of the bottom face of the carrier as otherwise it can bind with the lower edge of the subframe slot Although the ai...

Page 17: ... main longitudinal folds each of which is in three parts carried over the transom sections under each axle slot Ensure the folds are at a true right angle Remove the spring Seat Ear etches S5 from the fret There are two of each hand for each bogie Check that the small etched holes are clear to pass a 0 5mm drill Bachmann Class 66 Subframes 17 60 c PenBits Model Railways All Rights Reserved 27 09 2...

Page 18: ...e fold slot to the outside of the fold at the centre of each Seat Ear to fold the two layers of the ear back on themselves Fold out the lateral restraint ear and the longitudinal restraint from each Seat Ear Bachmann Class 66 Subframes 18 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 19: ...e springs remain free of solder use a 0 5mm drill to clear them if required Ensure each of the fold over tags along the top edges of the Seat Ears is reinforced with a small fillet of solder Re check that the main mainframe folds are at 90 and then check against a flat surface that the eight secondary suspension seats are square and level Remove the Baseplate S1 etches from the fret and make the 9...

Page 20: ...o spot axle end of each frame is the outer i e coupling end Engage the top parts of the stretchers in their slots in the Mainframe sides support their lower ends against the Mainframe cross members and solder them in place Check that the whole assembly is square and true Reinforce each of the Mainframe folds with a fillet of solder Take care to ensure that the region immediately around the axle be...

Page 21: ...Clean off flux residues and tidy up excess solder from the outer surfaces Bachmann Class 66 Subframes 21 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 22: ...lsters Remove the Bolster Centre etch B1 from the fret Make the two folds as shown Remove two of the Upper Stiffener etches B4 from the fret and fit them into the slots in the Bolster Centre Bachmann Class 66 Bolster 22 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 23: ... fillets of solder around the nut and the Upper Stiffeners Check that the screw can be removed from the nut the grease should have prevented it from being soldered in place It is as well to tighten it again and leave it in place while the rest of the bolster is soldered up Remove two of the Bolster Side etches B3 one of each hand from the fret Check that the vertical slots are clear to take the et...

Page 24: ...f the traction ears are parallel with the upper part of the Bolster Side Adjust all folds as required Remove two of the Bolster Frame etches B2 one of each hand from the fret Check that the round part of the slot in each secondary suspension seat will pass a 0 5mm drill Make the longitudinal fold in two sections to fold out the two brackets from the lower edge of each frame Fold down the secondary...

Page 25: ...h as shown Leave the central parts free of solder Assemble one of the Bolster Sides and its Bolster Frame Fit the Bolster Centre to the slots in the middle of the assembly and support clamp the three components together ensuring that they are square and that the tabs are fully home in their slots Solder up the Bolster Centre Side and Frame reinforcing all the main folds with fillets of solder Repe...

Page 26: ...ateral restraints on the subframe sides with a free sliding fit or just a slight resistance the traction ears should just fit between the longitudinal restraints on the subframe sides again with a free sliding fit A tight fit can be addressed in the first instance by light filing on the circular edges of the traction ears or lateral restraints half etched guides are provided to help preserve the c...

Page 27: ...es from the terminals and disconnect the wires leading to the bogies It might be necessary to desolder them but they may just be passed through holes in the terminals and retained by the sleeves Select one of the bogies and undo the screw which retains the bogie pivot in the chassis block Drop the bogie out from the bottom of the block The cardan shaft joining the motor to the bogie will either co...

Page 28: ... the middle and inner axles to feel how free running they are as you will need to reproduce this later when reassembling the drive unit Gently press out the idler axles We found that the axles are a tight fit in one side of the moulding only so once you have removed the first one and thereby determined which side that is press them out from the tight side and when the time comes replace them from ...

Page 29: ... moulding remove the bogie frame retaining clips and then thin down the vertical end faces of the moulding to about half their original thickness Exercise some care as in spite of being somewhat soft and soapy the plastic can crack in a brittle manner if overstressed Take great care at all stages not to damage the retaining lugs for the main axle bearings Cut the pivot parts from the combined Pivo...

Page 30: ... a C C corresponding to the Co Co arrangement of the prototype But you can avoid a certain amount of complication by using the 4 wheel parts of the drive as they are and assembling the loco as a B1 1B in which configuration it will perform perfectly adequately and retain much of its hauling capacity If you wish to take this option you can skip the remaining steps in this section Remove the Drive P...

Page 31: ...off with a very sharp knife To hold the gear while working it clamp one of the idler axles into a collet pin chuck with about 2 1mm projecting The gear can then be placed over the axle and worked with the file or knife while holding the pin chuck in the other hand Filing will leave fuzzy clods of deconstituted plastic around both the outside edges of the bosses and the axle holes It is essential t...

Page 32: ...oles in the moulding and insert the idler axle to retain the axle and plates in position Check for freedom of movement between the two parts of the drive train moulding it should be sufficient for the inner axle to move up and down about 1mm with respect to an imaginary line joining the centres of the other two axles It will probably be much more than this but if there is a problem just file back ...

Page 33: ...That concludes the modifications to the bogie drive units Bachmann Class 66 Modifying the Bogie Drive 33 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 34: ...ting here with the loco dismantled body separated from chassis and bogies and drive shafts removed Remove the two Pivot Plate etches P1 from the fret Invert the chassis block and check the fit of the Pivot Plates over the bogie pivot holes with their slots engaging in the cast transverse ribs either side of the holes Clear any raised features oxidation grease or loose material from the inside of t...

Page 35: ...t the top faces of the Pivot Plates are parallel to the surface A slight deviation can be accommodated any significant slope would indicate an error in assembly Arrange the Bolsters on the blocks standing at approximately the correct pivot centres and rest the loco over the bolster tops adjusting their positions until the cast ribs either side of the bogie pivot holes engage in the slots in the Pi...

Page 36: ...n the Pivot Plate and casting but not so much as to squeeze out significantly beyond the edges of the plate Carefully lower the loco back into place on to the bolster tops and any third support ensuring that the casting ribs engage in the slots in the Pivot Plates that the four feet of each bolster are firmly in contact with the reference surface and that the loco is supported in the previously es...

Page 37: ...olding the drive gears in mesh and transmitting the tractive forces from the drive train to the axles Open out the internal diameters of each of the Bachmann axle bearings from 2 0 to about 2 1 to 2 2 mm We found that the tapered end of a 2 3mm cutting broach was about 2 1mm diameter so used that to cut half way through the bearing from each side finishing off with a smooth broach Not a technique ...

Page 38: ... unit using the Bachmann bearings Fit the drive unit into the subframe engaging the four bearing carriers into the slots in the subframe Holding the drive unit with one hand and the subframe with the other check that the drive unit can move freely up and down relative to the subframe with the carriers sliding in their slots At rest the tops of the carriers will be level with the tops of the subfra...

Page 39: ... amount of lateral play There should be just a little enough to allow the wheelset to tilt such that the wheel on one side is raised about 1mm with respect to that on the other If necessary dismantle the wheelset and fit full and half width 2mm washers supplied on the fret between the bearing carriers and wheels until this condition is met If there is insufficient play even with no washers fitted ...

Page 40: ...ted wheel is adjacent to the carrier for the insulated side of the bogie Test fit each inner and outer axle in its slot to confirm that the correct number of spacing washers has been fitted Lubricate the bearings with a light machine oil and ensure that the oil is taken in to all the axle bearing interfaces That completes the assembly of the wheelsets Fitting Wheelsets 40 60 c PenBits Model Railwa...

Page 41: ...Return to the primary suspension wires and check that the epoxy resin beads have set hard Take four of the primary springs one of the central wheelsets and insert one spring through each of the four holes in the ears of the bearing carriers feeding them through until retained by the epoxy beads Check that the epoxy beads do not restrict the movement of the springs in the carrier Reduce their lengt...

Page 42: ...ng carriers of the central axle aligned over their slots Pull the primary springs outwards so that their inner ends are sitting properly in the tops of the central bearing carriers Move the inner and outer wheelsets towards the ends of the bogie until their bearing carriers are engaged in their slots Adjust the assembly so that the primary springs are sitting on top of the secondary spring seats U...

Page 43: ... bearings wobbly wheels etc It is easiest to correct such things at this stage Fit the secondary springs to the subframes insert the plain end of each spring through the secondary seat adjacent to the spring retaining ear then steer the plain end through the opposing seat continuing to slide the spring through the seats until the bent over end slips inside the retaining ear Secondary spring after ...

Page 44: ...n the chassis block by the M2 screws nylon insulators and brass washers P2 P3 provided in the kit A plastic card spacer is fixed to the top of the Bolster the thickness of the spacer being selected to produce the desired ride height for the loco The nylon insulator is shortened so that the screw can pull the Bolster Top up against the Pivot Plate without the insulator touching the top of the Bolst...

Page 45: ...r buffers just in the way that they ve been fitted to the loco You might also wish to check the maximum height overall and then reflect on whether the manufacturer has got the buffers in the right place Ultimately working to tenths of millimetres it will be a judgement call as to exactly where the correct ride height lies Once you are satisfied with the spacers dismantle the loco once more Remove ...

Page 46: ...remlins now before the mechanical drives and detail are fitted It is also extremely satisfying to feel how the locomotive moves with its sprung suspension You also have the option at this stage to do rolling tests with the Drive Units fitted to the axles provided that you have not re fitted the worms into the drives Remove the bogies from the loco and the Bolsters from the Subframes Carefully plac...

Page 47: ...k couplings Cut through the two vertical pillars at each end of the undertray Cut through the two outriggers on each side of the undertray between the brake detail and the inner faces of the detail moulding File down the remaining outrigger stubs to 0 3 0 5mm and remove any other projections from the inside faces of the detail moulding Put the undertrays safely to one side for later Tidy up the in...

Page 48: ...of the outer extensions of the etched subframe sides to get the plastic frames to sit level on the etched Subframe with their wheel hubs aligned vertically and horizontally with the axle centres For vertical alignment the tops of the etched bearing carriers should be level with the top edges of the Subframes Check that there is clearance between the inner ends of the Drive Units and the plastic fr...

Page 49: ...Make the main fold in each outrigger Check the fold is at 90 and reinforce it with solder Make the outer fold in the brake detail support note that the fold is not exactly perpendicular to the sides of the etch Bachmann 66 Cosmetic Sideframes 49 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 50: ...igger Completed Inner and Outer Outriggers Taking the Subframes fit the Outriggers to the Longitudinal Restraints fettling either or both as necessary but being careful not to disturb the alignment of the restraints Bachmann 66 Cosmetic Sideframes 50 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 51: ... if not File away the tabs if still necessary You ve now completed the assembly of the visible brass parts for the kit so this is the time to chemically blacken them if you wish Returning to the moulded undertrays use a file to mark the inside faces of the cylindrical mouldings joining the brake shoes Take the flitchings and mountings on each outrigger down flush with the top surface of the outrig...

Page 52: ...ent of the centre axles The height of each detail should be set by the top of its square mounting spigot against the underside of the bracket off the etched outrigger Cut out sections of the rear plastic framing as shown leaving enough to engage in the slots in the Subframe sides This is to give access to the body mounting screws Refit the plastic bogie frames to the Subframes springing them outwa...

Page 53: ... unit moulding make sure that they do not interfere with the free movement of the drive unit within the bolster and subframe Limit their overall width to approximately that of the cover over the worm drive If you run wires between the two articulated parts of the drive train ensure that they do not restrict the articulated movement Connecting wires should be sufficiently flexible or routed in such...

Page 54: ...hat the pick ups themselves are preloaded below their operating position by about 1mm The wires are tinned and then soldered to the copper clad with a touch of the iron with the feed wires tinned and soldered on in turn resin cored solder being used throughout The feed wires from the pickups back to the loco PCB are firmly anchored to the bogie bolsters holes are provided near the top of each bols...

Page 55: ... the shafts are tight they were pretty much immovable in our test build the covers seem to sit differently now we have removed the pivot part of the moulding the solution is to relieve the semicircular bearing retaining surfaces of the top cover using a round file To check that the worm shafts are absolutely free it may be advisable to dismantle the wheelsets from the Drive Unit Lubricate sparingl...

Page 56: ... the ears of the bearing carrier of the remaining axle Similarly fit the two springs on the other side of the bogie Take the Subframe which goes with the Drive Unit and place it on the narrow block for wheeling Orientate the Drive Unit correctly with the Subframe Slot the Drive Unit into the subframe with the primary springs resting on the tops of the secondary spring seats Ensure that the bearing...

Page 57: ...r that Subframe make sure it is facing the right way and slide it into place in the Subframe until the lower edges of the four secondary spring seats are resting on the secondary spring wires Pushing down gently on the Bolster use a small screwdriver to bend each spring slightly inwards so that it slides up the inner face of its spring seat and snaps into the slot in the seat Bachmann 66 Final Ass...

Page 58: ...t on the tops of the worm covers you might wish to substitute the plastic worm covers by the etched covers supplied in the kit Fitting Etched Worm Cover if required If you do wish to use one or both of the etched worm covers note that we did NOT find that this was necessary in our test build and for preference would use the original plastic covers remove the cover etch from the fret Having first f...

Page 59: ...old in the end bearing retainers of the cover Strengthen the folds around the top of the cover with a touch of solder Remove the plastic worm cover and the worm shaft bearing assembly from the Drive Unit Bachmann 66 Final Assembly 59 60 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 60: ... with its drive shaft and clip the correct end the shaft into the drive socket of the bogie Offer up the bogie into the aperture at its end of the loco Route any pickup wires through the holes in the chassis block Engage the free end of the cardan shaft into the loco s flywheel drive socket and line up the bogie top pivot with its pivot hole Position the insulator a nd washers in the pivot hole an...

Page 61: ...under the speaker enclosure if you machine away most of the thickness of the original moulded dimple raised over the pivot screw If you are taking power feed through the pivot screw you can make an additional channel through the speaker enclosure moulding to take the connecting wire Finally replace the body of the locomotive Place it on a level surface and adjust the alignment of the cosmetic bogi...

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