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PenBits PK002, Assembly Instructions Manual, Page: 3 / 52

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General Notes

A Few Words …
Safety
The Instructions

Structure
P rinting

The Etches

T a gs
Slo ts
De gre e  o f Etching
C usps
Fo lds

Soldering
Warranties

A Few Words …

These  advices,  taken,  several  moons  since,  from  John  Lythgoe's  instructions  for  his
Formil  Model  Engineering  Dyna-drive  kits,  have  proved  to  be  useful  and  enduring
tenets:

"Proceed with patience and due care at ALL stages and a free-running  locomotive
should result."
"Allow  sufficient  time  to  spread  the  conversion  over  a number  of  modelling
sessions."
"Work  in  good  light  conditions.  Use  an  anglepoise-type  lamp  if possible.  A  self-
supported magnifier is a useful aid."

Safety

Our  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
met al components  have  sharp  edges.  Chemical  products  used  in  assembly  can  be
injurious  through  contact  with skin  or  eyes,  ingestion  or  inhalation.  Some  processes
involve high temperatures.  The user should be aware  of  and  follow the  manufacturers'
or suppliers' safety data and instructions for all tools, materials and products.

The Instructions

Structure

We've  divided  up  the  instructions  into  "narrative"  paragraphs,  like  this  one,
which indicate what is being accomplished by a particular stage,

"instruction"  paragraphs,  like  this  one,  with  the  tick-box;  "box-ticking"  not  our
favourite  activity  perhaps  but  nonetheless  can  be useful,  on  a  printed  copy,  for

General Notes

3/52

(c) PenBits Model Railways, All Rights Reserved

04/05/2017

Summary of Contents for PK002

Page 1: ...ASSEMBLY INSTRUCTIONS PK002 SPRUNG BOGIE KIT BACHMANN CLASS 47 PenBits Model Railways www penbits co uk c o 12 Fieldside Long Wittenham ABINGDON Oxon OX14 4QB ...

Page 2: ...ing Warranties Bearing Carriers Subframes Main frames Spring Seats End Stretchers F004 Stretchers F003 Stretchers Undertray and End Plates Class 47 Bogie Bolster Bachmann 47 Preparing the Locomotive Modifying the Bogie Drive Fitting Wheelsets Springs Bogie Assembly and Rolling Test Class 47 Brake Detail Class 47 Cosmetic Sideframes Pickups and Power Final Assembly Table of Contents 2 52 c PenBits ...

Page 3: ...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 involve high temperatures The user should be aware of and follow the m...

Page 4: ...rs does a better job of rendering them than others We find that Print function of the Google Chrome browser produces a good printed result it also gives the option of Save as PDF which is a convenient way of creating a single portable file including all the illustrations which you can view or print on any device If your printer can produce half size A5 prints two per A4 sheet or better still doubl...

Page 5: ...cant 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 lighter etch ...

Page 6: ...er corner of the fold Try therefore not to work a fold unnecessarily once made as it will become increasingly brittle and prone to breakage In general folds are reinforced with a fillet of solder but this is explicitly dealt with in the instructions for each component Soldering We use Carrs 145 wire solder with Carrs Green Label liquid flux except where stated otherwise Flux can be applied to the ...

Page 7: ...omotive 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 whose performance will bring much pleasure However as the fitting of the kit by the user is ...

Page 8: ...welve 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 N...

Page 9: ...xcluding 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 and parallel surfaces clamped together Use a rigid piece of flat material to make each bend simultaneously along its whole length...

Page 10: ...lots Repeat for the two sections of fold on the carrier frame Make Fold 2 You will need a thin firm flat piece of material to drive this fold a robust steel rule not a thin springy 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...

Page 11: ...xed into the carriers An alternative is to use a permanent marker the ink should resist the flow of solder Place the carrier frame the correct way up over the bearings and press down firmly the back of the frame and carriers above Fold 2 on to the tape as shown here The unflanged end of each bearing should protrude from the face of its carrier by a very small amount not quite as much as in the ske...

Page 12: ...wer edge of the carrier Working against a hard flat surface make the fold to form the bottom flange of the bearing carrier Then invert the carrier in the vice so that the carrier top is projecting Fold in the ears at the top of the carrier You may find that the ear catches against the top flange do not apply brute force but adjust Fold 2 and or the direction of the applied force and you will find ...

Page 13: ... the next paragraph for a solution to bearing misalignment It is as well at this point to associate each bearing assembly with a slot according to the markings on the bearing carriers and subframes whether or not you have individually matched the bearings with slots File away any burrs from the outer edges of the carrier tops The fit along the line of the axle i e of the subframe plate between the...

Page 14: ... To finish off clean them up to remove any flux residues and put the carriers and subframes safely away in their respective containers Bearing Carrier Instructions for Six wheel Bogies 14 52 c PenBits Model Railways All Rights Reserved 04 05 2017 ...

Page 15: ... folds 1 2 and 3 in each spring seat as shown DO NOT make the fourth fold on the reverse side of the spring seat etch at this stage From inside the subframes fit each spring seat through the slots in the side of the subframe between the centre and outer axle slots The back of the spring seat should come up flush to the inside face of the subframe side Solder each spring seat in place ensuring that...

Page 16: ...rs For kit PK001 use the stretchers from etch F004 For kit PK002 which has the etched brake gear components use the stretchers from etch F003 F004 Stretchers F003 Stretchers Bachmann Class 47 Subframes 16 52 c PenBits Model Railways All Rights Reserved 04 05 2017 ...

Page 17: ...g the stretchers to the subframes it s convenient to work with the subframes inverted and the stretchers supported on heatproof blocks of some kind leaving both hands free for the soldering operation If you wish to fit the Alex Jackson coupler mounts ensure the holes in the mounts are opened out to about 0 3mm before fitting them to the stretchers at the outer ends of the bogies as shown Undertray...

Page 18: ...Fit the end plates across the subframe ends support them against a block and solder in place from the inside Bachmann Class 47 Subframes 18 52 c PenBits Model Railways All Rights Reserved 04 05 2017 ...

Page 19: ...t to distort the legs of the etch The hole in the centre of the bolster is sized to take a 10BA screw To use the 2mm pivot screw supplied in the kit open out the hole to 2 0mm Make sure the hole is clean and thoroughly deburred Open out the holes using tapered broaches to ensure that centres are preserved Deburr the holes using a larger drill Make the two folds in the etch Class 47 Bogie Bolster 1...

Page 20: ... up Check that the nut is central between the stiffeners and flat to the face of the bolster top Run generous fillets of solder around the nut and the Upper Stiffeners Remove the screw from the nut it should have been prevented from being soldered in place by the grease Remove the two bolster side etches from the fret Fold up the traction ears as shown Note that Fold 3 is 180 with the etched slot ...

Page 21: ...re on the outside of the fold fit and solder them in place along the bolster sides noting that each has a slot which engages in a tab on the outside edge of the traction ears For each traction ear hold the two laminations of the traction ear firmly together and clamp the end of the Inner Bolster Frame against its outside edge engaging the tab and slot Ensuring that the other folds on the ear are a...

Page 22: ...tween the traction ears Again holding the 180 folds of each traction ear firmly together run a good fillet of solder under the traction ear where it engages with the Central Stiffener Pair up the bolster with its subframe as designated by the presence or absence of the tiny etched triangular marks Note that the outer end of the bolster as distinguished by the horizontal parts of the outer bolster ...

Page 23: ... longitudinal restraints If you do need to tweak the bolster try to end up with the faces of the traction ears vertical adjust the fit over the lateral ears by grasping firmly the central arch as well as by rotating the outriggers Remove four secondary spring hanger detail etches from the fret fold them up and solder them in place on the outside faces of the traction ears engaging their tabs into ...

Page 24: ...eading to each bogie are connected Note also to which side of each bogie they go Pop off the insulated sleeves 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 Dr...

Page 25: ...y Note that the fit is for the tube passing perpendicularly through the hole pitch and roll movements of the bogie are not accommodated at this pivot Cut two sections of the 4mm OD tube about 4mm in length Check that the nylon insulators supplied are a free fit through the tube opening out the bore if necessary Remove the M2 x 5 5mm diameter washers from the main fret For each pivot offer up one o...

Page 26: ...hem to one side Rotate the three free idler gears between the middle and inner axles to feel how free running they are as you will need to reproduce this later when reassembling the drive train Undo the cross headed screws which retain the metal pickup strips on the side of the drive train moulding Remove the strips and with a sharp knife the moulded pips which locate them Put the pickup wires and...

Page 27: ...retaining lugs and bogie frame retaining clips from the moulding Take them right down flush to the surrounding faces of the moulding 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 The drive train needs to be split between the inner two...

Page 28: ...sure that the thinned gears each rotate freely on the idler axles The bosses of the plastic gears can be thinned by filing them down To hold the gear while working it clamp one of the idler axles into a collet pin chuck with about 2 7mm projecting The gear can then be placed over the axle and worked with the file while holding the pin chuck in the other hand The filing operation will leave fuzzy c...

Page 29: ...e remaining idler gear between the plates line it up with the holes in the plates line up the holes in the plates with the holes 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 ...

Page 30: ...he 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 for the purist perhaps but adequate for our purpose Alternatively using a lathe we have simply drilled through the bearings The following operations check the differential movement between the drive train and the bogie ...

Page 31: ... 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 32: ...o the correct back to back measurement Test fit the axle in the bogie subframe to determine the 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 an...

Page 33: ... back to back measurement If you are using the American pickup system make sure that the insulated 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 interfa...

Page 34: ...ets Cut eight lengths of the secondary spring wire each 24mm long Make a bend in each wire 8mm from one end of just slightly less than 90 Fold up the four spring retaining ears on the corners of each bolster Pass the longer arms of the wires through the holes in the secondary spring seats and clip the shorter arms into the spring retaining ears Put the bolsters safely to one side Return to the pri...

Page 35: ...gh until retained by the epoxy beads Rest the springs on top of the secondary spring seats Taking one of the outer wheelsets thread the free ends of two of the springs through the slots in the ears of the bearing carriers and locate the bearings in the tops of their mainframe slots Springs Bogie Assembly and Rolling Test 35 52 c PenBits Model Railways All Rights Reserved 04 05 2017 ...

Page 36: ...ng seats and then part way down the outsides of the primary spring seats Finally push each spring downwards until it snaps into its primary spring seat Repeat this operation for the other outer wheelset Springs Bogie Assembly and Rolling Test 36 52 c PenBits Model Railways All Rights Reserved 04 05 2017 ...

Page 37: ...lster then lift it away from the subframe Repeat the above operations for the other bogie so that you now have two rolling bogies You can now fit the bogies into the chassis block of the loco and do a rolling test to check ride height body clearances ability to handle curves and suspension characteristics Remove the bogies from the loco and dismantle them ready for the next stage To remove the bol...

Page 38: ... holes in the etch as indicated by the red rings in the drawing To help prevent distortion press the components against a hard surface with a fine screwdriver while drilling There is fine detail in the etch which can easily become obscured by solder It is perhaps as well to tin all components with a thin film of solder now to avoid bringing excess solder on the iron to the components when assembli...

Page 39: ...tain the nut on the wire while you now lift the nut onto the crank detail and push the wire into the hole in the crank Cut the crank from its tag again using the wire to retain control of it Now lift the nut and crank detail still retained on the wire by the paste flux onto the bracket extending downwards from the plank and locate the end of the wire into the hole in the bracket Slide the crank de...

Page 40: ...centres of the 180 folds and to drive each one over Fold over 180 and solder up the boss at the lower end of the outer brake lever Fold over 180 and solder up the boss towards the outer end of the pull rod Fold over 180 the boss at the lower end of the intermediate brake lever Pass a length of 0 3mm wire through the hole in the boss using the wire to align the two parts Solder in the wire Finish i...

Page 41: ...er taking care not to fill the adjacent fold lines Using a file smooth the lower inside edge of the plank leaving it with a slight chamfer This is to guard against any possibility of the secondary spring detail fitted to the bolster picking up on that edge Make the two remaining folds in the plank to turn it back on itself and reinforce them with solder also This is how the inside of the intermedi...

Page 42: ...nce between the brake shoes and the wheels over the operating range of the suspension the design static position of the wheelsets is with the tops of the bearing carrier ears level with the top of the subframe sides with dynamic deflections of 0 5mm service 0 75mm max from there Small adjustments can be made by judicious filing or bending of the detail parts If you find that you need to adjust the...

Page 43: ...d at the other end of the support to swing the inner pull rod up into position Reinforce the fold with a touch of solder and that s it finished Repeat for the remaining sets of brake gear You may wish to take a well deserved break first To complete the detailing you may wish to glue in place a suitable representation of the actuator between the inner and outer pull rods the moulding Class 47 Brake...

Page 44: ...l pieces of plastic strip and rod brought together with some filler can do the job Finally reassemble the wheelsets and bogie bolsters into the subframes and check all clearances Class 47 Brake Detail 44 52 c PenBits Model Railways All Rights Reserved 04 05 2017 ...

Page 45: ...e subframe The sideframes should fit flush to the vertical faces of the end stretchers the outriggers and if fitted the planks joining the intermediate and centre parts of the etched brake detail You might make rebates in the inside faces of the sideframes to accommodate any discrepancies and to set the desired overall width If you adjust the planks of the brake detail etches be sure to re check t...

Page 46: ...il etches as shown Fix the springs and bolster detail etches in place on the traction ears using quick set epoxy Make sure that the detail etches are securely home in their slots and that the half etched 180 foldback is glued back flat against the outer face of the detail Test fit the bolster into the bogie frames to check clearances Class 47 Cosmetic Sideframes 46 52 c PenBits Model Railways All ...

Page 47: ... 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 48: ...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 49: ...crewdriver to manipulate the bearing carriers thread one of the primary springs through one of the holes in the ears of the central bearing carrier Thread the spring through the slots in the ears of the bearing carrier of the outer axle Thread a second spring through the hole in the other ear of the central bearing carrier Final Assembly 49 52 c PenBits Model Railways All Rights Reserved 04 05 201...

Page 50: ...resting on the tops of the secondary spring seats Ensure that all six bearing carriers are correctly engaged in the slots in the subframe and that the drive train is the right way round worm end towards the coupling end of the bogie Use a screwdriver to spring the springs outwards and downwards on to the outer faces of the secondary suspension seats Final Assembly 50 52 c PenBits Model Railways Al...

Page 51: ...ogie Identify the correct end of the loco s chassis block Route the pickup wires through the appropriate holes or slots in the 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 Take up any slack in the pick up wires Fit the bogie retaining screw sleeve and washer Repeat all of the above for the other bogie Connec...

Page 52: ...achmann loco you ll find that you ll need a slim shafted cross headed screwdriver to replace the four screws adjacent to the bogies IMPORTANT NOTE If you need to remove the body subsequently please DO NOT at any stage attempt to pull the chassis from the loco by pulling on the bogies as this may damage the secondary spring mountings Final Assembly 52 52 c PenBits Model Railways All Rights Reserved...

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