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PenBits PK017, Assembly Instructions Manual, Page: 26 / 66

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PenBits PK017 Assembly Instructions Manual Download Page 26

Fit the two parts together, adjusting the folds
as necessary.

Along  the  vertical  fold  lines,  fold  in  the  outer
ends of the Mainframe (S4) a small amount.

Adjust the folds so that they are equal and fit
snugly  against  the  sides  of  the  Pony  Flitching

(S10) etch.

Hold  the  components  firmly  together  in
alignment…

Bachmann Co1 Bogies: Subframes

26/65

(c) PenBits Model Railways, All Rights Reserved

27/09/2021

Summary of Contents for PK017

Page 1: ...ASSEMBLY INSTRUCTIONS PK017 SPRUNG BOGIE KIT BACHMANN CLASS 44 45 46 PenBits Model Railways www penbits co uk c o 12 Fieldside Long Wittenham ABINGDON Oxon OX14 4QB ...

Page 2: ......

Page 3: ...Bogies Subframes Bachmann Peak Bolster Bachmann Peak Preparing the Locomotive Dismantling the loco Making up the Pivot Frame Fitting the Pivot Frame Bachmann Peak Modifying the Bogie Drive Dismantling the Bogie Altering the Drive Train Mouldings Inner Worm Bearing Retainer Reassembly Bachmann Peak Wheelsets Bachmann Peak Springs Bogie Assembly and Rolling Test Bachmann Peak Cosmetic Bogie Frames a...

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 65 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: ... one of the 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 ...

Page 12: ...matching bearing carriers on the correct sides The remaining four carriers on the centre and inner axles are interchangeable 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...

Page 13: ...l 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 part of the finished carriers This is a view of the folded carrier frames Fold 3...

Page 14: ...f its 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...

Page 15: ...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 that it folds easily Folding against a block as shown gives a good tight fold Pass a piece of the 0 9mm nickel silver wire through the hole in the back of each carrier and across the top parallel to the line of the axle With a small amount of flux solde...

Page 16: ... 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 aim is to have the bearing flange parallel with the front face of the carrier a cert...

Page 17: ...fret from around the mainframe s axle slots makes a suitable tool when held in a hand vice for checking and if necessary reaming the slots to pass the material thickness Make the two main longitudinal folds in each Mainframe Each fold is in three parts carried over the cross members under each axle slot Ensure the folds are at a true right angle throughout Bachmann Co1 Bogies Subframes 17 65 c Pen...

Page 18: ... seat on each etch and then fold back the 180 folds at the other end of each etch with the half etched folding tags on the insides of the folds Remove the Inner Ear etches S1 from the fret Fold out the inner lateral and longitudinal restraint ears Bachmann Co1 Bogies Subframes 18 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 19: ... feed the ears and seats through the slots in the Mainframe Take time to align each folded part with its slot and ease them through carefully but firmly Apply flux to the laminations the etched holes facilitate this and hold them firmly together while soldering them in Ensure that the half etched recess and the slots for the springs remain free of solder Apply a fair sized globule of solder to the...

Page 20: ...ing away from the end of the jig Examine the slots in the Mainframe etch to determine which side matches the Outer Ear etch and insert the ears and seat through the slots in the Mainframe Take the pair of Secondary Seats for that side and place them on the jig Place another block on the jig to act as a fence Bachmann Co1 Bogies Subframes 20 65 c PenBits Model Railways All Rights Reserved 27 09 202...

Page 21: ...of the components are aligned with the bottom edge of the Mainframe and solder up the assembly Repeat for the Outer Ears and Secondary Seat on the other side of the Mainframe Remove the Pony Axle S5 and Pony Lower Axle S8 etches from the fret Check that the main bodies of the wheel bearings will pass through the holes in the Axle and between the legs of the Lower Axle filing the etches as required...

Page 22: ...h engages in a slot in the edge of the Axle etch You can turn down the ends of a pin point axle to represent the cylindrical extensions of the prototype s carrying axles Holding one of the bearings firmly against the outer edge of the Axle etch and ensuring that the two etches are correctly fitted together apply flux to the area around the bearing and apply a generous amount of solder to the joint...

Page 23: ... right angle to approximately 70 from the side of the frame Fold the frame returns to 90 Completed horncheek and return folds Fold up the two sides of the frame Bachmann Co1 Bogies Subframes 23 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 24: ...upport for the sides of the frame when adjusting the folds to avoid distorting them Remove the Pony Flitching etch S10 from the fret Check that the 8 thou spring wire will pass the hole in the etch Drill it through 0 3mm if necessary Fold up the seat for the pony truck s control spring Bachmann Co1 Bogies Subframes 24 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 25: ...a 0 5mm drill will pass the holes in the primary spring seats in the production etches they are holes rather than the open slots shown in these photos Invert the etch and fold the outer primary spring seats Invert the etch again and fold up the side plates Offer up the Pony Frame S7 to the Pony Flitching S10 Bachmann Co1 Bogies Subframes 25 65 c PenBits Model Railways All Rights Reserved 27 09 202...

Page 26: ...in the outer ends of the Mainframe S4 a small amount Adjust the folds so that they are equal and fit snugly against the sides of the Pony Flitching S10 etch Hold the components firmly together in alignment Bachmann Co1 Bogies Subframes 26 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 27: ...emove the Pony Bearer etch S6 from the fret Fold in the four spring retaining ears around the etch and reinforce the folds with solder Fold up the two sides of the etch Bachmann Co1 Bogies Subframes 27 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 28: ...ire flush with the outer face of the side Repeat for the other side Remove the Pony Outer Frame S9 from the etch Check that the 8 thou spring wire will pass the hole in the etch Drill it through 0 3mm if necessary Fold up the two arms of the etch Support the Mainframe assembly inverted with the top plate of the Pony Frame resting on a parallel surface Bachmann Co1 Bogies Subframes 28 65 c PenBits ...

Page 29: ...it of the Pony Axle in the slot should provide free sliding radial and vertical movements for the axle and allow it to tilt a small amount no more than to allow the wheel on one side to rise or fall about 0 5mm with respect to the wheel on the other side There will be a little bit of play in the location of the axle Remove the Pony Axle assembly and solder the Outer Pony Frame in position Test the...

Page 30: ...at the inner end of the Mainframe and solder them up Use the slots closest to the end for the Class 40 For the Peak use the other pair of slots and cut and file away the projecting parts of the Mainframe Remove two of the Primary Splint S11 etches from the fret Make the 180 folds in the Primary Splints with the half etched folding tag on the inside of the fold Bachmann Co1 Bogies Subframes 30 65 c...

Page 31: ...the longitudinal slot and solder them up Clean up to ensure that there is no solder on the outer faces of the splints and that the slots in the splints are clear of solder Clean up the Subframe assembly to remove any stray solder from its outer faces including from the half etched housings for the primary spring splints Check the assembly for squareness and that the sides are vertical Reinforce th...

Page 32: ...Bolster Frame etches B2 from the etch Check that the slots in the etch are clear to pass the material thickness Place the washer and top hat bearing flange towards the washer on to the 12BA screw Apply a smear of grease to the lower face of the bearing and to the projecting screw threads Pass the screw through the pivot hole from the plain side of the etch thread on the nut and tighten the assembl...

Page 33: ...s Fit the Bolster Frame into the Bolster Base Start by fitting the cross member of the Frame through the widest part of the aperture in the Base then spring the outer and inner legs of the Frame into the aperture and manoeuvre the Frame into position Push out the sides of the Frame to reset the folds to as close to 90 as you can get them Locate the tags at the inner and outer projections of the Fr...

Page 34: ...eframe support foldover and reinforce the folds with solder Make the second folds in the sideframe support foldovers Check that the foldovers are parallel with the rest of the etch and reinforce the second folds with solder Fold up the small stiffener bracket at the top of each leg Bachmann Peak Bolster 34 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 35: ...that the foldbacks are aligned parallel with the edges of the legs adjusting the folds if necessary Apply flux to the joint between the foldovers and the outer faces of the legs crimp the 180 folds firmly closed and solder them up The completed Inner Leg foldup The lower cross piece is a spacing and alignment jig which will be removed later Bachmann Peak Bolster 35 65 c PenBits Model Railways All ...

Page 36: ...t and true Make the outer fold in each sideframe support and reinforce the folds with solder Make the inner fold in each sideframe support and reinforce the folds with solder Fold in the small support brackets at the tops of the legs Support them well to prevent them from distorting Bachmann Peak Bolster 36 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 37: ...he top of each leg Fold back each sideframe support outrigger against the outer face of its leg These are 180 folds with the half etched folding tag to the inside of the fold Check that the foldbacks are aligned parallel with the edges of the legs adjusting the folds if necessary Apply flux to the joint between the foldovers and the outer faces of the legs crimp the 180 folds firmly closed and sol...

Page 38: ... until the solder is sucked in to the joint and flashes around the folds Keep solder away from the inward facing surfaces of the legs as these slide against the lateral control ears of the Subframe Fit the Outer Leg to the Bolster assembly ensuring that the small tabs and slots are engaged The cross member is a jig piece for distance and alignment and will be removed later Apply flux to the mating...

Page 39: ...e Bolster and Subframe correctly the pointy end of the Bolster faces towards the outer end of the Subframe Check the fit of the Bolster on to the Subframe the inside faces of the Inner and Outer Legs should just fit over the radiused edges of the lateral control ears on the Subframe sides with no more than just a slight resistance the longitudinal control arcs on the legs should just fit between t...

Page 40: ...he block The cardan shaft joining the motor to the bogie will either come with the bogie or be retained at the motor end Either way remove it but note that the ears on each end of the cardan shaft are of subtly different shapes so record which end is which Assign the bogie to one or other of your sets of etched bogie parts marking the bogie drive and chassis block accordingly Similarly remove the ...

Page 41: ...Frame Fold up the flanges on either side of the Pivot Plate Adjust the folds in the Pivot Frame to fit the Pivot Plate and solder the two together Reinforce the folds around the Pivot Frame with solder Bachmann Peak Preparing the Locomotive 41 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 42: ... The connecting wire can either be a piece of hook up wire as shown or an uninsulated length of spring wire in copper brass or phosphor bronze The tag on the washer supplied in the kit makes things a little easier than the arrangement shown here Fitting the Pivot Frame Open out if necessary the pivot holes in the chassis casting to be a sliding or loose fit for the 4mm brass tube supplied with the...

Page 43: ...r Base resting on the bottom surface of the plastic chassis moulding Use scraps of plastic card probably 10 20 and 30thou to find the maximum thickness that can be placed between the Pivot Plate and the cross piece at the highest part of the Bolster Frame remove the 1 5mm CSK pivot screw and fittings first without lifting the Bolster Base away from the chassis moulding Cut two rectangles of plasti...

Page 44: ...with its lower end clear of the top of the Pivot Spacer The M2 nylon insulator can be shortened by placing it over the shank of a 2 1mm drill for support then rolling it on the bench under a sharp knife blade to make the cut around its circumference When the glue has set thoroughly fit the Pivot Frames into their bogie apertures flat up against the Pivot Spacers filing down the thickness of the 11...

Page 45: ...ag washer that tends to lift the outer end of the Pivot Frame away from the Bolster Make a hole in the plastic chassis undertray to allow you to see the UJ socket fitting at each end of the motor taking care not to damage the fitting as you make the hole Without sight of the fitting it is very difficult to tell whether the driveshaft is correctly engaged Bachmann Peak Preparing the Locomotive 45 6...

Page 46: ... Using a small screwdriver gently unclip the bogie frame undertray moulding from the outer end then the inner end of the bogie drive unit Put the moulding safely to one side for now Discard the inner wheelset bearer and spring Unclip the two driven wheelsets from the drive unit moulding and put them to one side Bachmann Peak Modifying the Bogie Drive 46 65 c PenBits Model Railways All Rights Reser...

Page 47: ...uter worm bearing out of its plastic housing support the housing firmly with the fingers to prevent it being bent outwards and remove the worm shaft and bearings The two plastic upstands to either side of the inner worm bearing splay outwards to permit this but take it gently If the idler axle for the worm gear sticks out either side of the moulding like this Bachmann Peak Modifying the Bogie Driv...

Page 48: ... them out from the tight side and when the time comes replace them from the loose side As you push out each axle remove its gearwheel and record its position in the drive train so that you can replace it later in the same position When removing the idler axles support the moulding on a hard surface with some kind of slot or hole to receive the axle We used the blind end of a 1 4mm drill held in a ...

Page 49: ...the line of the centre axle just beyond the cross member in the lower part of the moulding Thin down the sides of the drive unit by about 0 5mm in the region between the two white arrows in the photo corresponding to the part of the Subframe where its sides have three etches laminated At the inner end of the gear tower indicated by the black arrow in the photo remove the top corner of the tower a ...

Page 50: ...f the retainer Fit the inner worm bearing into position between the two plastic upstands Fit the slots formed at the sides of the Worm Retainer around the upstands and slide the Retainer downwards so that it rests on the bearing Bachmann Peak Modifying the Bogie Drive 50 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 51: ... Retainer and worm bearing and put them safely to one side If for any reason such as variation in manufactured dimensions of the drive unit the etched Retainer can not be fitted a perfectly serviceable arrangement is to omit the etch and secure the bearing by the 14BA screw and nut alone The holes are drilled such that the shaft of the screw is in contact with the top of the bearing Reassembly Giv...

Page 52: ...ghtly under sized Their similar 12mm wheelsets may be used for the carrying wheels though current stocks as at November 2016 are insulated on both sides We have used this technique on Alan Gibson wheels Make a curled end on a length of phosphor bronze wire and solder it to the edge of one of the 2mm spacing washers supplied in the kit Put a kink in the wire shape it so that the the washer sits fla...

Page 53: ...f etched dot the outer axles by two half etched dots see the Bearing Carriers instructions for a full explanation of the marking system Dismantle the Bachmann OO driven wheelsets Recover the final drive gears and the axle bearings Discard the wheels and axles Press the gear muffs on to the replacement 2mm driving axles centreing them in position The Bachmann axle bearings need to be opened out to ...

Page 54: ...g 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 subframes The suspension is designed to deflect 0 5mm so the free movement needs to ...

Page 55: ... the operation on the remaining wheels Take off an extra 0 5mm on the wheels for the two centre axles subject to not going beyond the line of the inner wheel rim Now we can assemble the remaining wheelsets Assemble the inner wheelset inserting washers as for the outer wheelset Assemble the centre wheelset This wheelset will have no or fewer washers to allow sideplay In P4 with gauge widening 0 5mm...

Page 56: ...rs inside the wheels if required to take up any lateral slack but leave enough to keep the wheelset a free running fit Fit the other wheelset to the other Pony Truck initially using the same number of washers if any as the first one That completes the assembly of the wheelsets Bachmann Peak Wheelsets 56 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 57: ...ame deep and narrow enough to allow the wheelsets to drop all the way down in their slots We use this tufnol jig for wheeling up and other assembly work It allows the whole bogie to be turned round without disturbing any of the parts Place the subframe on to the block and fit the central and inner wheelsets into their slots Orientate the inner primary springs with the slots in their Splints toward...

Page 58: ...wdriver to push the Splints down over the ends of the Primary Spring Seats to the point at which they spring inwards and back up into the seats Turn the bogie round and insert the outer wheelset into its slots Bachmann Peak Springs Bogie Assembly and Rolling Test 58 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 59: ...ring carriers on each side Find the Pony Axle and Pony Bearer for the bogie The Pony axle is placed upside down in this photo Place the Pony Axle on to the wheeling jig with the Pony Bearer on top Lower the subframe over the Pony Axle and Bearer Bachmann Peak Springs Bogie Assembly and Rolling Test 59 65 c PenBits Model Railways All Rights Reserved 27 09 2021 ...

Page 60: ... shorter leg into the retaining hook The principal purpose of this wire is to retain the Pony Truck in the bogie Lateral response to the movement of the pony truck on the prototype appears not to be from a sprung centreing action but rather through damping this we get from sliding friction between the components The wire does offer some centreing force at large lateral displacements The long leg o...

Page 61: ...he Pivot Frames upwards against the underside of the chassis block When satisfied that the threads are engaged and not crossed gently tighten the screws You can now do static and hand powered rolling tests with and without the body fitted to check overall height body clearances ability to handle curves and suspension characteristics It s helpful to clear any gremlins now before the mechanical driv...

Page 62: ...ies Offer the moulding up to the Bolster engaging the two central pairs of outriggers in the slots in the etch Mark the plastic outriggers for cutting flush with the inside faces of the Bolster s legs Cut through the two central pairs of plastic outriggers at the marks Cut through the outer outriggers closer to the inside faces of the sideframes Leave the inner cross member in place for now Cut th...

Page 63: ...as jigged off the buffer centres 13 8mm coupling height 10mm Modify the shape of the sandpipes The sideframes are fitted around the wheelsets from above when the Bolsters and Subframes are bought together so the sandpipes need to be brought slightly outside and or away from t h e wheels Bending them as shown is a reasonable approximation to prototype arrangements and gives the required clearance I...

Page 64: ...fit the bogies back into the loco Repeat the static and rolling tests you now have buffers and couplings to enable pushed and pulled on track testing Check the height and alignment of the bogie frames with respect to the wheelsets and the loco body The kit has been designed to give a ride height which places the top of the loco at the correct distance above the railhead Variations in manufacture a...

Page 65: ...ces around the drive unit and for free running of the gears Refit the Bolster to the Subframe again checking clearances Repeat the above for the other bogie You now have the option of re assembling the bogies into the loco and doing some unpowered testing to check for free running of the gears Bear in mind that the components are not yet run in in their current configuration any slight imperfectio...

Page 66: ...cular attention to lubrication of the axle bearings You can feel for any binding by rotating the wheel rims with the fingers there is enough slack in the drive train gears that you should be able to distinguish between a binding and a free wheelset Finally replace the body of the locomotive All being well thats it the modifications are complete and you have a nother sprung diesel loco IMPORTANT NO...

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