PenBits PK002 Assembly Instructions Manual

Sprung bogie kit bachmann class 47

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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

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Summary of Contents for PenBits PK002

Page 1: Assembly Instructions
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: Table Of Contents
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 (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 3: General Notes
"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 (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 4: Printing
Any remnants of the tag may be cleaned up using a flat file. We have tried to avoid putting tags on mating faces, but there are some instances where they need to be removed thoroughly. Slots (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 5: Degree Of Etching
'heavier' etch one might leave more of the cusps in place. In places which can't be reached by a file, e.g. in acute corners of the etch, the cusp may be pared away with a sharp knife. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 6: Folds
Green Label flux may be rinsed away with water; a little added citric acid will neutralize it. Liquid or paste fluxes can be washed away either with a proprietary flux cleaner or a 50/50 mix of methylated spirits and water. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 7: Warranties
However, as the fitting of the kit by the user is out of our direct control, we can make no warranty, expressed or implied, as to the performance and continued serviceability of the locomotive following modification. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 8: Bearing Carriers
Put the subframes in their containers safely to one side for now. Test fit the axle bearings on the 2mm replacement axles. They should be a free running fit. Remove any burrs or swarf from the front and rear faces of the bearings. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 9 This will help minimise any unwanted distortion in the fret. Note that Fold 3 is a jig fold, made along the tags at the base of the carriers. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 14 Bearing Carrier Instructions for Six-wheel Bogies 14/52 That completes the bearing carrier assemblies. To finish off, clean them up to remove any flux residues, and put the carriers and subframes safely away in their respective containers. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 15: Subframes
Check that they are all at the same height by inverting the subframes and resting the tops of the spring seats against a flat surface. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 16: End Stretchers
16/52 End Stretchers There are two alternative sets of end stretchers. 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...
Page 17: Undertray And End Plates
Fit the plates into the subframes, noting that the lugs on the sides of the plates engage in the recesses in the lower edges of the subframe, and solder the joints between the two. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 18 Bachmann Class 47 Subframes 18/52 Fit the end plates across the subframe ends; support them against a block and solder in place from the inside. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 19: Class 47 Bogie Bolster
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 (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 20 3. Finally, gripping surface A with pliers and supporting the main part of the fret on a hard, flat surface, make fold 2 and complete fold 3. Don't apply any solder to these folds just yet. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 22 Note that the outer end of the bolster, as distinguished by the horizontal parts of the outer bolster frame being lower than those of the inner bolster frame, should be oriented towards the coupling end of the subframe. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 23 Clean up the bolster assembly to remove all flux residues. If you wish to chemically blacken the bolster, do it at this stage. Do the four bolster detail etches at the same time, they'll be fitted later. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 24: Bachmann 47: Preparing The Locomotive
Similarly remove the other bogie. Fix the four sole plates to the lower face of the chassis plastic moulding as shown, using an epoxy resin glue or double-sided tape. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 25 M2 screw and 5.5mm washer. Ensure that the bolster can rotate with the chassis sole plates resting on its shoulders, and allow the glue to set completely. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 26: Modifying The Bogie Drive
When removing the idler axles, support the moulding on a hard surface with some kind of slot or hole to receive the axle. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 27 Co-Co arrangement of the prototype. It is, however, possible to 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 (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 30: Fitting Wheelsets
Bachmann axle bearings and the second bearing carrier. Note that the ears at the tops of the bearing carriers face outwards towards the ends of the axle. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 32 If you have one wheel already fitted to the axle, slide on the required number of washers adjacent to that wheel, then the bearing carrier (ears facing the wheel), then a Bachmann drive bearing. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 33 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. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 34: Springs, Bogie Assembly And Rolling Test
...and clip the shorter arms into the spring retaining ears. Put the bolsters safely to one side. Return to the primary suspension wires and check that the epoxy resin beads have set hard. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 36 ... 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. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 38: Class 47 Brake Detail
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 assembling. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 39 Trim and clean up the ends of the wire; flush to the back of the bracket, and with a little protruding from the front of the nut to represent the end of the crank pivot bolt. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 41 This is how the inside of the intermediate/central brake shoes etch looks when folding is complete. All the detail features are now facing outwards, the same way. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 42 Line up the boss, on the inside of the other end of the rod, with that at the base of the outer brake shoe hanger and solder them together. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 43 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 (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 44 Bachmann brake gear does nicely, otherwise small 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. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 45: Class 47: Cosmetic Sideframes
Class 47: Cosmetic Sideframes This section deals with fitting either Bachmann sideframes with the etched brake components or Heljan sideframes in any circumstances, for kits PK002, PK003, PK004 and PK012, all using the subframe stretchers from etch F003. If you are fitting...
Page 46 180° foldback is glued back flat against the outer face of the detail. Test-fit the bolster into the bogie frames to check clearances. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 49: Final Assembly
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. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 50 (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. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 51 Run the locomotive in gently at first. If the loco does not run freely or begins to bind up at any point, pay particular attention to lubrication of the axle bearings. You can feel for any binding by rotating the wheel rims with the fingers - there is (c) PenBits Model Railways, All Rights Reserved 04/05/2017...
Page 52 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. (c) PenBits Model Railways, All Rights Reserved 04/05/2017...

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