Related Manuals for PenBits Bachmann Class 66
Summary of Contents for PenBits 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: Table Of Contents
Soldering Spring Winding Warranties Bearing Carriers Bachmann Class 66: Subframes Bachmann Class 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... -
Page 4: General Notes
The instructions are available on line in both HTML and pdf formats. The HTML versions have one page for each major section, whilst the pdf versions have a single file for each kit. Structure (c) PenBits Model Railways, All Rights Reserved 27/09/2021... -
Page 5: 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 (c) PenBits Model Railways, All Rights Reserved 27/09/2021... -
Page 6: Slots
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 27/09/2021... -
Page 7: 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 27/09/2021... -
Page 8: Spring Winding
Keeping the coil on the armature, you can stretch or compress the spring axially to get the coil spacing you need. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 9 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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 10: 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 27/09/2021... -
Page 11: 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 27/09/2021... - Page 12 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 27/09/2021...
- Page 13 Stick a length of double-sided tape, large enough to take one of the carrier frames, onto a clean, flat, heatproof working surface. Ensure the tape is firmly smoothed down (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 14 Unfold Fold 3 and separate the individual bearing carrier assemblies from the frame. Take care, as the top parts of the carriers are quite fragile at this stage: it may be (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 15 Keep the bearing clamped in the vice while soldering; this will act as a heat sink and prevent melting of the joint between the bearing and carrier. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 16 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 27/09/2021...
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Page 17: Bachmann Class 66: Subframes
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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 18 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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 19 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 90° fold at each end of each one. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 20 Take care to ensure that the region immediately around the axle bearing slots, for at least about 1mm around the edges of the slots, is kept free of solder. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 21 Bachmann Class 66: Subframes 21/60 Clean off flux residues and tidy up excess solder from the outer surfaces. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 22: Bachmann Class 66: Bolster
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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 23 Make the longitudinal fold (in two sections) closest to the main body of each Bolster Side. Check that each part of the fold is to 90°. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 24 Make the longitudinal fold (in two sections) to fold out the two brackets from the lower edge of each frame. Fold down the secondary spring seat at the outer end of each bracket. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 25 Solder up the Bolster Centre, Side and Frame, reinforcing all the main folds with fillets of solder. Repeat for the Side and Frame on the other side of the Bolster. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 26 Other adjustments may be made by gentle tweaking of either the bolster assembly or the longitudinal restraints. If you do need to tweak the bolster, try to end up with the faces of the traction ears vertical. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 27: Bachmann Class 66: Modifying The Bogie Drive
Bachmann Class 66: Modifying the Bogie Drive 27/60 Bachmann Class 66: Modifying the Bogie Drive This section describes the operations involved in modifying the drive units. Dismantling the loco Following the manufacturers' recommendations for running-in, ensure that the locomotive is performing smoothly and to your satisfaction generally. Deal with any issues now, especially those covered by warranty or your basic statutory rights as customer, before making any modifications. - Page 28 Bachmann Class 66: Modifying the Bogie Drive 28/60 Separate the Drive Unit from the Sideframe / Undertray and put the latter safely to one side for now. Undo cross-headed screws retaining the bogie pivot / worm cover moulding to the tops of the two pivot towers.
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Page 29: Modifying The Drive Train Mouldings
Bachmann Class 66: Modifying the Bogie Drive 29/60 chuck, to push the axles through. Modifying the Drive Train Mouldings Referring 'before' 'after' illustration here, and using your favoured combination of saws and craft knives or burrs, cutting discs and grinders in a mini electric drill,... -
Page 30: Reassembly
Bachmann Class 66: Modifying the Bogie Drive 30/60 A razor saw may be used to make these cuts. Take care that the moulding is adequat ely supported while cutting - it's helpful to have a solid block of material which just fits between the sides of the moulding. - Page 31 Bachmann Class 66: Modifying the Bogie Drive 31/60 Fit the plates together as shown (there is no need to solder them together), making sure that the larger holes are opposite each other, and that the assembly is square. Orientate each Drive Plate assembly with one of the smaller ends of the Drive Units.
- Page 32 Bachmann Class 66: Modifying the Bogie Drive 32/60 Slide the central (smaller) of the three idler gears into position between the plates, lining up with the axle hole in the middle of the plates. Press the idler axle into place to retain the gear.
- Page 33 Bachmann Class 66: Modifying the Bogie Drive 33/60 That concludes the modifications to the bogie drive units. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 34: Bachmann Class 66; Preparing The Locomotive
Bachmann Class 66; Preparing the Locomotive 34/60 Bachmann Class 66; Preparing the Locomotive This section deals with the simple modification you need to make to the cast chassis block of the locomotive, namely, the fitting of pivot plates to provide surfaces against which to secure the bogie bolsters. - Page 35 Bachmann Class 66; Preparing the Locomotive 35/60 Check that the nylon insulators are a free fit through the holes in the Pivot Plates. Prepare two 30thou plastic card spacers to fit between the top of each Bolster and its Pivot Plate. Each spacer should be drilled M2 for the pivot hole, and not extend beyond the perimeter of the Pivot Plate.
- Page 36 Bachmann Class 66; Preparing the Locomotive 36/60 stage is to glue the Pivot Plates into position. The glue acts both as an adhesive to retain the plates and as a filler to hold them at the correct spacing and alignment relative to the inside top surface of the chassis casting.
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Page 37: 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 27/09/2021... - Page 38 If there is binding when one axle is raised, open out the Bachmann axle bearings just a fraction more, up to a maximum of 2.3mm. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 39 If it is a driven axle, slide one of the Bachmann final drive gears into position centrally. The gear should be a tight fit on to the axle, sufficient to transmit drive forces without slipping. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 40 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 27/09/2021...
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Page 41: Bachmann 66: Springs, Bogie Assembly And Rolling Test
(having only recently hardened, they will respond quite well to paring with a sharp knife). Take the inner and outer wheelsets, check their correct orientation to the central wheelset, and slide their bearing carriers on to the primary springs. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 42 Adjust the assembly so that the primary springs are sitting on top of the secondary spring seats. Using a small screwdriver to manipulate the springs, bend them outwards to slide over the secondary spring seats… (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 43 Secondary spring after fitting. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 44 The washer, P2, carries a soldering tag for the pickup wire for 'American' current collection. Remove the Pivot Washers (P2, P3) from the fret. Fold up the wiring tag on the edge of part P2. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 45 2.1mm drill, held in a pin chuck. This will prevent the insulator from collapsing while you roll it on the edge of a hard surface and make the cut with a sharp knife. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 46 Repeat for the other side, then lift the wheelset to slide the springs up over the outsides of the primary and secondary spring seats. Repeat for the axle at the other end of the bogie. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 47: Bachmann 66: Cosmetic Sideframes
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 inner… (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 48 (If the Drive Units are not already in place, rest them in position on top of their axle bearings). Remove the wheelsets, Drive Units and frame mouldings from the Subframes. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 49 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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 50 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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 51 Cutting the outrigger away, close to the spigot, on one or two sides is usually sufficient to separate them. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 52 Do not glue them in place as yet (this can be done later when the loco is finally assembled, to get a precise alignment). (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 53: Pickups And Power
They act on the outer wheelsets only, as there is limited space to fit pickups to the centre wheels. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 54 (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 55: Bachmann 66: Final Assembly
Take one of the Drive Units and fit its wheelsets, ensuring that they are in the correct locations and the correct way round, as indicated by the id marks on the bearing carriers. While doing this, adjust any pickups to give a light preload onto the wheels. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 56 Ensure that the bearing carriers are correctly engaged in the slots in the subframe. Push the primary springs down to slide them outside the secondary spring seats. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
- Page 57 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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 58: Checking Clearance Over Worm Cover
Having first fluxed the inner surface of each fold-back, make the 180° folds, with the fold line on the inside of each fold, at the corners of the etch. Hold the folds closed and secure them with solder. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 59 Fold 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. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
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Page 60: Final Assembly
- there is enough slack in the drive train gears that you should be able to distinguish between a binding and a free wheelset. (c) PenBits Model Railways, All Rights Reserved 27/09/2021... - Page 61 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 spring mountings. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...