TO CHECK THE FABRICATION DEFLECTION AND TO ACCURATELY ALIGN THE BOGIE SUB ASSEMBLIES THE FOLLOWING PROCEDURE SHOULD BE CARRIED OUT IN THE MANUFACTURERS WORKS.
1. SET 2 RAILS AT 4000 CENTRES ON A HORIZONTAL SURFACE
2. SET THE BOGIE SUB ASSEMBLIES AS SHOWN ON DRAWING NO. 11269-016-215 AT 4000 CENTRES ON EACH RAIL IN THEIR SPECIFIC LOCATION AND WEDGE THE WHEELS SO THAT THEY ARE EQUISPACED ON THE RAIL HEAD.
3. LOWER THE UNDERFRAME FABRICATION ONTO THE BOGIES AND PASS THE PIVOT BRACKET TUBES THRU THE UNDERFRAME STAND PIPES.
4. CHECK THAT THE 4000x4000 CENTRES ARE MAINAINED WITHOUT DISTORTION OF EITHER THE UNDERFRAME OR THE BOGIE ASSEMBLIES.
5. WITH THE UNDERFRAME SUPPORTED ON JACKS LEAVING A GAP OF APPROXIMATELY 120mm BETWEEN THE UNDERFRAME TUBE FLANGE AND THE BOGIE EQUALISING BRACKET FLANGE ADJUST THE JACKS TO LEVEL THE SLEW RING FLANGE ALONG THE RAILS AND AT 90° ACROSS THE RAILS.
6. MEASUERE AND RECORD THE GAP AT EACH OF THE 4 CORNERS.
7. MANUFACTURE 4 SPACING TUBES AS DETAILED BELOW WITH A NOMINAL LENGTH OF 118mm ADJUSTED BY ANY OFFSETS MEASURED IN THE TRIAL ASSEMBLY.
8. LIFT THE UNDERCARRIAGE, INSERT THE TUBE SPACERS CENTRALLY AROUND THE EQUALISER BRACKET TUBES AND RESEAT THE UNDERFRAME ON THE SPACERS.
9. RECHECK THE WHEEL SPACING ON THE RAILS AND RECHECK THAT THE SLEWRING FLANGE IS HORIZONTAL.
10 WELD THE EQUALISER BRACKET TUBE TO THE TOP FLANGE OF EACH OF THE UNDERCARRIAGE LEGS. 6mm FILLET CONTINUOUS.
11. STITCH WELD THE SPACERS TO BOTH THE TOP AND BOTTOM FLANGES . 6 FILLET 100 RUN 200 MISS.
12 MATCH MARK EACH BOGIE ASSEMBLY AND REMOVE FOR TRANSPORT TO SITE.
THE BOGIES ARE TO BE ASSEMBLED AS SHOWN ON THIS DRAWING WITH THE DRIVES LOCATED ON THE RIGHT HAND SIDE OF THE BOGIE FRAME AND ON THE OUTSIDE OF THE RAILS. THE BOGIES ON THE OPPOSITE SIDE OF THE UNDERFRAME ASSEMBLY ARE TO BE FITTED IN THE SAME MANNER. IE THEY ARE NOT HANDED LEFT AND RIGHT.