Lionel ElectroCoupler Upgrade Kit Instruction Manual 72-4141-250 1/04
Congratulations! Congratulations on your purchase of the Lionel ElectroCoupler Upgrade Kit! These couplers are activated by commands from your CAB-1 Remote Controller, so you can release the couplers anywhere on your layout without an Uncoupling Track section. Note! A Command Control Upgrade is necessary for ElectroCoupler operation. Follow the steps in this instruction manual to replace the magnetic couplers on your diesel locomotive or your steam locomotive s tender. For more specific instructions about your particular locomotive, see the owner s manual for that product. Note! Two ElectroCouplers Kits are required for diesel locomotives. Table of contents Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive 3-8 Installing ElectroCouplers on your early GP-9 diesel locomotive 9-13 Installing ElectroCouplers on your more recent GP-9 diesel locomotive 14-17 Installing an ElectroCoupler on the tender (steam locomotives) 18-19 Limited Warranty/Lionel Service 20 The following Lionel marks may be used throughout this instruction manual and are protected under law. All rights reserved. Lionel, TrainMaster, Odyssey, RailSounds, CrewTalk, TowerCom, DynaChuff, StationSounds, Pullmor, ElectroCoupler, Magne-Traction, CAB-1 Remote Controller, PowerMaster, Lionel ZW, ZW, PowerHouse, TMCC, Lionelville, Lockon 2
Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive 1. Remove the body. Refer to the locomotive s manual for the location of the body screws. 2. Remove the Phillips-head screw from the recessed hole in the bottom of the truck. Refer to Figure 1. C-420 SD-60/70 Dash-9 Remove this screw Remove this screw Figure 1. Screw locations (underside of the truck) 3. Locate and remove the pick-up roller mounting screw on the top of the truck. This screw is visible in front of the motor through the slot in the frame. The pick-up wire is attached to this screw. Refer to Figure 2 on page 4. Note! With this screw removed, the pick-up roller assembly will disengage from the truck. 3
Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive (continued) C-420 Dash-9 SD-60/70 Motor Motor Remove this screw Remove this screw Motor Frame Frame Frame Figure 2. Pick-up roller screw 4. Dash-9 Locomotives only. Position the truck as if the locomotive was traveling straight forward so that a second screw is visible through the slot in the frame, then remove this screw. Refer to Figure 3. Motor Remove this screw Frame Figure 3. Extra screw on Dash-9 locomotives 4
Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive (continued) 5. Lift the truck away from the frame. 6. Compress the washer and the spring under the C-clip, then remove the C-clip with a pair of needle-nose pliers. Carefully release the spring and washer after the clip is removed. Refer to Figure 4. Caution! Carefully release the spring and washer to avoid launching them off the post. We recommend wearing safety glasses. C-Clip Washer Spring Washer Retaining Post Figure 4. Components on the retaining post 5
Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive (continued) 7. As illustrated in Figure 5, remove the pilot from the truck. Allow the retaining post to drop out of the truck far enough to remove the old coupler and to install the ElectroCoupler. Figure 5. Pilot removal 6
Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive (continued) 8. Slide the entire coupler out through the pilot. 9. Insert the ElectroCoupler and its two wires through the front of the pilot and under the mounting boss. 10. Push the retaining post through the hole in the shank of the ElectroCoupler. 11. Pass the ElectroCoupler wires up through the round hole in the pilot, then reinstall the pilot. 12. Slide the metal washer, the spring, and the fiber washer (in this order) down the retaining post as illustrated in Figure 6. 13. Compress the spring and washers, then re-install the C-clip. Caution! Carefully release the spring and washer to avoid launching them off of the post. We recommend wearing safety glasses. 14. Route the coupler leads through the frame. The wires should follow the truck s pick-up wires. 15. Insert the ends of the ElectroCoupler wires into the two-pin connector that was included with the upgrade kit. 16. Plug the connector into the circuit board as illustrated in Figure 7 on page 8. Note! The location of this connection will vary. C-Clip Fiber Washer Spring Washer Retaining Post Figure 6. ElectroCoupler installation 7
J8 Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive (continued) 17. Carefully bundle the wires together and keep them clear of the motor and truck guides. 18. Reposition the motor. Be sure that there are no gaps between the motor mounting plate and gear box. 19. Reinstall that motor screw on the bottom of the truck. 20. Replace the pick-up roller screw. Pass the screw through the metal washer with the pickup wires and then the insulating grommet. On the bottom on the truck, reposition the pick-up roller so that the roller is seated on the plastic insulating surface. 21. Dash-9 locomotives only. Replace the extra screw on the top of the truck. Refer back to Step 4. 22. Repeat this process for the other ElectroCoupler. 23. Reinstall the body, taking care not to pinch any wires between the frame and the body. Front J3 Rear Figure 7. Plugging in the connector 8
Installing ElectroCouplers on your early GP-9 diesel locomotive 1. Remove the body of the locomotive. Refer to your owner s manual for the location of the body screws. 2. Remove the screw from the bottom of the motor truck, then lift it away. Note! To release the rear truck, remove the retaining clip from the mounting pin, then lift away the truck. 3. Compress the washer and the spring under the retaining clip, then remove the retaining clip with a pair of needle-nose pliers. Carefully release the spring and washer after the clip is removed. Refer to Figure 8. Caution! The spring and washer will launch off the truck if you are not careful. Eye protection is recommended. C-Clip Washer Spring Washer Retaining Post Figure 8. Removing the magnetic coupler 9
Installing ElectroCouplers on your early GP-9 diesel locomotive (continued) 4. At this point, the retaining post will drop down. Simply remove the retaining post and slide the magnetic coupler through the pilot. 5. Slide the ElectroCoupler and the two wires through the pilot and under the mounting boss. 6. Push the retaining post through the ElectroCoupler s shank. 7. Slide on a washer, the spring, and then another washer. Refer to Figure 9. C-Clip Fiber Washer Spring Washer Retaining Post Figure 9. Installing the ElectroCoupler 10
Installing ElectroCouplers on your early GP-9 diesel locomotive (continued) 8. Compress the washers and spring and replace the retaining clip. Caution! The spring and washer will launch off the truck if you are not careful. Eye protection is recommended. 9. Route the coupler wires up through the frame through the openings shown in Figure 10. RUN LCRU PROG FULL RS SIGNAL Figure 10. Routing the wires through the frame 11
Installing ElectroCouplers on your early GP-9 diesel locomotive (continued) 10. Reposition the truck, motor and the spring plate, then replace the screw on the underside of the motor truck. Note! To install the rear truck, reposition the truck and install the retaining clip. 11. Repeat steps 2 through 10 for the other truck. 12. Notice that the ends of the ElectroCoupler wires are fitted with crimped metal ends. Cut off and strip the end of one wire from each of the ElectroCouplers. In other words, each ElectroCoupler should have one wire with a crimped metal end and one wire with a stripped end. 13. Identify the method of connection for your locomotive and connect the ElectroCoupler wires (one from each coupler) as discussed below. Black wires with a wire nut On some locomotives, the ends of all the black wires are bundled in a wire nut connection. Refer to Figure 11. Remove the wire nut from the bundle and twist the stripped ElectroCoupler wires (one from each coupler) with the bundled wires. Replace the wire nut to secure the connection. Soldered connections On other locomotives, the ends of all the black wires will be connected to a solder lug mounted to the frame in front of the electronics boards (beside the motor). Refer to Figure 12 on page 13. Solder the two stripped ElectroCoupler wires (one from each coupler) to the solder lug. Alternately, you may choose to loosen the solder lug screw, wrap the wires around the post, and gently tighten the screw. 14. Locate the two-position female connector packed with your ElectroCoupler. Insert the remaining two ElectroCoupler wires (with crimped ends) into the connector as illustrated in Figure 11. Wire nut Front ElectroCoupler Rear ElectroCoupler Metal projections Tabs Figure 11. Wire connections 12
Installing ElectroCouplers on your early GP-9 diesel locomotive (continued) Be sure the crimped metal projection is inserted so that it snaps in place below the connector tabs. Looking at the side of the connector with the tabs, the rear ElectroCoupler should be inserted into the right slot and the front ElectroCoupler should be inserted into the left slot. Note! Be sure to position the couplers in these slots for proper functioning. 15. Plug the two-pin connector into the bottom portion of the connector mounted to the circuit board. Note! The position of the connector may be different in your locomotive. Consult your owner s manual. FRONT/CAB Solder lug Figure 12. Plugging in the connector 16. Be sure that the wires are clear of the motor and truck guides. We recommend that you bundle the wires neatly with twist ties or tape for added protection. 17. Replace the body and the body screws, taking care not to pinch any wires between the frame and the body. 13
Installing ElectroCouplers on your more recent GP-9 diesel locomotive 1. Remove the body of the locomotive. Refer to your owner s manual for the location of the body screws. 2. Remove the screw from the bottom of the motor truck, then lift it away. Note! To release the rear truck, remove the retaining clip from the mounting pin, then lift away the truck. 3. Compress the washer and the spring under the retaining clip, then remove the retaining clip with a pair of needle-nose pliers. Carefully release the spring and washer after the clip is removed. Refer to Figure 13. Caution! The spring and washer will launch off the truck if you are not careful. Eye protection is recommended. C-Clip Washer Spring Washer Retaining Post Figure 13. Removing the magnetic coupler 14
Installing ElectroCouplers on your more recent GP-9 diesel locomotive (continued) 4. At this point, the retaining post will drop down. Simply remove the retaining clip and slide the magnetic coupler through the pilot. 5. Slide the ElectroCoupler and the two wires through the pilot and under the mounting boss. 6. Push the retaining post through the ElectroCoupler s shank. 7. Slide on a washer, the spring, and then another washer. Refer to Figure 14. C-Clip Fiber Washer Spring Washer Retaining Post Figure 14. Installing the ElectroCoupler 15
Installing ElectroCouplers on your more recent GP-9 diesel locomotive (continued) 8. Compress the washers and spring and replace the retaining clip. Caution! The spring and washer will launch off the truck if you are not careful. Eye protection is recommended. 9. Route the coupler wires up through the frame through the openings shown in Figure 15. RUN LCRU PROG FULL RS SIGNAL Figure 15. Routing the wires through the frame 16
Installing ElectroCouplers on your more recent GP-9 diesel locomotive (continued) 10. Reposition the truck, motor and the spring plate, then replace the screw on the underside of the motor truck. Note! To install the rear truck, reposition the truck and install the retaining clip. 11. Repeat steps 2 through 10 for the other truck. 12. Locate the two-position female connector packed with the ElectroCoupler. Insert the two ElectroCoupler wires (with the crimped ends) into the connector as illustrated in Figure 16. Be sure that the crimped metal projections snap in place below the connector tabs. Note! The two wires from the rear coupler go into one connector while the two wires from the front coupler go into the other. For each coupler, the wires are interchangeable between the right and left positions. 13. As illustration in Figure 16, plug in the connectors. 14. Be sure that the wires are clear of the motor and truck guides. We recommend that you bundle the wires neatly with twist ties or tape for added protection. 15. Replace the body and the body screws. Front coupler wires Rear coupler wires Metal projections Front of locomotive Connector tabs Rear of locomotive Figure 16. ElectroCoupler connections 17
Installing an ElectroCoupler on the tender (steam locomotives) 1. Remove the body of the tender. Refer to your owner s manual for the locations of the body screws. 2. Remove the speaker-mounting screws. Refer to Figure 17 on page 19. Remove the RailSounds circuit board, if necessary. 3. Remove the truck-mounting screw that was located beneath the speaker to release the truck. 4. Compress the spring under the retaining clip, then remove the retaining clip with a pair of needle-nose pliers. Carefully release the spring after the clip is removed. Caution! The spring will launch off the truck if you are not careful. Eye protection is recommended. 5. At this point, the retaining post will drop down. Simply remove the magnetic coupler. 7. Slide the ElectroCoupler and the two wires under the mounting boss. 8. Push the retaining post up, then slide on the spring. 9. Compress the spring, then press on the retaining clip. Caution! The spring will launch off the truck if you are not careful. Eye protection is recommended. 10. Reposition the truck, then reinstall the truck-mounting screw. 11. Route the coupler wires up through the frame, passing through the slot at the rear of the frame. 12. Reposition the speaker, then reinstall the speaker-mounting screws. 13. If there is a two-pin connector mounted to the circuit board, insert the two wires into the two-pin connector that was included with your upgrade kit. Refer to the right-hand portion of Figure 11 on page 12 and disregard the FRONT and REAR designations to make these connections. Plug the two-pin connector into the bottom portion of the connector mounted to the circuit board. If the two-pin connector is not present, you will find a black and a brown wire. Remove the wire nut to free the wires. Cut off the ends of the ElectroCoupler wires, then strip the wires back about 1/4. Connect each ElectroCoupler wire with one tender wire. We recommend that you twist and solder the wires together, or you may install wire nuts for the most secure connections. Wrap the wires with electrical tape to avoid short circuits. 14. Be sure that the wires are clear of the body. We recommend that you bundle the wires neatly with twist ties or tape for added protection. 15. Reinstall the tender body. 18
IInstalling an ElectroCoupler on the tender (steam locomotives) (continued) Speaker mounting screw Truck mounting screw Electrocoupler wires Retaining clip Spring Armature Magnetic coupler White Connector Retainer clip post Figure 17. ElectroCoupler installation 19
Limited Warranty/Lionel Service This Lionel product, including all mechanical and electrical components, moving parts, motors and structural components, except for light bulbs, is warranted to the original consumer-purchaser, for one year against original defects in materials or workmanship when purchased through an authorized Lionel merchant. This warranty does NOT cover normal wear and tear, light bulbs, defects appearing in the course of commercial use, or damage resulting from abuse or misuse of the product by the purchaser. Transfer of this product by the original consumer-purchaser to another person voids this warranty. Modification of this product voids this warranty. Any warranted product which is defective in original materials or workmanship and is delivered by the original consumer-purchaser to Lionel L.L.C. or an authorized Lionel L.L.C. Service Center, together with proof of original purchase will, at the option of Lionel L.L.C., be repaired or replaced, without charge for parts or labor. In the event the defective product cannot be repaired, and a replacement is not available, a refund of the original purchase price will be granted. Any products on which warranty service is sought must be sent freight or postage prepaid, as transportation and shipping charges are not covered by the warranty. In no event shall Lionel L.L.C. be liable for incidental or consequential damages. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you. This limited warranty gives you specific legal rights, and you may have other rights which vary from state to state. Instructions for Obtaining Service If service for this Lionel L.L.C. product is required, bring the item, along with your dated sales receipt and completed warranty information to the nearest Authorized Lionel Service Center. Your nearest Lionel Service Center can be found by calling 1-800-4-Lionel, or by accessing our Website at www.lionel.com. If you prefer to send your product back to Lionel L.L.C. for repair in Michigan, you must first call 586-949-4100 or FAX 586-949-5429, or write to Customer Service, P.O. Box 748, New Baltimore, MI 48047-0748, stating what the item is, when it was purchased and what seems to be the problem. You will be sent a return authorization letter and label to ensure your merchandise will be properly handled upon receipt. Once you have received your return authorization and label, make sure that the item is packed to prevent damage during shipping and handling. We suggest that you use the product s original packaging. This shipment must be prepaid and we recommend that it be insured. Please make sure you have followed all of the above instructions carefully before returning any merchandise for service. You may choose to have your product repaired by one of our Authorized Lionel Service Centers after its warranty has expired. A reasonable service fee will be charged. Warranty Information Please complete the information below and keep it, along with your dated sales receipt. You must present this and your dated sales receipt when requesting warranty service. Name Address Place of Purchase Date of Purchase Product Number Product Description 2004 LIONEL L.L.C., CHESTERFIELD, MI 48051-2493 UNITED STATES OF AMERICA PRINTED IN U.S.A.