MTHTrains Proto-Sound 3.0 User manual

STEAM LOCOMOTIVE UPGRADE KIT
INSTALLATION MANUAL
Compatibility
This Proto-Sound 3.0 Steam Locomotive Upgrade Kit is compatible with any AC or DC
Powered locomotive equipped with a DC can motor and motor flywheel. The locomotive
must be large enough to house the electronics. The instructions herein are generic in
nature and will not provide the installer with specific installation details for specific
locomotives. Consult the individual item’s operator’s manual for specific instructions on
how to disassemble the locomotive prior to installing the upgrade kit.
WARNING: This product is not covered by a warranty unless installed by an M.T.H.
Authorized Conversion Center.
PLEASE READ BEFORE USE AND SAVE FOR REFERENCE
www.mthtrains.com
3

Table of Contents
WARNING: This product is not covered by a warranty unless installed by an M.T.H.
Authorized Conversion Center.
Contents Of The Kit ...................................................3
Required Tools ....................................................6
Locomotive Inspection & Review ........................................7
Preparing The Tender For The Upgrade ..................................8
Installing The Proto-Sound 3.0 Components Into The Tender .................9
Mounting The Proto-Sound 3.0 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing The Proto-Coupler..........................................13
Coupler Installation.................................................14
Optional Front Proto-Coupler Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installing The Tender Harness.........................................16
Soldering Speaker Connections .......................................19
Installing The Volume Pot............................................20
Preparing The Locomotive For The Upgrade ..............................21
Determining The Locomotive Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installing The Tach Reader Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installing The Flywheel Tach Tape.....................................23
Mounting The Tach Reader To The Tach Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installing The Proto-Sound 3.0 Harness Into The Locomotive.................25
Mounting The Proto-Sound 3.0 Harness Connector . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Motor, Ground & Pickup Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installing Headlight Into RailKing Steam Engines . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting The Proto-Sound 3.0 Harness To The Smoke Unit . . . . . . . . . . . . . . . 28
Other Proto-Smoke Circuit Wiring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Connecting Power To The Constant Voltage Board . . . . . . . . . . . . . . . . . . . . . . . . 30
Wire Management/Short Circuit Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Testing The Proto-Sound 3.0 Installation ..................................32
Loading Proto-Sound 3.0 Files Into Locomotive ............................33
Proto-Sound 3.0 Operation Instructions...................................36
Conventional Operation .............................................36
Troubleshooting....................................................42
Service & Warranty Information ........................................44
This product may be protected by one or more of the following patents: 6,019,289; 6,280,278;
6,281,606; 6,291,263; 6,457,681; 6,491,263; 6,604,641; 6,619,594; 6,624,537; 6,655,640.
©2018, M.T.H. Electric Trains®, Columbia, MD 21046
CAUTION: ELECTRICALLY OPERATED PRODUCT:
Recommended for Ages 14 and up. Not recommended for children under 14 years of age without adult supervision.
As with all electric products, precautions should be observed during handling and use to prevent electric shock.
WARNING: When using electrical products, basic safety precautions should be observed, including the following:
• Read this manual thoroughly before using this device.
• M.T.H. recommends that all users and persons supervising use examine the hobby transformer and other electronic
equipment periodically for conditions that may result in the risk of fire, electric shock, or injury to persons, such as damage
to the primary cord, plug blades, housing, output jacks or other parts. In the event such conditions exist, the train set should
not be used until properly repaired.
• Do not operate your layout unattended. Obstructed accessories or stalled trains may overheat, resulting in damage to your
layout.
• This train set is intended for indoor use. Do not use if water is present. Serious injury or fatality may result.
• Do not operate the hobby transformer with damaged cord, plug, switches, buttons or case.

Contents Of The Kit
A) Proto-Sound 3.0 board (1)
B) Proto-Sound 3.0 plastic mounting bracket (1)
C) Tender harness (1)
D) Proto-Sound 3.0 metal heat sink bracket (1)
E) Proto-Coupler, long (1)
F) Tender Back-up light (1)
G) Tender Marker Light Harness w/2 LEDs (1)
H) Locomotive Harness w/Tach Reader
I) Speaker, 4 ohm 50mm diameter (1)
J) Headlight (1)
K) Tach reader brackets (2)
L) Tach tape stripes (4)
M) Screws M2 x 4 mm (2)
N) Screws 6/32 x 6 mm (3)
O) Nuts 6/32 (3)
P) Screw 6/32 x 8 mm (1)
Q) Plastic Wire Sleeve
(for wire managment) (1)
R) Shrink tubing (1)
S) Wire Ties (7) (6) 4”, (1) 7”
T) Inductor (1)
U) Headlight Grommet
V) Locomotive Harness Spacer/Insulator
W) Pittman Tach Reader Screws (2)
X) Coupler Insulator
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(B) Proto-Sound 3.0 Plastic
Mounting Bracket (IH-0000474)
(A) Proto-Sound 3.0 Circuit Board
AE-1000035, AE-1003V36
(C) Tender Wiring Harness
(BC-1000005)

(G) Tender Marker LEDs
(CC-0000062)
(D) Proto-Sound 3.0 Metal
Heat Sink Bracket
(IH-0000473)
(F) Tender Backup Light
(CF-0000030)
(H) Locomotive Wire
Harness w/Tach Reader
(BC-1000003)
(J) Locomotive Headlight
(CA-00000078)
(K) Tach Reader Brackets
Pittman
(IH-0000479)
(L) Tach Tape
(BE-0000151)
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(I) Speaker
(BF-0000043)
(E) Proto-Coupler
(DD-0000032)
Mabuchi / IDG
(27mm Flywheel) (pictured above)
IH-0000475
(30mm Flywheel) (not pictured)
IH-0000478

(Q) Plastic Wire Sleeve
(S) Wire Ties
(U) Headlight Grommet
(IH-0000010)
(V) Loco Harness Spacer
(BD-0000065)
® Shrink Tubing
(P) 6/32 Screw x 8mm
(IA-0000050)
(N) 6/32 x 6mm Screws
(IA-0000027)
(O) Nuts
(TP-MS00075)
(M) M2 Screws
(IA-0000058)
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(T) Inductor
(AI-0000044)
(X) Coupler Insulator
(ID-0000123)
(IA-0000375)
(8-32)
(W) Pittman Motor Tach Bracket Screws
(IA-0000466)
(6-32)

Required Tools
Soldering iron
ESD safe work area
White thermally conductive grease
Screw drivers, Philips #2 & #00
Wire cutters
Drill
Drill bits (1/8”, 5/32”)
Drill bit (3/8” or ½”) or de-burring tool
Allen key (1.5 mm for Pittman motor
flywheel set screw)
Electrical Tape
Razor Saw What Is An ESD?
As ESD safe work area is an area
set aside in your workshop that is
electrically grounded and
includes anti-static mats and
grounding straps
ESD Mat
Work Only in an ESD Safe Zone
Grounding Strap
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Inspection & Review
Before beginning the installation, Inspect the engine and tender to be upgraded
and verify the following are in good working order:
Pick-up rollers
Motor w/flywheel
Smoke unit
Speaker mounting hardware
Volume pot
Coupler mounting hardware, “T” bar, spring, c-clip
Constant voltage lighting board and connected bulbs.
Note: If any of the above items are missing or not in working order, procure the
required parts before continuing.
Note: Before beginning installation, see discussion on page 31 on “wire
management” which should be planned as you proceed during the installation.
Part of the plastic wire tube (Q) may be used for this purpose.
Make sure pickup rollers are clean & lubed and roll freely.
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Preparing The Tender For The
Proto-Sound 3.0 Upgrade
Before you can install the Proto-Sound 3.0 components into your tender, any
existing sound boards or reversing units must be removed. The Proto-Sound 3.0
Kit contains all the necessary electronics your locomotive requires to operate.
Some existing mounting brackets may be utilized during the installation of the
Proto-Sound 3.0 components. Follow the instructions below taking care to save
the parts when noted.
Remove The Following Items From The Tender Chassis
Tender shell (save the mounting screws).
Proto-Sound 1, DCRU Reverse Unit, Mechanical Whistle, Electronic Whistle,
any other electronics and tender harnesses.
Speaker (save mounting hardware).
Existing coupler (save the “T” bar, spring, and c-clip).
Any lights including the rear back-up light and marker LEDs (if present). These
will likely be mounted inside the tender shell.
Do NOT remove the volume pot used on Proto-Sound 1 models.
Remove the old coupler by slipping off the “C”-clip from the coupler “T”-Bar.
If your locomotive does not have a volume pot, order BI-0000040 (volume pot),
IA-0000035 (screw), ID-000071 (spacer) and IC-0000006(nut).
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Installing The Proto-Sound 3.0
Components Into The Tender
Required Upgrade Kit Components
Typical component arrangement on tender floor. Note position of heat sink.
A) Proto-Sound 3.0 board (1)
B) Proto-Sound 3.0 plastic mounting bracket (1)
C) Tender harness (1)
D) Proto-Sound 3.0 metal heat sink bracket (1)
E) Proto-Coupler, long (1)
F) Tender Back-up light (1)
G) Tender Marker Light Harness w/2 LEDs (1)
I) Speaker, 4 ohm 50mm diameter (1)
N) Screws 6/32 x 6 mm (3)
O) Nuts 6/32 (3)
P) Screw 6/32 x 8 mm (1)
Q) Plastic Wire Sleeve
(for wire managment) (1)
R) Shrink tubing (1)
S) Wire Ties (7) (6) 4”, (1) 7”
X) Coupler Insulator
Proto-Sound 3.0 Upgrade Kit Installation Guide
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85mm
100mm
33mm

Mounting The Proto-Sound 3.0 Board
Remove the Proto-Sound 3.0 Board
(A) from the sealed anti-static bag
Verify Proto-Sound 3.0 board is
securely inserted into the plastic
mounting bracket (B)
Remove the speaker (I) from the protective packaging.
Note: Be careful not to damage the speaker cone.
Place the Proto-Sound 3.0 board/plastic mounting bracket (A/B) in the tender
to verify the best location to mount the plastic mounting bracket (B) and the
metal heat sink bracket (D) to the tender floor.
Make sure the Proto-Sound 3.0
board is firmly inserted into the
plastic mounting bracket. If not,
gently push the board into the
bracket until fully “captured” by
the bracket. DO NOT REMOVE
THE BOARD FROM THE
BRACKET.
Place the components on the tender floor in the best position given the space.
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NOTE: If you are not a
participating M.T.H.
Authorized Service Center
there is NO warranty once
the bag is opened
NOTE: Use ESD safe work
area and procedures when
handling the Proto-Sound
3.0 board.

Mounting The Proto-Sound 3.0 Board Cont’d
Once you have determined the best locations for mounting the plastic bracket
(B) and metal heat sink bracket (D), mark the tender floor locations using a
pencil or silver marker so you can drill the holes in the proper locations.
Drill the appropriate mounting holes as determined from positioning the Proto-
Sound 3.0 board and other components
Remove the Proto-Sound 3.0 board (A) with plastic mounting bracket (B), metal
heat sink bracket (D) and speaker from the tender and place on an ESD safe area
on your workbench.
Drill the holes as marked with the proper drill size. A 5/32” bit will be required
for the Proto-Sound 3.0 plastic mounting bracket (B) and heat sink bracket (D).
De-burr the holes slightly using a larger drill bit (3/8”) or a deburring tool.
Carefully remove any metal burrs resulting from drilling the mounting holes.
Loose metal burrs can damage the Proto-Sound 3.0 circuit board!
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Mounting The Proto-Sound 3.0 Board Cont’d
Mount the plastic mounting bracket (B) containing the Proto-Sound 3.0
board (A) using the 2 of the screws (N) and nuts (O)
Apply white thermally conductive grease to the bridge rectifier on the
Proto-Sound 3.0 board.
Mount the Proto-Sound 3.0 plastic mounting bracket
Apply white thermally conductive grease to bridge rectifier & metal heat sink
bracket.
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Mounting The Proto-Sound 3.0 Board Cont’d
Secure the metal heat sink bracket (D) to the bridge rectifier using screw (P)
Note: If screw is too long, cut it down so it does not hit the relay
Apply thermal conductive grease to the metal heat sink bracket surface that
contacts the frame and mount to the tender frame using screw (N) and nut (O).
Installing The Proto-Couplers
The Proto-Coupler installs in the same location as the original engine coupler.
Install the proto-coupler (E) onto the existing tender trailing truck or coupler
mount location using the existing hardware. Be sure to route the coupler wire
harness through the tender floor.
Connect black Proto-Coupler connector to black tender harness connector on the
brown & purple wires.
Note: Use coupler insulator as required to prevent shorts from coupler solder
connections to tender truck axle.
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Coupler Installation
A plastic insulator, item EE in the parts list of your Proto-Sound 3.0 Upgrade Kit
has been included with the rest of your Proto-Sound 3.0 Upgrade Kit parts.
This insulator should be inserted
between the coupler and the spring,
washer and the C clip that holds the
coupler to the T-Bar and truck bolster.
The insulator prevents the coupler
wiring from contacting and short
circuiting against the truck’s axle.
Failure to insert the insulator could
permanently damage the coupler and
Proto-Sound 3.0 board.
Shown here is the insulator
attached to the truck and coupler.
Ensure that the part of the
insulator which protects the
coupler’s wires extends up not
down when installed.
Shown above is the
coupler unassembled.
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Tach Reader
(Bottom View)
Tach Reader
(Top View)
Pickup Roller
Leads
Ground Lead
Motor Leads
(Green) Smoke
Unit Fan Motor
(Blue) Headlight
Leads
(Red) Smoke Unit
Heating Element
Proto-Sound 3.0
Tender Plug
Boiler Connector
Optional Front Proto-Coupler Wiring
**Move the purple wire in the tender 12 pin connector from pin 5 location
(purple wire next to green wire) to pin 9 location (between brown and blue
wires).
*If front proto-coupler is desired purchase a coupler DD-0000032 and give up
Headlight Control. Power headlight as it was powered prior to Proto-Sound 3.0
upgrade. Use the headlight connector (Blue) to control the front proto-coupler.
Move the purple wire in the tender 12 pin connector from pin 5 location (purple
wire next to green wire) to pin 9 location (between brown and blue wires).
PIN 5
**PIN 9
Engine Harness
Tender Harness 12 Pin Connector
*
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Installing The Tender Harness, Speaker, Switches & Lights
*Note: If tender has harness to connect an auxiliary tender, connect the
back-up light and coupler connectors to the harness. Use switch to select
light/coupler operation in tender or auxiliary tender.
Proto-Sound 3.0 Volume Pot Leads
Proto-Sound 3.0 Speaker Leads
Proto-Sound 3.0 Smoke Unit Switch
Proto-Sound 3.0 Tender Harness
Proto-Sound 3.0 Tender Backup
Light*
Proto-Sound 3.0 Proto-Coupler*
Proto-Sound 3.0 Tender
Marker Lights
12 PIN
5 PIN
4 PIN
7 PIN
8 PIN
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Proto-Sound 3.0 Board Connections
5 PIN
4 PIN
12 PIN
8 PIN
7 PIN
Proto-Sound 3.0 Upgrade Kit Installation Guide
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DCS Jumper
(Remove for DCC Operation)
These Connections
Are NOT Used

Installing The Tender Harness, Speaker, Switches & Lights
Attach tender harness (C) to the Proto-Sound 3.0 board (A) noting the
connectors all should fit in their respective locations. See previous pages for
locations.
Take care to insert the correct plug into the correct connector on the Proto-
Sound 3.0 board. Each plug is polarized and has a different number of pins.
Install the speaker (I) into the previous speaker mounting location us ing the
existing hardware.
Install the smoke unit switch (attached to the tender harness) in the tender frame
cut out using screws (M). If one does not exist, locate the switch in the best
possible location.
Mount the smoke unit switch into the existing switch hole on the tender floor
using screws (M).
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Soldering Speaker Connections
Install the rear back up light (F) with green connector and marker lights (G)
with yellow connector as required in the model. Connect the backup light green
connector and marker light yellow connector to the green and yellow Proto-Sound
3.0 harness connectors, respectively. (Note: If only 1 marker light is required,
secure one of the LEDs from the wire harness inside the tender.)
Ensure proper wire management by using pieces of plastic sleeve (R) to hold
various cables in place.
Solder the yellow and white wires to the speaker (I) making sure soldered wires do
not short to speaker frame.
WARNING: If either wire shorts to the speaker frame the Proto-Sound 3.0
electronics will be damaged.
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Installing The Volume Pot
Proto-Sound 3.0 Upgrade Kit Installation Guide
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Solder the wires to the existing volume POT. Red wire to the center terminal,
blue to one outer terminal and gray to the other outer terminal.
Note: Volume pot not required for command operation. Solder gray and red
wires together to get full volume in conventional mode and insulate the blue wire
from chassis ground.