MTHTrains RailKing SW-9 User manual

SW-9 Switcher
Diesel Engine
OPERATOR’S MANUAL
Compatibility
This engine will operate on any
traditional O-31 Gauge track system,
including M.T.H.’s RealTrax®or
ScaleTrax™or traditional tubular track. It
is also compatible with most standard
AC transformers. (See page19 for a
complete list of compatible transformers
and wiring instructions.)
PLEASE READ BEFORE USE AND SAVE

CAUTION:ELECTRICALLYOPERATEDPRODUCT:
Not recommended for children under 10 years of age. M.T.H. recommends adult supervision with children ages 10 - 16.
As with all electric products, precautions should be observed during handling and use to reduce the risk of electric shock.
WARNING:Whenusingelectricalproducts,basicsafetyprecautionsshouldbeobserved,includingthefollowing:
Readthismanual thoroughlybefore usingthis 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
properlyrepaired.
Donot operateyour layoutunattended. Obstructed accessoriesor stalledtrains may overheat,resultingin damageto yourlayout.
Thistrainsetisintendedfor indooruse. Donotuseifwateris present. Seriousinjuryorfatality mayresult.
l
l
l
lDonotoperatethe hobbytransformerwith damagedcord,plug,switches, buttonsorcase.
Table of Contents
Set Up Checklist...................................................................................................3
Lubrication.............................................................................................3
Checking The Battery............................................................................ 3
Basic Operation....................................................................................................4
Activating Features................................................................................4
Proto-Sound 2.0 Operating Instructions............................................................6
Activating Proto-Sound 2.0 Conventional Mode Features.................... 6
Freight Yard Sounds (FYS)................................................................... 7
Proto-Coupler® Operation.................................................................... 8
Speed Control........................................................................................ 9
Locking Locomotive Into A Direction.................................................. 10
Reset To Factory Default.......................................................................10
Automatic Sound Effects.......................................................................10
Maintenance......................................................................................................... 11
Lubricating and Greasing Instructions...................................................11
Cleaning The Wheels, Tires and Track..................................................12
Traction Tire Replacement Instructions.................................................13
Headlight Replacement Instructions......................................................14
Self Charging Battery Back-Up.............................................................15
Troubleshooting Proto-Sound® 2.0 Problems.......................................16
Transformer Compatibility and Wiring Chart........................................19
Additional Features Accessible with the DCS Remote Control System........ 20
Service & Warranty Information........................................................... 21
Limited One-Year Warranty..................................................................21
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.
©2004, M.T.H. Electric Trains, Columbia, MD 21046

RailKing SW-9 Switcher Diesel Engine 3
Set Up Checklist
•Lubricate the locomotive
•Check to see whether the battery needs to be charged for full sound effects
•Apply power to run as described in the Basic Operating Section of this manual
Lubrication
You should lubricate the engine to prevent it from squeaking. Use
light household oil and follow the lubrication points marked “L” in
Fig. 1. Do not over-oil. Use only a drop or two on each pivot point.
Figure 1. Lubrication Points on the Locomotive
DO NOT
OVER OIL
Checking The Battery
You may find, if your locomotive was built several months before you set it up, that the
rechargeable battery has run down and needs to be charged before operating. If you
notice that the sounds are garbled, test and charge the engine as described in the
"Self-Charging Battery Back-Up" on page 14.

4RailKing SW-9 Switcher Diesel Engine
Basic Operation
The Throttle knob controls how fast your train will travel.
Turn the throttle knob up ½-way, until the engine and caboose lights shine bright.
Put the engine into motion by pressing the Direction button on your transformer once.
(hold it for approximately 1 second)
If the engine does not begin to move as soon as you firmly press the Direction button,
you may not have sent enough voltage to the track to make the train move. Turn the
throttle up a bit higher until the train begins to move.
Throttle To increase or decrease track voltage, and therefore train speed, turn the
throttle control knob. Turning clockwise will increase voltage and speed, while turning
counterclockwise will decrease voltage and speed. The engine will maintain the speed
you set after you release the throttle until you turn it again to change the voltage and
speed.
Bell - To sound the bell, in an engine equipped with a bell firmly press and release the
Bell button. To turn the bell off, press and release the Bell button again. The bell will
continue to ring from the time you turn it on until you press and release the button again
to turn it off.
Horn/Whistle - To sound the horn or whistle, firmly press the Horn/Whistle button. The
whistle will sound for as long as you continue to depress the button. It will stop when
you release the button.
Direction Your train is programmed to
start in neutral. The train will always
cycle neutral-forward-neutral-reverse with
each press and release of the direction
button. The engine is programmed to
restart in neutral each time the track
voltage is turned off for 25 seconds or
more.
Cycle Phases
Neutral
Neutral ForwardReverse
Activating Features

RailKing SW-9 Switcher Diesel Engine 5
Manual Volume Control
To adjust the volume of all sounds made by this engine, turn the master volume control
knob located next to the fuel tank clockwise to increase the volume and
counter-clockwise to decrease the volume.
Figure 2: Manual Volume Adjustment Knob

6RailKing SW-9 Switcher Diesel Engine
This manual contains the operating instructions for Proto-Sound 2.0 in conventional
mode only. Instructions for accessing DCS command mode features accompany the DCS
Remote Control System equipment.
Proto-Sound 2.0 features are activated by sequences of Bell and Whistle/ Horn button
pushes described below. Please read the full descriptions of each feature before using it.
To use these buttons to activate features rather than to blow the horn or ring the bell, you
should tap the buttons very quickly with a ½-second pause between button presses. You
may need to practice your timing to make this work smoothly.
Proto-Sound 2.0
Operating Instructions
Timing Chart
Total Time Lapse:1 Seconds
½
Press
Horn
Short &
Firm
½ Sec.
Pause ½ Sec. Pause
Press
Bell
Short &
Firm
Press
Bell
Short &
Firm
Activating Proto-Sound 2.0 Conventional
Mode Features

RailKing SW-9 Switcher Diesel Engine 7
Your engine is equipped with a sound package of freight yard sounds that you can play
when you pull into a yard. Each sequence described below will play as long as it is left
on, randomly generating sounds, but be sure to allow approximately 30 seconds between
the button pushes described below to allow the FYS sufficient time to run through each
sequence.
•To cue the sound system to play the FYS, quickly but firmly tap the Bell button
once followed by 2 quick taps of the Whistle/Horn button while the engine is
moving. Tap the buttons quickly but allow approximately ½ second between
each press.
•Press the Direction button once to stop the engine. This will trigger the first
sequence of FYS. The reverse unit is temporarily disabled so that the train will
not move as you use the Direction button to trigger the sounds, and Proto-Sound
2.0 has disabled operator control over the Whistle/Horn and Bell buttons until the
full FYS sequence is complete.
•After waiting about 30 seconds for that sequence to run, press the Direction
button again to trigger the second sequence of FYS.
•After about 30 seconds, press the Direction button again to trigger the third FYS
sequence.
•Again, after allowing about 30 seconds for that sequence to run, press the
Direction button one more time to trigger the fourth and final FYS sequence.
The FYS will continue, and within a few seconds, the engine will start and move
out on its own at the current throttle setting, in the same direction it was traveling
when you began the sequence. Once the bell turns off, the operator regains
control of the transformer's Bell and Whistle/Horn buttons and can ring the bell
or blow the horn as usual.
Freight Yard Sounds (FYS)

8RailKing SW-9 Switcher Diesel Engine
Tips on Using FYS
•You can terminate FYS at any time by turning off power to the track for 15
seconds.
•You do not have to be in Forward to use FYS. At the conclusion of the full
sequence, the train will pull away from the station in whatever direction you
were going when you activated the feature.
•You can use FYS even if you are double-heading with another engine. If the
second engine is not equipped with Proto-Sound 2.0, you must remember
not to leave the throttle at a high voltage level once you have stopped the
engine to run the FYS. Otherwise, the engine without FYS will begin
vibrating on the track as its motors strain to move the train, since they
cannot be automatically disabled during the FYS cycle (or if an original
Proto-Sound engine, FYS are triggered differently and that engine's
motor-disable feature will not be active when you run FYS in Proto-Sound
2.0).
•FYS can be triggered from Neutral. It will operate the same as if triggered
while in motion except that, at the conclusion of the FYS, the engine will
depart in the next direction of travel, as opposed to the direction it was
traveling before entering Neutral.
This locomotive is equipped with one or more coil-wound Proto-Couplers for remote
uncoupling action. Because Proto-Couplers are controlled through the Proto-Sound 2.0
microprocessor, they do not require an uncoupling track section or modification to your
layout to function. You can fire a coupler from neutral or while in motion. Use the code
shown below (and in the chart on p. 6) to fire the coupler(s).
Rear Coupler:
To fire the rear coupler, quickly tap the Bell button once followed by three quick taps of
the Whistle/Horn button, allowing approximately ½ second to lapse between each quick
button press. The sound of the liftbar and air line depletion will play, and the knuckle
will be released.
Horn Horn
Fire
Rear
Coupler
=
Horn
Bell
Proto-Coupler® Operation

RailKing SW-9 Switcher Diesel Engine 9
Front Coupler:
To fire the front coupler (if your engine has one), quickly tap the Bell button once
followed by four quick taps of the Whistle/Horn button, allowing approximately ½
second to lapse between each quick button press. The sound of the liftbar and air line
depletion will play, and the knuckle will be released.
Horn Horn
Fire
Front
Coupler
= Horn Horn
Bell
M.T.H. engines equipped with Proto-Sound 2.0 have speed control capabilities that allow
the engine to maintain a constant speed up and down grades and around curves, much
like an automobile cruise control. You can add or drop cars on the run, and the engine
will maintain the speed you set.
While the engine is programmed to start with the speed control feature activated, you can
opt to turn it off. This means the engine's speed will fall as it labors up a hill and increase
as it travels downward. It is also affected by the addition or releasing of cars while on the
run. Because the engine will run more slowly at a given throttle voltage when speed
control is on than when it is off, you should adjust the throttle to a lower power level for
operation with speed control off to avoid high-speed derailments. When speed control is
off, the volume will drop to allow for better low voltage operation.
To turn speed control on and off, put the engine in neutral, then quickly tap the
transformer's Whistle/Horn button one time then quickly tap the Bell button two times,
allowing approximately ½ second to lapse between each quick button press. Two horn
blasts will indicate that the engine has made the change. Repeat the 1 Whistle/Horn, 2
bells code to return it to the other condition. You will want to do this during the initial
neutral upon start-up if you ever couple this engine to another engine that is not equipped
with speed control to avoid damaging the motors in either engine. Each time you shut
down the engine completely, it will automatically turn speed control on.
Horn
Place
Engine into
Neutral
Bell Bell
=SpeedControl
Two Horn Blasts
Repeat to Return
to Normal Condition
(indicates change is made)
Speed Control

10 RailKing SW-9 Switcher Diesel Engine
You can lock your engine into a direction (forward, neutral, or reverse) so that it will not
change directions. To do this, put the engine into the direction you want (or into neutral
to lock it into neutral), run it at a very slow crawl (as slowly as it will move without
halting), and quickly but firmly tap the Whistle/Horn button once followed by three quick
taps of the Bell button, allowing approximately ½ second to lapse between each quick
button press. Two horn blasts will indicate that the engine has made the change. The
engine will not change direction (including going into neutral) until you repeat the 1
Whistle/Horn, 3 bells code to return the engine to its normal condition, even if the engine
is kept without power for extended periods of time.
Horn
Place
Engine into
Desired
Direction
Horn Bell Bell Bell
=Direction Lock
Two Horn Blasts
Repeat to Return
to Normal Condition
(indicates change is made)
To override the settings you currently have assigned to the engine and reset it to its
factory defaults, while in Neutral tap the Horn button quickly once, followed by five
quick taps of the Bell button, allowing approximately ½ second to lapse between each
quick button press. Two Whistle/Horn blasts will indicate that the engine has made the
change.
Reset
Two Horn Blasts
Repeat to Return
to Normal Condition
(indicates change is made)
Horn
Place
Engine in
Neutral =
BellBellBellBellBell
Certain Proto-Sound 2.0 sound effects automatically play in programmed conventional
mode conditions:
•Squealing Brakes play any time the engine's speed decreases rapidly.
•Cab Chatter plays at random intervals when the engine idles in neutral.
•Engine Start-up and Shut-down sounds play when the engine is initially powered
on or is powered off for five seconds or more.
Locking Locomotive Into A Direction
Reset To Factory Default
Automatic Sound Effects

RailKing SW-9 Switcher Diesel Engine 11
The engine should be well oiled and greased in order to run properly.
Regularly lubricate all axles and linkage components and pickup rollers
to prevent squeaking. Use light household oil, such as that found in M.T.H.'s
maintenance kit. Do not over oil. Use only a drop or two on each pivot point.
DO NOT
OVER OIL
Figure 3: Body Removal Screw Locations (Turn truck blocks to access body mount screws)
The locomotive’s internal gearing was greased at the factory and should not need
additional grease until after 50 hours of operation or one year, whichever comes first.
Follow the greasing instructions below. Note that in some tightly packed engines you
may need to move internal components temporarily in order to access the gears.
1. To access the gear box, remove the cab from the chassis by unscrewing the chassis
screws indicated in Figure 3 and lifting the cab from the chassis.
2. Once the cab is removed, remove the trucks by unscrewing the black Phillips motor
mount screw located on the underside of the drive trucks (see Fig. 3).
3. Once the motor mount screw has been removed, pull the motor away from the truck
block and lightly coat the motor worm gear and bronze drive gear (in the truck block)
with grease.
4. Reassemble the truck and motor, being careful not to pinch any wires between the
truck block and motor mount.
Lubricating and Greasing Instructions
Maintenance

12 RailKing SW-9 Switcher Diesel Engine
5. After repeating the procedure for the other motor, reassmble the chassis and body,
being careful that the wire harnesses are not caught between the chassis and body, and
reinstall the chassis screws.
Lubricate the outside truck block
idler and drive gears with grease.
Use the diagram shown in Figure 4
as a guide and add grease to the
points marked with a “G.”
Periodically check the locomotive
wheels and pickups for dirt and
buildup, which can cause poor
electrical contact and traction and
prematurely wear out the neoprene
traction tires. Wheels and tires can be
cleaned using denatured (not rubbing)
alcohol applied with a cotton swab.
To clean the track, use RailKing Track
Cleaning Fluid or denatured (not
rubbing) alcohol, and a clean rag.
Unplug the transformer and wipe the
rails of the track, turning the rag
frequently to ensure that you are using
clean cloth on the rails. Thereafter,
keep an eye on the track and clean it
when it gets dirty to ensure good
electrical contact and to lengthen the
life of the tires.
Cleaning The Wheels, Tires and Track
Grease Idler Gears (G)
Figure 4: Greasing The Idler Gears

RailKing SW-9 Switcher Diesel Engine 13
Your locomotive is equipped with two neoprene rubber traction tires on each powered
truck block. While these tires are extremely durable, you may need to replace them at
some point.
First, remove the truck sides from the truck block. To do this, turn your engine upside
down. If there are visible Phillips screw heads between the truck frame and truck block
(see Fig.4), go to step A. If not, go to step B.
A. Remove the two Phillips screws that attach each truck side to the truck block.
B. Remove the trucks from the chassis and the truck sides from the trucks in order to slip
the new tire over the grooved drive wheel. See Fig. 5for which screws you must remove
to do this.
Once the truck sides have been removed:
1. Make sure the old tire has been completely removed from the groove in the drive
wheel, using a razor blade or small flathead screwdriver to pry away any remains.
2. Slip the new tire onto the wheel.
You may find it useful to use two
small flathead screwdrivers to stretch
the tire over the wheel.
3. If you twist the tire while
stretching it over the wheel, you will
need to remove and reinstall the tire.
Otherwise your engine will wobble
while operating.
4. Make sure the tire is fully seated
inside the groove. Use a razor blade
to trim away any excess tire that
doesn’t seat itself inside the groove
properly.
5. Reassemble in reverse order.
One set of replacement tires is packaged with the model. Additional tires are available
directly from the M.T.H. Parts Department (phone: [phone]; fax: [phone];
e-mail: [email protected]; mail: 7020 Columbia Gateway Drive, Columbia MD
21046-1532).
Traction Tire Replacement Instructions
Truckside Screws
Figure 5 Truckside Screws

14 RailKing SW-9 Switcher Diesel Engine
Locomotive Light Bulb Replacement
To replace the light bulbs in the locomotive, follow these instructions:
Follow the cab removal instructions found in the “Lubrication and Greasing” section of
this booklet. Once the body has been removed, remove the lights as shown in Fi g. 6and
replace it.
You can obtain replacement bulbs directly from the M.T.H. Parts Department.
The locomotive’s headlight is controlled by a constant voltage circuit in the engine. The
headlight is easy to remove and replace when it burns out. The bulb has a quick
disconnect plug that attaches the bulb harness to a connector terminal inside the body
shell. Replacement bulbs are available directly from the M.T.H. Parts Department.
Follow the body removal instructions found in the Lubrication and Greasing Instructions.
Gently disconnect the bulb harness from the socket on the constant voltage circuit or
connector terminal and replace the bulb.
Figure 6a: Removing The Replaceable Headlights
Headlight Replacement Instructions
Figure 6b: Removing The Replaceable Cab Interior Lights

RailKing SW-9 Switcher Diesel Engine 15
The special NiCad 7-cell 8.4v self-charging battery recharges continuously during train
operation and should last for up to five years. The battery is a dry battery that should not
leak or cause any damage to your engine. Depending upon when your engine was built,
it may need to be charged right out of the box. If engine sounds seem distorted or
garbled at low voltages or become silent when power from the transformer is turned off,
test the battery to determine whether it should be recharged or replaced.
Test: Put the engine in neutral and
leave the track voltage at 10-12
volts (high enough for the lights to
shine brightly and the engine to
move steadily) for 15 minutes.
Recharge: If the sounds are
improved at the end of the
15-minute test charge, the battery
charge has run down and can be
recharged. There are a number of
ways you can do this:
•Leave the engine in neutral with track voltage at 10-12 volts for 6-7 hours so the
battery can fully recharge (if your engine has a smoke unit, be sure it is turned
off).
•Use M.T.H.'s battery recharger (sold separately) that plugs into a wall outlet and
a special port under the engine to recharge the battery overnight without leaving
it on the track.
Replace: If the sounds are not improved at the end of the 15-minute test charge, it is
time to replace the battery. Available through M.T.H. Parts. A standard 9v alkaline
battery can be substituted until your replacement arrives, but since alkaline batteries
cannot be recharged, it will eventually wear down. Do NOT use a 6-cell 7.2v battery.
Disconnect Battery,
And Slide Out Battery In Direction Of Arrow
Remove two screws
to gain access to the battery.
Figure 8: Removing The Battery
Battery Charger Port
Figure 7: Battery Charger Port
Self Charging Battery Back-Up

16 RailKing SW-9 Switcher Diesel Engine
Although Proto-Sound 2.0 has been designed and engineered for ease of use, you may
have some questions during initial operation. The following table should answer most
questions. If your problem cannot be resolved with this table, contact M.T.H. for
assistance (telephone: [phone]; fax: [phone]; [email protected],
7020 Columbia Gateway Drive, Columbia MD 21046-1532).
Troubleshooting Proto-Sound® 2.0 Problems

RailKing SW-9 Switcher Diesel Engine 17
Cab Chatter
Lock-out
Volume
Battery
FYS
Remedy
Remedy
Remedy
Remedy
Remedy
Sometimes the Cab Chatter sounds
don’tplay.
I can’t get the engine to run after I
power up the transformer. It sits still
with the engine sounds running.
The engine won’t lock into forward,
neutral, or reverse.
The sounds seem distorted, especially
when the whistle or bell is activated.
The engine will not leave the initial
neutral setting.
The FYS sounds occasionally repeat
themselves.
I get no sounds when the engine shifts
betweendirections.
After I turn off my transformer, my
engine continues to make sounds
before quitting.
Cab Chatter plays only in neutral at
random intervals.
The engine is locked into the neutral
position. Follow the procedure in the
“Lock into a Direction” section.
Engine speed must be below 10 scale
mph (approx. 10 volts or less in
conventional mode).
Proto-Sound 2.0 volume is set too
high. Turn the volume control knob on
the bottom of the chassis counter-
clockwise to reduce the volume.
Check to be sure the battery is
installed and fully charged. See the
“Self-Charging Battery Back-Up”
section.
The battery may be dead or need to
be charged. See the “Self-Charging
Battery Back-Up” section.
Proto-Sound 2.0 is designed to
continue to sound for a few seconds
after power to the track has been shut
off.
Proto-Sound 2.0 has a built-in random
number generator that randomly
selects each sound clip to play.
Because there are a limited number of
sound clips available in each FYS
sequence, it is probable that some of
these sound clips will be repeated
from time to time.

18 RailKing SW-9 Switcher Diesel Engine

RailKing SW-9 Switcher Diesel Engine 19
Proto-Sound 2.0 is designed to work with most standard AC transformers. The chart
below lists the many compatible transformers. Note that many of the operational
commands described in these instructions require a bell button, so if your transformer
does not have its own bell button, you should consider adding one to get the full benefit
of the system. In addition, the chart details how the terminals on these transformers
should be attached to your layout.
Transformer Compatibility and Wiring Chart

20 RailKing SW-9 Switcher Diesel Engine
(Additional equipment required)
While conventional mode operation of a Proto-Sound 2.0 engine yields wonderfully
realistic sound and several train control features, command mode operation allows the
user to access a world of command functions never before accessible to O Gauge
railroaders. With the addition of the DCS Remote Control System (including a DCS
remote handheld and Track Interface Unit) users gain many advanced features, including:
•DCS Proto-Speed Control - Establishes desired locomotive speed in scale miles
per hour increments via a thumbwheel control and allows operator to set
maximum speed and acceleration/deceleration rates
•ProtoSmoke® Variable Output Control - Controls how much smoke each engine
outputs and matches smoke to locomotive speed
•Locomotive Lighting Control - Controls locomotive headlights, marker and
interior lights, beacon lights, ditch lights, and MARS lights
•Emergency Stop-Single button push stops all Proto-Sound 2.0 trains but does not
turn off the power
•One Touch Global Mute/UnMute-Single button mutes or unmutes all
DCS-controlled locomotives' user-defined actions, including sound, lights, and
smoke
•Proto-Dispatch Operation-Public Address-like feature allows users to speak
through locomotive speaker during operation
•Proto-Cast-Allows users to play audio recordings through locomotive speaker
during operation
•Proto-Doppler Sound Effects Set Up-Users can configure locomotive for
Doppler Operation, including setting distance points for Doppler start, repeat,
and stop modes
•Independent Volume Control of Engine Sounds, Bell, Horn & Whistle for each
Locomotive
•Control up to 50 different DCS-Equipped Locomotives at one time with multiple
TIUs
•Proto-Effects™ Set Up-User can select individual Proto-Effects™ operations to
be active or inactive, including cab chatter, train wreck sounds, coupler sounds,
and wheel clickety-clack sounds
•Direction Control Set Up-User can set initial individual start-up direction (start
in forward or reverse) for double-heading operations
•Locomotive Consist Set-up-User can determine locomotive values for consist
make-ups, allowing multiple locomotives belonging to a consist to operate
together
Additional Features Accessible With The DCS
Remote Control System