Rail King Rugged Rails 2-8-0 Steam Locomotive User manual

PLEASE READ BEFORE USE AND SAVE
OPERATOR’S MANUAL
Rugged Rails 2-8-0
Steam Locomotive
(3V PS2)
Compatibility
This engine will operate on any traditional O-
27 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 page 23 for a
complete list of compatible transformers and
wiring instructions.)

2Rugged Rails 2-8-0 Steam Engine
Table of Contents
Set Up Checklist................................................................................................... 3
Lubrication............................................................................................. 3
Priming The Smoke Unit....................................................................... 3
Checking The Battery............................................................................ 4
Basic Operation.................................................................................................... 5
Activating Features................................................................................ 5
Proto-Sound 2.0 Operating Instructions........................................................... 7
Activating Proto-Sound 2.0 Conventional Mode Features.................... 7
Freight Yard Sounds (FYS)................................................................... 8
Proto-Coupler® Operation.................................................................... 9
Speed Control........................................................................................ 10
Locking Locomotive Into ADirection.................................................. 11
Reset To Factory Default....................................................................... 11
Automatic Sound Effects....................................................................... 11
Maintenance......................................................................................................... 12
Lubricating and Greasing Instructions................................................... 12
Cleaning The Wheels, Tires and Track.................................................. 13
Traction Tire Replacement Instructions................................................. 13
Headlight Replacement Instructions...................................................... 15
Self Charging Battery Back-Up............................................................. 16
ProtoSmoke® Unit Operation................................................................ 18
Troubleshooting Proto-Sound® 2.0 Problems....................................... 20
Transformer Compatibility and Wiring Chart....................................... 23
Additional Features Accessible Of DCS Remote Control System........ 24
Service & Warranty Information........................................................... 25
Limited One-Year Warranty.................................................................. 25
CAUTION: ELECTRICALLY OPERATED PRODUCT:
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:
Readthismanualthoroughlybeforeusingthisdevice.
lM.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.
lDonotoperateyourlayoutunattended. Obstructedaccessoriesorstalledtrainsmayoverheat,resultingindamagetoyourlayout.
lThistrainsetisintendedforindooruse. Donotuseifwaterispresent. Seriousinjuryorfatalitymayresult.
lDonotoperatethehobbytransformerwithdamagedcord,plug,switches,buttonsorcase.
Thisproductmaybeprotectedbyoneormoreofthefollowingpatents: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.ElectricTrains,Columbia,MD21046

3
Rugged Rails 2-8-0 Steam Engine
Set Up Checklist
• Lubricate the locomotive
• Prime the smoke unit
• 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
Priming The Smoke Unit
When preparing to run this engine, add 15-20 drops of smoke fluid
through the smokestack. We recommend M.T.H. ProtoSmoke, Seuthe,
LGB, or LVTS fluids. Do not overfill the unit or the fluid may leak out
and coat the interior engine components.
If you choose not to add the fluid (or have already added the fluid but
choose to run smoke-free), turn off the smoke unit switch located under
the engine (see Fig. 2). Failure either to add fluid to the unit or to turn it
off may damage the smoke unit heating element and/or wicking
material.
DO NOT
OVER OIL
DO NOT
OVER OIL
DO NOT
OVER OIL
Figure 2: Smoke Unit Switch Location
Smoke Unit
ON/OFF Switch
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
Lubricate axle

4Rugged Rails 2-8-0 Steam Engine
Placing The Engine On The Track
Place the engine on the track, then insert the reverse unit plug that extends out of
the tender into the receptacle at the back of the boiler cab (Figure 3. WARNING:
DO NOT CONNECT THIS ENGINE TOA TENDER FROMANOTHER
ENGINE; IT MAY CAUSE SERIOUS DAMAGE. Look at the bottom of the
engine and tender where each will have a color-coded stamp. If they match you
may connect those two pieces; if not, don’t.)
Connect the draw bar between the
engine and tender. The draw bar hole
located farthest from the tender is
for applications such as display.
The second hole is for normal operation
on the track.
At this point, you are ready to begin
running your engine.
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 page16.
Figure 3

5
Rugged Rails 2-8-0 Steam 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.
Activating Features
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 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.

6Rugged Rails 2-8-0 Steam Engine
Manual Volume
Control To adjust the volume of all sounds made by this engine, turn the master
volume control knob (located on the bottom of the tender) clockwise to increase
the volume and counter-clockwise to decrease the volume.

Timing Chart
Total Time Lapse: 1 Seconds½
Press
Horn
Short &
Firm
½ Sec.
Pause ½ Sec. Pause
Press
Bell
Short &
Firm
Press
Bell
Short &
Firm
Feature to Be Activated Button Code:
Freight Yard Sounds
Fire the Rear Coupler
Fire the Front Coupler
Speed Control On/Off
Lock into a Direction
Reset to Factory Defaults
1 Bell, 2 Whistles
1 Bell, 3 Whistles
1 Bell, 4 Whistles
1 Whistle, 2 Bells (from Neutral only)
1 Whistle, 3 Bells
1 Whistle, 5 Bells (from Neutral only)
7
Rugged Rails 2-8-0 Steam Engine
Proto-Sound 2.0 Operating Instructions
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.(Sold Separately)
Activating Proto-Sound 2.0 Conventional Mode Features
Proto-Sound 2.0 features are activated by sequences of Bell and 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.

+
Horn Horn
Bell
Direction
+
Direction
+
Direction
+
Direction
=Operator
Controls
When Bell
Turns Off
Sound System Cued
to Play Passenger
Station Announcements (FYS)
1st
Sequence
FYS
2nd
Sequence
FYS
3rd
Sequence
FYS
4th
Sequence
FYS
8Rugged Rails 2-8-0 Steam Engine
Freight Yard Sounds (FYS)
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 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 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 Horn buttons and can ring the bell or blow
the horn as usual.

Horn Horn
Fire
Rear
Coupler
=
Horn
Bell
9
Rugged Rails 2-8-0 Steam 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.
Proto-Coupler® Operation
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. 7) 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 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
Place
Engine into
Neutral
Bell Bell
=
Speed Control
Two Horn Blasts
(indicates change is made)
Repeat to Return
to Normal Condition
10 Rugged Rails 2-8-0 Steam Engine
Horn Horn
Fire
Front
Coupler
=
Horn Horn
Bell
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 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.
Speed Control
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 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 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.

11
Rugged Rails 2-8-0 Steam Engine
Locking Locomotive Into ADirection
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 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 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.
Reset To Factory Default
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 horn blasts will indicate that the engine has
made the change.
Automatic Sound Effects
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.
Horn
Place
Engine into
Desired
Direction
Horn
Bell Bell Bell
=
Direction Lock
Two Horn Blasts
(indicates change is made)
Repeat to Return
to Normal Condition
Reset
Two Horn Blasts
(indicates change is made)
Repeat to Return
to Normal Condition
Horn
Place
Engine in
Neutral =
BellBellBellBellBell

12 Rugged Rails 2-8-0 Steam Engine
Maintenance
Lubricating and Greasing Instructions
The engine should be well oiled and greased in order to run properly.
You should regularly lubricate all side rods, linkage
components and pickup rollers to prevent them from
squeaking. Use light household oil and follow the
lubrication points marked “L” in Fig. 5. Do not
over-oil. Use only a drop or two on
each pivot point.
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. To access the gear box and axles, do the following:
1. Turn the engine upside down.
2. Remove the boiler by removing the body mounting screws shown in Fig. 6
3. Remove the Phillips screw (marked “GREASE”) (Fig. 6).
4. Use a grease tube dispenser to put a small amount (approx. 1-2 ml.) of lithium-
based grease into the gearbox and axles.
5. Replace the screws and reassemble the boiler.
You should also grease the leading locomotive truck tongue to enhance its ability
to slide on the chassis. Follow the grease points shown on Fig. 6.
Figure 5: Lubricating the Locomotive
Lubricate axle

Rugged Rails 2-8-0 Steam Engine 13
Cleaning The Wheels, Tires and Track
Periodically check the locomotive wheels
and pickups for dirt and buildup, which can
cause poor electrical contact and traction
as well as prematurely wear out the
neoprene traction tires.
Wheels and tires can be cleaned using
denatured (not rubbing) alcohol or
M.T.H. Track Cleaner applied with
a cotton swab.
Traction Tire Replacement Instructions
Your locomotive is equipped with two neoprene rubber traction tires on the rear
set of flanged drivers. While these tires are extremely durable, you may need to
replace them at some point.
1. Use a hexnut driver to remove the hex screws and make sure to note the
position of all rods before removing.
2. 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.
3. 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.
Figure 6: Traction Tire Replacement Instructions

14 Rugged Rails 2-8-0 Steam Engine
4. 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.
5. Make sure the tire is flat and fully seated inside the groove. Use a razor blade to
trim away any excess tire that doesn’t seat itself inside the groove properly.
6. Reinstall the side rods in the same positions as noted. Failure to align rods may
cause binding or damage to the drive system.
One set of replacement tires is packaged with your model. Additional sets are
available directly from the M.T.H. Parts Department (order online: www.mth-
railking.com, e-mail: [email protected]; mail: 7020 Columbia Gateway
Drive, Columbia MD 21046-1532, FAX: [phone]).

15
Rugged Rails 2-8-0 Steam Engine
Headlight Replacement Instructions
The locomotive’s lights are controlled by a constant voltage circuit in the engine.
They are easy to remove and replace when they burn out. See the diagrams and
directions below for instructions on accessing and replacing the light bulbs in
this locomotive.
You can obtain replacement bulbs directly from the M.T.H. Parts Department
(order online: www.mth-railking.com, e-mail: [email protected]; mail:
7020 Columbia Gateway Drive, Columbia MD 21046-1532, FAX: 410-381-
6122).
1. To replace the headlight in this model you will need to follow the disassembly
instructions for greasing the engine in figure 6 on pg. 13. Once the boiler has been
removed you can access the headlight (see figure 8).
2. Unscrew the bulb.
3. Screw a new bulb into the socket, and reassemble boiler shell to chassis, being
careful not to pinch any wires.
Figure 7

16 Rugged Rails 2-8-0 Steam Engine
Self Charging Battery Back-Up
The special 2.4v 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) 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
the AC Battery recharging jack on the bottom of the tender 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.
Figure 8

17
Rugged Rails 2-8-0 Steam Engine
Figure 9
Figure 10: Battery Recharging JAck
Unhook wires, Remove
and Replace Battery

18 Rugged Rails 2-8-0 Steam Engine
ProtoSmoke® Unit Operation
This steam locomotive contains a self-powered smoke unit that outputs smoke
through the smokestack on the roof of the engine. The smoke unit is essentially a
small heating element and wick that soaks up and then heats a mineral oil-based
fluid that emits smoke. The smoke is
then forced out of the stack by a
small electric fan. Smoke
volume is controlled by the
Proto-Sound 2.0 system.
With a few easy maintenance
steps, you should enjoy trouble-free
smoke unit operation for years.
When preparing to run this engine,
add 15-20 drops of smoke fluid
through the smokestack (see Fig. 11).
We recommend M.T.H. ProtoSmoke,
Seuthe, LGB, or LVTS fluids. Do
not overfill the unit or the fluid
may leak out and coat the interior
engine components.
If you choose not to add the fluid
(or have already added the fluid but
choose to run smoke-free), turn off the
smoke unit switch located under the
engine chassis (see Fig. 12). Failure either to add fluid to the unit or to turn it off
may damage the smoke unit heating element and/or wick material.
When the smoke output while running the engine begins to diminish, add another
10-15 drops of smoke fluid or turn the smoke unit off.
When storing the unit for long periods of time, you may want to add about 15
drops of fluid to prevent the wick from drying out.
After removing the engine from storage, add another 25 drops of fluid, letting the
wick soak up the fluid for 15 minutes prior to operation.
If you experience poor or no smoke output when the smoke unit is on and has
fluid, check the wick to see if it has become hard, blackened, and unabsorbent
around the heating element. To remove the smoke unit you will first have to
remove the boiler shell (by removing the body mounting screws shown in Fig. 6
on pg. 13).
Figure 11
Figure 12 Smoke unit on/off switch

1. Once the boiler has been removed, locate the smoke unit assemby (see Figure
13).
2. Use a phillips head screwdriver to remove the inspection cover screws as seen
in Figure 13.
3. After removing the inspection cover,
inspect the wick. If it is darkly
discolored and hard, it should
be replaced.
Replacement parts and wick replacement
instructions are available directly from
the M.T.H. Parts Department phone: [phone]
(order online: www.mth-railking.com, e-mail: [email protected]; mail:
7020 Columbia Gateway Drive, Columbia MD 21046-1532,
FAX: [phone]).
19
Rugged Rails 2-8-0 Steam Engine
Figure 13

20 Rugged Rails 2-8-0 Steam Engine
Troubleshooting Proto-Sound® 2.0 Problems
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).