S-Helper Service Showcase Line EMD NW-2 User manual

tnginenttm
TTlonuat
NW-2, SW-8 & SW-9
SWITCHER
Tl-IE SHOWCASE L.INE"
Quality S-scale model trains
from S-Helper Service, Inc.
S HELPERSERVICE INC.O2004
77 Cliffwood Ave,Unit 7C, Cliffwood, NJ 07721

TABLE OF CONTENTS SW-9-TofC
TABLE OF CONTENTS
THANKYOU 2
SECTION I - Prototype Data 2
SECTION 2 - Features 3
SECTION 3 - Getting Started 3
3-1 AC/DC American Flyer® Compatible
Layouts 4
3-2 AlternatePilots 4
3-3 Couplers 5
3-4 Code I 10 NMRA RP-25 Wheelsets 6
3-5 AC/DC Sound Unit 7
3-6 DC Polarity Reversing Options 8
3-7 DCC (Digital CommandControl) 8
SECTION 4 - Maintenance 16
4-1 Lubrication 16
4-2 LED replacement 17
4-3 Cleaning 17
4-4 Pick-up wipers replacement 18
4-5 HeavyDutyLubrication 18
SECTION 5 - Parts List 20
DRAWINGS
6-1 Bottomview - Gear Box& parts 5
6-2 Side view-Truck & details 6
6-3 NMRA socket diagram 7
6-4 14 Pin socket Key. 7
6-5 10 Button LocoMatic Conroller. 12
6-6 LocoMaticConrollerwiring 14
6-7Dip Switches 15
6-8 Cross-section - Gear box& parts 19
6-9 Explodedview - Body & chassis 22
WARRANTY..

GENERALDESCRIPTIONSW-9-Sec I
THANKYOU
Thank you for purchasing our dieselswitcher. Your new
switchercomesready-to-run on AmericanFlyercompatible
S gauge track with either AC orDC power. Just be sure to
break in yourswitcher before placing itin normaloperation.
Simplyoperate itfor20 minutes in bothdirections atmid
voltage(about 9 volts),lubricate per the instructions in
Section4-1, and then it's ready. We haveincluded additional
parts for easyadaptation to different operating conditions.
Withpropercare and maintenance,yourdieselswitcher
shouldgive youa lifetime of operatingpleasure.
SECTION I - Prototype Data
The Electro-MotiveCorporationbegan to produce 600hp
dieselswitchers inthe late '30s. In 1940GeneralMotors
bought EMCand changed its name to Electro-MotiveDivision
(EMD). Sincethen,evolvingdesignimprovementswere
incorporated as newermodelswereproduced.Modifications
includedincreasedhorsepower,multiple-unit(MU)options,
welded construction, and changes in bodystyling. EMD
sold 1149 NW-2s, manufacturedbetween1939 and 1940,
779 SW-9s(1951-1953) and369 SW-8s(1950-1953).Hundreds
of railroads and industrieshave owned these switcherswith
many still inuse today.
GeneralSpecifications:
Wheel Diameter 40"
TruckWheelbase 8'-0"
Locomotive Wheelbase 22'-0"
Length 44'-9"
Height l4'-6"
Weight 248,000 Ibs
Horsepower (NW-2) 1000 hp
Horsepower (SW-8) 800hp
Horsepower(SW-9) 1200 hp
Speed (max.) 55- 65mph
2

GENERAL DESCRIPTION SW-9-Sec 2
SECTION 2 - Features
Right outofthe box,yourswitcherwill runonany layout
withAmericanFlyercompatible track and standard
transformer,rectifier, and/or rheostat speedcontrol.
Warning - UseofAC voltageshigherthan 21 volts may
damage the electronics and willvoid the warranty.
Your switchercomeswithseveraloptionalfeatureslisted
below: (Thosewith an asterisk (*) are factory-installed.)
•Two sets of pilots.
a. Standardhandrails*.
b. A second set withsplit handrails and walk-
over steps forMU operation.
• Accepts two types of couplers.
a. AmericanFlyercompatibleautomaticcouplers*
b. SHS #01295couplerswithincludedmachine
threadmountingscrews(coupler not included).
c. Kadee No.802 couplers(notincluded)
•Two sets of wheels.
a. AmericanFlyercompatible wheelsets*.
b. Code 110 NMRA RP-25contourwheelsets.
• Electronicoptions.
a. AC/DC sequence-reversing*.
b. LocoMatic™ or Sountraxx DCC sound unit
c. Reversing headlights*.
d. DC shortingplug(cab light on)*.
e.DC shortingplug(cab light off)*.
f. DigitalCommandControl (DCC) NMRA socket*.
• Complete setof spareelectricalpick-upwipers.
The following paragraphs tell you how to set up your
switcher touseany combination of thesefeatures.
SECTION 3 - GettingStarted
You can perform anyorallofthe following modifications
before or after you begin to operateyourswitcher. Ifyou
haven't yet broken itin (seeSection4-1), be sure todoso
before placingyour switcherintonormaloperation.
3

GETTING STARTED SW-9-Sec3-l
3-1 AC/DC American Flyer Compatible
Layouts
Your switcher has American Flyercompatiblewheels and
automaticcouplers. It also has factory-installed forward-
neutral-reverse-neutralsequencing(1.0 sec stop) just like
mostAmericanFlyerlocomotives. In order to enhanceyour
operating enjoyment, we haveincluded the following standard
ready-to-runfeatures:
•A circuitdelay so that the locomotivedoes not cycle
intoneutral in case power is momentarilyinterrupted,
as withdirtytrack.
• Directional lighting,only the headlight pointing
in the direction that yourswitcher is moving lights
up.
• Smart reversing.Whenstopped for30 seconds or
more, yourswitcherwillalwaysresumerunning in
the forward direction.
Thesefeatures areall factory-installedwith theno sound
option.
3-2 Alternate Pilots
Your switchercomesready to operate asa single unit. If
you want toruntwo units in tandem, youmay want to
install the alternate setofMU pilots ononeor bothends of
eachunit.Thesehavesplithandrails and fold-up walk-over
steps that allowcrewmembers to walkbetween the units.
Both pilotstyles are compatiblewith either the American
Flyercompatiblecouplers or KD style No. 01295couplers.
To replaceeachpilot, lift the side handrails outof
their sockets onthe pilot.Place the locomotiveupside down
on a soft protectedsurface.Unscrew thetwo screws that
hold the pilot in place. The pilotshould lift straight up.
Slide the alternate pilotonto the chassis, (ifthe pilotdoes
not seat properly,trim any flash from the bottom ofthe
pilot) replace thetwo screws (Donot overtighten), andre-
insert the handrails.

GETTING STARTED
SW-9-Sec 3-3
3-3 Couplers
If you wish to replace the AmericanFlyercompatiblecouplers
with the body mounted SHS #01295 orKD 802/808couplers,
place yourswitcherupsidedown ona soft protectedsurface.
Carefully remove the four screws that hold the American
Flyercompatiblecouplerbracketassemblies in place and
lift off. Each coupler padonthe chassis has three holes
cored for mounting the Kadee S coupler. TheAF coupler
box lid with front flangeremoved is used asa spacerabove
the KD802/808 orSHS #01295couplerbox. Please usethe
six threadedmetricmachinescrewsincludedwithyour
switcher orthe screws that held theAF couplerbracket
assy. TheKD screws arenot intended foruse with a metal
chassis andmay break.
•Donot overtighten the screws or theywillbreak.
•Donotusethe screws that come with the Kadee
couplers; these are designed foruse withplastic or
wood rather than metal. Their use will void the
warranty 'pertaining tothe chassis.
6-1 Bottomviewpartsdrawing - gear boxand details

GETTING STARTED
SW-9-Sec 3-4
3-4 Code I 10 NMRA RP-25 Wheelsets
Code 110 wheelsmust be used ifyou have a railheight that
is smaller than code 125 (0.125"), or with open-frog turnouts
built tothe NASG scalestandards(AmericanFlyerswitches
are closed-frog). Installthese as follows:
Step 1.Ifyou have not alreadydone so, remove the
American Flyercompatiblecouplerbracketassy.
Step 2. With a smallscrewdriver,gently pry off the
endofthe plasticsideframe/gearboxcover to release
thetab that holds ittoone of the gearboxes. Setthe
sideframe/gear box cover aside.
Step 3. Remove the two AmericanFlyercompatible
wheelsets.
Step 4. Replace these wheelsetswith two code 110
wheelsets.Canteachwheelset soasto position one
axle bearing ata timeinto the gearbox.Eachbearing
must align perfectly in order to slide the wheelsets
intoposition.
Step 5. Oncebothwheelsets arein place,bend the
pick-up wires so that they are touching the back
surface of each wheel.
Step 6. Replace the plasticsideframe/gearbox cover
by snapping the tabsover the gearbox.
Step 7. Repeatwith the othertruck.Thencheck to
be sure the trucks move freely.
If you intend to retain the AmericanFlyercompatible
couplers, be sure to replace the couplerbracketassemblies.
6-2 Lateral viewpartsdrawing-Truck and details
6

GETTING STARTEDSW-9-Sec 3-5
3-5 Alternate AC StartingDirection
Right outofthe box,your switcherwillalways start inthe
forward (long hood in front) direction ifithas been standing
for more than 30 seconds.However, ifyou wish to designate
thecabendas "front" (asyou would foroneoftwo back-to-
back units), the default starting direction can be reversed.
To change the defaultdirection,remove the four screws that
hold the bodyassembly tothe chassis and lift off the body.
You will find a smallsocket just behind the front radiator
grille.(Thissocket is Part No.16inthe "cross-section parts
drawing - gearbox and details" on page 11.) In this socket
there isa slideswitchwhosepositiondetermines the default
locomotive direction. To change the defaultdirection,simply
slide the toggle tothe oppositeside ofthe switch.Replace
the body onthe chassis and secure it with the four screws
(Do not overtighten).
Front of switcher
ooooooool
1
rp.
\3
•
10
1
2
3
4
11
OO
0000
0000
OO
9
8
7
6
5
12
Expanded 8 pin NMRA socket (2:1)
6-3 Socketdiagrams
pin
I
2
3
4
9
II
function
motor(+/R)
light - rear
shorted topin7
pick-up(L-fi reman)
speaker
strobe light
color
orange
yellow
-
black
purple
green
pin
5
6
7
8
10
12
function
motor(-/L)
light - front
light(common)
pick-up(R-engineer)
speaker
cab light
color
gray
white
blue
red
purple
brown
6-4 Eight Pin NMRA socket Key
7

GETTING STARTED SW-9-Sec 3-6
3-6 DC Polarity Reversing Options
WARNING: Donotuse this feature with AC current.
If yourun yourSW-9with the AC/DC no soundoption on
a layoutpowered by DC,it willoperateperfectly and cycle
reverse the same asifit werepowered byAC. Most DC
layouts useDC polarity to reverse direction,however. You
can convertyourswitcher toDC polarityreversing.Access
the reversingplug by following the instructions inthe
previous paragraph(Section3.5).Remove the factory-
installedplug from the socket and replace it with theDC
shortingplug,furnished asa separate part in yourswitcher
packaging. TwoDC shortingplugs are provided, one with
thecab light onandthe otherwith thecab light off. Once
the plug is inserted, setthe body onthe chassis and test
the locomotive.Replace the body onthe chassis and secure
it with the four screws (Donot overtighten).
3-7 AC/DC LocoMatic™ Sound Units
Another optionavailable for yourswitcher is LocoMatic™
Control withsound.Thisfeature canbe orderedfactory
installedwith the switcher, or purchased later for installation
by the owner.Thisallows the unit to operatewith ACor
DC track power andis different from mostother LocoMatic™
systems. It does not contain the DC shift for operation of
the Horn and Bell.Therefore it requires theuse of the
#00552 LocoMatic™ 10 ButtonController for thesefunctions.
This was designed forSHS Inc. by DalleeElectronics, Inc
andis available for $69.95. DC operatorsshouldoperate
in LocoMatic™ COMMAND CONTROL only. If operated
withvariable DC trackpower in standardmode,thennormal
AC likesequencingwilloccur. The Horn or Bellwill not
constantlyoperatingsince the decodingcircuitry isnot
present in this system.Conventional AC operation follows
the usualsequence of forward - neutral - reverse - neutral
- forwardsequence pattern except that the initial state is
switchselectable for either start in forward or start in
neutral. A locomotive can also be switchlocked inthe forward
8

GETTING STARTED SW-9-Sec 3-7
position to accomodateoperationunderautomatedsituations.
An additional direction switch is provided so that if several
locomotives arerunina multiple unit lash-upsimply set
this switch on eachlocomotive to specify whichdirection is
forward, engine. Ifthe direction of the locomotive is opposite
of that desiredsuch as back to backoperation as commonly
seenwithswitchers.
SOUNDS REPRODUCED
The sounds ofthe switcherhavebeenrecorded from an
actual locomotive andare prototypicallycorrect for utmost
realism.
HORN is useractivated bythe HORNbutton ononthe
LOCOMATTC™ CONTROLLER. The hornwillplay as long
asthe switch or button is held on.
BELL is useractivated bythe BELLbutton onthe
LOCOMATIC™ CONTROLLER. The BELLsoundwill latch
"on" when the bellcontrol is activated and willlatch "off
when the control is againactivated. Any BELLrequests at
higherspeedswill be ingored. The BELL canbe activated
at higher speeds if requested at lowerspeeds and then the
locomotive speed is advanced.WhenBELLsound is
requested, the soundsystemwillfirstadjust the diesel
sound totheRPM required for simultaneousplay.When
deactivating, the BELLwillstop attheendofa ring and
the dieselsoundwill return tothe correct throttle setting.
BELL sound can also be requestedwhendieselprimemover
sound has beenturned "off1. Again, a manualswitchallows
the bell tobe deactivated for multipleunit(MU)operation.
AIR SYSTEMRELEASE(POPS) Airis pumped
continuously ina diesellocomotive to maintainpressure in
the brakesystem andfor otherpurposes.Periodically,
accumulatedmoisture and any excesspressurewill be
ventedthrough a releasevalve.These AIR RELEASEsounds
(pops) are generated at randomintervalsduringidle and
atall throttle settings.
9

GETTING STARTED SW-9-Sec 3-7
BRAKE RELEASEsound is producedwhen the locomotive
changes from neutral toa movementdirection and will
alwaysprecedelocomotivemovement.
PRIMEMOVER(Diesel)sounds range from idle to full
RPM witheight throttle notches. In neutral or with no
power tothe motor the soundsystemwillproducediesel
engineidlesounds.When a movementdirection is selected
andthe speedcontrol is advanced toputthe locomotive in
motion, a brake release willsound(seeabove) andthe
dieselsoundwill initially accelerate to about throttle notch
#4, and then seek the correctnotch setting for locomotive
speed.This simulates the normaldelay ona diesel
locomotive between throttle action and actual movement.
Therewill bea distinctvolumeincreaseduringacceleration.
Soundvolumeshould be somewhatloweroncespeed has
stabilized and should be reducedduringdeceleration.
Depressing theALT/ FORWARD button onthe
LOCOMATIC CONTROLLER willdirect the soundsystem
to accelerate to full RPM regardless of motorvoltage.
Depressing theALT/ FORWARD buttonagainwillrelease
the soundsystem to return tothe correct throttle notch
setting. Thisfeatureallows the simulation ofa heavy load
withveryslowlocomotivespeed or "pumpingair" ina
standing train.
LIGHTING FEATURES
The switcher is equippedwith lighting that is directional
so that the headlight will illuminate when the locomotive
isin forwardmotion.When the locomotive isin reverse
motion the headlight will turn off. The headlights and
interior cab light also be manuallyoperated by means of
theSHS #00552 LOCOMATIC™ CONTROLLER.
OPERATION USING ATRANSFORMER
With this sound / controlsysteminstalled,yourlocomotive
willoperate inthe samemanner as otherlocomotiveswhen
using a transformer to varyspeed.Whenpower is applied
the locomotivewillcome"on" in either the forward or
10

GETTING STARTED SW-9-Sec 3-7
neutralposition asyou haveselected.Momentary
interuptions of powerwillallow the locomotive to sequence
through the usualdirectionpositions.Sequencing canbe
accomplished either bya direction switch/button orby
turning the speedcontrol to "off and then back"on".
An added feature of this sound / controlsysteminvolves
thewaythe motor is driven,particularly at slowspeeds.
When track power isat lowervoltages the systemfurther
reduces the power tothe motor soasto provideextremely
smooth slow speeds for starting and stoppingyourtrain.
If the trackpowerfluctuates at theselowervoltages you
may notice a slight surging inthe speed ofthe locomotive.
If track power isset highwhile in neutral andyou sequence
to a direction, the locomotivewillgraduallyincrease its
speed rather than jumpdirectly tothe highspeed.Thistype
of operation not onlylooksbetter but also results in less
strain onthe entiremotor / geardrivesystem andis less
likely to causederailments ofthe locomotive orits train.
SHS #00552 LOCOMATIC™ CONTROL
Your SHS switcherwilloperatecorrectlywithyour
transformer inthe samemanner as traditionallocomotives,
but with the simpleinstallation ofthe optional LocoMatic
Control Box,operationwill be greatlyenhanced.
The LocoMaticControllercontains ten operating buttons
and is usableeither in conjunctionwithyour regular
transformer orasan independentcontrolwith a fixed voltage
applied tothe track. The LocoMatic Controller isa pass
through type of devicewhich is wiredbetweenyour
transformer and the track. The LocoMatic Controlleritself
is powered bya 9 volt DC plug-inpowersupplywhich is
included. Some ofthe buttonscause activation as long as
they are held"on"whileotherswork ina push-on,push-off
mode. The lower right handbutton,labled 'ALT', isthe
alternatebuttonwhichprovides a second function to each
of the otherninebuttons. For example;pressing the HORN
II

GETTING STARTED SW-9-Sec 3-7
6-5 LocoMatic 10 ButtonControl Box
button willoperate the HORN. Notallofthe buttonshave
alternate functions on this locomotive. Theten controller
buttons perform the following:
BELL - turnsbell"on" or "off', push onand push off.
ALT/BELL - restoresautomaticdirectionallighting.Note
- lighting on this locomotive is directionaluntil a request is
made viathe CONTROLLER fora manualactivation.
Lighting functions willthenremainmanual viathe
CONTROLLER. Pressing ALT/BELL willallow all lighting
functions to return to directionaloperation atthe next
direction request.
HEADLIGHT - turns front headlight"on" or "off
ALT/HEADLIGHT - turnsrearheadlight "on" or "off .
MARKERS - no function on this locomotive.
ALT/MARKERS - no function on this locomotive.
NUMBERBOARD- no function on this locomotive.
12

GETTING STARTED SW-9-Sec 3-7
ALT/NUMBERBORARD - turns cab light "on" and "off.
MARSLIGHT/STROBE - no function on this locomotive
ALT/STROBE - turns strobe"on" and "off
HORN - activates the horn
ALT/HORN - no function on this locomotive
FORWARD - forwardmotionoverriding sequencing from
neutral in standardmode.Increasesspeed in command
mode if alreadyrunning in forward. If running in reverse,
speed willdecreasethroughneutral to forward depending
on how long the button is pressed.
ALT/FORWARD - this forces the primemover RPM sound
to full speed(notch 8) regardless of voltage setting. Use
this to simulate pulling heavy drags, pumping upair tanks
when sitting still,etc.Pressing ALT/FORWARD again
returns RPM sound to normal.
REVERSE - reversemotionoverridingsequencing from
neutral in standardmode.Increasesspeed in command
mode if alreadyrunning in reverse. If running in forward,
speed willincreasethroughneutral to reverse depending
on how long the button is pressed.
ALT/REVERSE - turns OFF mainsoundsleavingonly the
Horn and Bell if selected (only the horn ifdip switch 3 set
on). Anotherpushwillrestore the mainsounds. Main
sounds includebrakerelease, air pops and primemover.
SLOW - neutralposition overridingsequencing toa
momentum stop - in standardmode.Slowdown a step per
push of button in commandmode.
ALT/SLOW - neutral position or emergencystop.
13

GETTING STARTED SW-9-Sec 3-7
ALT - alternate button for secondfunctions of other 9 buttons.
Must be helddown in conjunctionwith one otherbutton. It
may be depressedfirst and heldwithout anotherbutton
leavingonly one otherbutton to press.
Notice: Pressingmore than one button,other than the ALT,
produces no signal. Itisan invalidoperation.
INSTALLATIONOFTHE LOCOMATIC™ CONTROLLER
Connect two wires from yourtransformer tothe terminals
on the CONTROLLER labeledTrans, IN.The "B" terminal
is the base andthe "16" terminal isthe "hot".Thenconnect
two wires from the terminalslabeledTrack OUTtothe
track. The"B" terminal is connected tothe inside rails of
your track andthe "16" is connected tothe outer rail. This
installs the CONTROLLER asa passthroughbetweenyour
transformer andthe track. We recommendusing #20
strandedwire, asa minimum, for these connections. Ifthe
CONTROLLER isnot "on",your transformerwill still
function normally.Connect the9 volt DC powersupply to
the inputjack onthe CONTROLLER and plug itin.The
CONTROLLER isnow "on" andis ready to operatewith
your transformer.
In summary,LocoMaticControlallowsfingertipoperation
of a uniquesound and controlsystemwith the additional
features of realistic,prototypicalspeed and directioncontrol.
Right out of the box,yourswitcherwillalways start inthe
forward direction ifithas been standing for more than 30
trans, tra
INOU
15 B 15
nnnn
I ,
FROM •
TRANSFORMER
TO
TRACK
TO 9 VOLT
TRANSFORMER
6-6 LocoMaticControllerwiring
14

GETTING STARTED
SW-9-Sec 3-5
seconds. However, ifyou wish to designate the rear endas
"front" the default starting direction canbe changed.
DIP SWITCH OPTIONS - MANUAL ADJUSTMENTS
The exhauststacksection canbe removed to reveal the
LocoMatic Soundunit.Grip oneofthe exhauststackswith
your thumb and finger, and pull straight out. It just snaps
in place.There are four dip switches anda volumecontrol
on the smallcircuitboard. The soundpotentiometer is
factory setata mid range (12 o'clock). Rotating this control
counter-clockwise willincrease the volume. Itis suggested
that the volumecontrol besetat about the middle of its
range for comfortablelistening. The four dip switches are
normally settothe "offposition and select the following
operations:
OFF
# 1 start in forward
# 2 sequencingnormal
# 3 bell can sound
# 4 forwarddirection is
ON
neutral
lock in start
does not sound
front rear
OFF- -ON
-»• m i
Switches 3&4 are usedprimarily
when two or morelocomotives
are operatedtogether. Youcan
turn off the bell inthe trailing
locomotives. Ifanyofthe
locomotives are actuallyfacing to
the rear,Switch 4 on such
locomotives allowsoperation in
concert withotherlocomotives
facing forward. When Switch 4
changes forward to rear, all
directionalfunctionssuch as 5.7 p|p Switches
headlights are switchedalso. (enlarged)
3-7 DCC (Digital Command Control)
A DigitalCommandControl (DCC) decoder isnot included
withyourswitcher.However,yourlocomotivecomes factory-
ready to receive a DCC decoderwithoutmodification*.
15

GETTING STARTEDSW-9-Sec 3-7
Purchase a DCC decoder from a vendor of yourchoice. We
recommend purchasing a 1.0to2.0amp decoder. To install
your DCC decoder,expose the reversing-plug socket by
following the instructions in Section 3.5. Remove the factory-
installedprintedcircuitboard (ortheDC shortingplug) and
plugyour DCC decoderinto the socket.Many DCC
manufactures offer the NMRA mediumplug.
Factoryinstalled"Tsunami" DCC Sounddecoders by
Soundtraxx are available.Thoseswitcherscomewith an
additionalinstructionbooklet on their operation and
installation.
* DCC Installation Note: If yourswitcher hasa DCC
warninglabelattached tothe socketprintedcircuitboard,
it was not wired to the NMRA standards and willneed to
be replaced for DCC operation. Replacementsockets are
available.Pleasecontact SHS regarding our replacement
program.
SECTION 4 - Maintenance
4-1 Lubrication
Your new switcherdieselswitchercomesfactorylubricated
and ready forthe break-inperiod. After break-in, we
recommend inspection and carefullubrication ofthe wheel
bearings.With the modelupsidedown,place a smalldrop
of Aero Lube"ConductaLube" on eachaxlenext to each of
itstwo bronzebushings andthe back ofthe wheels. Use
only a drop,overlubrication can damage the body as well
as void the warranty.
4-2 Golden White LEDs
The LEDs in yourswitcher are rated at3.5 volts and30
milliamps for maximum life and should not need tobe
replaced. But, just in case:
Step 1. Remove the four screws that hold the body
assembly tothe frame and lift off the body.
Step 2. Unplug the AC/DC circuitboard.
Step 3. Before removing LED printedcircuitboard,
16

MAINTENANCE SW-9-Sec 4-2
note the position ofthe wires and coppercontacts.
Rear LEDs (Steps 4-7):
Step 4. Push the rear LED contactwires(brass) to
the side
Step 5. With a smallflat-bladescrewdriver,release
thetab below thecab sidewindows and remove the
cab floor.
Step 6. Remove theLED circuitboardbracket by
unscrewing thetwo phillips-head screws.Gently
pull the contactwires from the tabs onthecab roof
and unsolder thetwo rear bulbleads.
Step 7. Solder a newLED circuitboardintoplace
and attach the rear LED bracket. Push the contact
wires backinto the tabs and position and replace the
cab floor. Re-install cab onto the body, bend the
contactwires up,and replace rear LED wires into
thesix body tabs.
Step 8. Remove the front LED bracket by unscrewing
thetwo phillips-head screws.Replacewith a new
LED pcb assembly and solder in place.Then re-
attach the front LED bracket.
Step 9. Re-insert the AC/DC circuit-boardplug (if
used) into its socket.Thenre-attach the body
assembly tothe frame (Donot overtighten
screws).
4-3 Cleaning
Body - Removedustwith a small soft brush (make-up brush
or similar). If yourswitcherrequiresmoreextensivecleaning,
we recommendremoving the body from the chassis and
cleaning the body with dishwashing detergent anda small
sponge. Rinse withcleanwater(makingsure nottoget
waterinto the interior ofthe cab) and blot or blow dry with
low heat. Pilots canbe removed from the chassis and cleaned
inthe sameway.
Wheels - Dirtwillbuild up on the wheeltreadsovertime.
To remove this and improvetraction and electricalpick-up,
we recommendusing 91% isopropalalcohol anda Q-tip.
17

MAINTENANCE SW-9-Sec 4-3
Again, remove the body from the chassis, asthe alcohol can
damage the body finish. Rub eachwheeltreadwith the
alcohol-moistened Q-tip,applyingslightpressure to remove
the dirtbuild-up. The wheels canbe rotated by hand-
turning theflywheel. Once the wheels'treads are clean,
check the electricalpick-upwipers for cleanliness andfor
contact against the insidesurfaces ofthe wheels.
Storage - Wheneveryourswitcher is withdrawn from service
for an extendedperiod, we suggest you store itinits original
foam tray and gift boxfor maximumprotection.
4-4 Pick-upwipersreplacement
Step 1. Using a smallscrewdriver,gently pry loose
theendofthe plastic sideframe/gearbox cover to
release thetab that holds ittothe gearbox.
Step 2. Remove thetwo wheelsets.
Step 3. Remove the pick-up wipers'bracketscrew.
Thenremove the worn pick-upwipers.
Step 4. Replace the wornpick-upwiperswith new
ones and reinstall the pick-upwipers'bracketscrew.
Step 5. Re-insert the wheelsets.Note that the
bearingsmustalign perfectly forthe wheelsets to
slideinto the gearbox.
Step 6. Oncebothwheelsets arein place,check that
the pick-up wipers areall contacting the inside surface
of the drivers.
Step 7. Replace the plastic sideframe/gearbox cover
by snapping the tabs over the gearbox.
Step 8. Check tobe sure the trucks move freely.
4-5 Heavy Duty Lubrication
If yourswitcheroperates ona clublayout, at shows, or
receives unusuallyheavyusage, the worm and idlergears
will needperiodiclubrication to preventexcessivewear. To
lubricatetheseareasmost effectively, completedisassembly
of the gearbox is necessary.
Step 1. Remove the four screws that hold the body
assembly tothe frame and lift off the body.
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MAINTENANCE
SW-9-Sec 4-5
Step 2. Unplug the AC/DC circuitboard (if you are
not using DC polarity reversing or DCC) andthetwo
forward and reverse lightplugs.
Step 3. Remove the AmericanFlyercompatible
coupler bracket andthe four wheelsets.(See Code
110 NMRARP 25 ContourWheelsets,Section4.4.)
Step 4. Remove the e-clips that hold the gearbox to
the geartower and lower the gear box from the chassis.
Step 5. Remove the plasticpick-upwiperassembly,
taking care notto break the wipers.Note on which
side ofthe gearboxeachbelongs.
Step 6. Remove thetwo screwsholding thetwo halves
of the gearboxtogether.Once the gearbox is apart,
clean theold grease from the gears and worm.
Lubricate the wormwith ACT gearLube andthe
idlergearswith ACT motorbearinglube.
Step 7. Re-assemble the gearbox (Donot
overtighten screws) and plasticpick-upwire
assembly.Carefullyre-connect the universaldrive
shaft tothe geartower and push the e-clip backonto
the gearbox stem.
Step 8. Re-insert the AC/DC circuitboardpluginto
6-8 Crosssectionpartsdrawing - gear boxand details
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