USA Trains ALCO S4 User manual

ALCO S4
DIESEL LOCOMOTIVE
OW ERS MA UAL
USA TRAI S
P.O. BOX 100
MALDE , MA 02148
USA
www.usatrains.com
K UCKLE COUPLER I STALLATIO
This Alco S4 switcher is warranted for one year from the date of
purchase against defects in material or workmanship. We will repair or
replace (at our option) the defective part without charge for parts or
labor within one year of the original date of purchase provided the
warranty registration card has been received by USA Trains. This warranty
does not cover items that have been abused or damaged by careless
handling or improper operation such as a train derailment, modification
or repair by non-factory technicians. Parts that “wear out” due to
excessive use are also not covered under warranty. USA Trains reserves
the right to determine “excessive use”. Transportation costs incurred by
the customer are not covered under this warranty.
This Alco S4 switcher is built with pride by USA Trains and is covered by
a limited warranty. (See limited warranty terms). Please follow these
instructions carefully before sending your locomotive for service:
1. Return locomotive in its original blue/red box with the proper foam
inserts and then pack the original box in a proper shipping carton so it is
well protected in shipment. The package must be fully insured and
prepaid. USA Trains is not responsible for damage or loss during shipment.
2. Include a note explaining the problem and servicing you need
performed. Be sure to include your name, street address, (NO P.O. BOXES
PLEASE) City, State, Country (if outside U.S.A) and zip code along with a
daytime phone number including area code. If the locomotive service is
not covered by warranty, a reasonable service fee will be charged. For
any locomotives to be returned outside the continental U.S.A., please
include $20.00 U.S. currency to cover return postage. Any locomotives
returned to customers in the continental U.S.A. will be pre-paid by USA Trains.
3. Ship your item to: USA TRAINS
662 CROSS STREET
MALDEN, MA. 02148
SERVICI G
LIMITED O E YEAR WARRA TY
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•
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Remove Hook & Loop coupler.
Clip tab "A" from end of tongue
and file smooth.
Attach USA knuckle coupler "B"
with #4 screw (C) provided. A
B
C
8

Dear Customer,
Congratulations on your purchase of this highly
detailed replica of the Alco S4 Switcher.
The engineering and design staff at USA Trains
has spent many hours reviewing original blueprints
and developing a locomotive that looks authentic
and will provide you with many hours of operating
enjoyment all at a reasonable price. This
locomotive will enhance the appearance of any modelers railroad.
Please read the following instructions which will help you understand and
operate the numerous features of this locomotive.
Happy Railroading
USA TRAI S
In the thirties and forties, when diesel locomotives began to supplant
steam engines, a number of manufacturers turned to producing diesels.
Among them was Alco. Alco produced one of the most popular diesel
switchers, the S1, S2, S3 and S4. These were rather boxy machines
compared to its competing EMD SW1, NW2, SW7, SW8, SW9, SW900 and
SW1200 diesel switchers. The 1.000 horse power Alco “S” series diesels were
Alco’s most popular diesel switcher and used by many railroads. Over 1,500
were sold in the forties and fifties.
The accurate reproduction of this locomotive by USA Trains will allow the
modeler of the early diesel - late steam era to have their favorite railroad
Alco S4 running among the other locomotives on his/her railroad.
HISTORY OF THE ALCO S4 SWITCHER
FEATURES
• Powerful dual-motored 8 wheel Power Trac drive train
• Operating fan driven smoke stack emits realistic diesel exhaust
• Metal handrails
• Front & rear directional headlights
• Interior cab lighting
• Opening cab doors
• Detail cab interior complete with 2 engineers and control panel
• Authentic detailing including diamond plate walkways, grating on
steps, window shades, sliding windows and see-thru grills
• Expert decoration reproducing authentic paint schemes of your favorite
railroad
• Multiple road numbers available for prototypical multi-unit operation
ITEM No. PART No. DESCRIPTION
17 R22-17 SLIDE SHOES & SPRINGS (4)
18 R22-562 COUPLER LIFT BAR W/4 HOLDERS (1)
19 R22-563 CORNER STEPS (specify color) (4)
20 R22-564 REAR BODY RAILINGS (specify color) (2)
21 R22-565 BATTERY BOXES (specify color) (2)
22 R22-566 BELL
23 R22-567 WINDSHIELD WIPERS (3)
24 R22-568 LIGHT BULB & WIRE (Cab)
25 R22-011 METAL WHEELS WITH GEARS (2)
26 R22-569 SAND FILL HATCH RIGHT/LEFT (specify color) (2)
27 R22-570 FUEL FILL (specify color)
R50001 USA TRAINS SMO E FLUID (1)
R50002 USA TRAINS CONDUCTIVE LUBRICANT (1)
5
7
18
8
22 11 12 192513
26
Please call our parts department for prices and availability or visit our
web site www.usatrains.com • Phone: [phone] • Fax: [phone]
2 7

Due to the high level of detail designed into the USA Trains Alco S4
switcher, some simple assembly is required.
(1) Coupler Lift Bar Assembly (2 pieces)
Insert 2 eye bolts onto each side of lift bar and then insert all 4 eye-
bolts into the end of pilot as shown in the diagram below. (both ends)
(2) Hand Rails - Sides and Ends (4 pieces)
Insert right and left siderails into openings in the side of frame and
into cab roof as shown in the diagram below. Next, insert the two slotted
plastic pins into the top of the frame. While pushing down lightly on the
end rails to hold the pins into the top of the frame, insert the wire ends
into the end pilot at all 4 points.
ASSEMBLY
(1)
ITEM No. PART No. DESCRIPTION
1 R22-551 DIESEL HORN
2 R22-552 SMO E STAC
3 R22-553 SMO E UNIT (Fan Driven)
4 R22-554 SMO E REGULATOR PCB BOARD
5 R22-555 FRONT LENS COVER (1)
6 R22-556 REAR LENS COVER (1)
7 R22-557 LIGHT BULB AND WIRE (Headlight)
8 R22-558 SIDE RAILS (specify color) (2)
9 R22-559 COUPLER MOUNTING BLOC & PIVOT ARM (
No Coupler )
10 R22-560 END RAILS (specify color) (2)
11 R22-11 TRUC SIDEFRAME SPRINGS (8)
12 R22-12 REPLACEMENT MOTOR TRUC (1)
13 R22-13 REPLACEMENT MOTOR ONLY (1)
14 R22-14 TRUC SIDEFRAME (2)
15 R22-15 TRUC MOUNTING BLOC (1)
16 R22-561 FUEL TAN (specify color)
1
15 1417 16 21
2 3, 4
6
23
24
27
10
20
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ALCO S4 SWITCHER
REPLACEME T PARTS LIST
(2)
(2)
SIDERAIL ASSEMBLY
E DRAIL ASSEMBLY
6 3

CAUTIO ! If the locomotive is going to be run for any period of time without
smoke fluid, please position the smoke switch to the OFF position.
SMOKE GE ERATOR
The locomotive contains a fan driven smoke unit which produces
“diesel exhaust” through the stack on the topside of the cab body. The
smoke generator requires the periodic addition of smoke fluid in order to
operate properly. To add smoke, remove the stack from the top of the
locomotive and add 25-30 drops of USA Trains smoke fluid (USA Trains part
# R50001) into the smoke generator hole. Never overfill the smoke genera-
tor and promptly wipe up any excess smoke fluid that may have spilled
onto any painted surfaces. Place the smoke stack back on top of the loco-
motive and begin operation. Smoke production will begin when the fluid
becomes heated and should last approximately 20 minutes. It may take
longer to generate the smoke if the unit is full. When the smoke chamber
is empty the unit will shutdown automatically until more fluid is added. By
following these directions the smoke generator will provide hours of
enjoyment and enhance the realistic operation of your S4 locomotive.
CAUTIO ! Even though your locomotive is equipped with an automatic
shut-off when the smoke generator runs out of fluid, we suggest you shut off
the smoke switch on the underside of the locomotive to prevent accidental
burning out of the smoke generator.
POWER REQUIREME TS
The locomotive is designed to operate on direct current (DC) with out-
puts of 0-22 volts.
CO TROL SWITCHES
The locomotive contains four switches to operate the on/off motors,
on/off smoke generator, on/off lights and on/off sound. The control
switches are located on the underside of the locomotive, between the
rear motor truck and the fuel tank. (see diagram below)
OPERATIO
LUBRICATIO
Your locomotive was lubricated at the factory and under normal
operating conditions will not need to be lubricated during the first 50
hours of operation. The locomotive has three lubrication points. (See
diagram below)
1. SIDEFRAME JOUR AL BOX: The axle ends fit into brass bushings which
bring power into the locomotive. These brass bushings should periodically
be cleaned out and lubricated with a small amount of USA Trains
electrically conductive lubricant (USA Trains Part #R50002). Use only our
conductive lubricant to avoid loss of electrical contact which could
cause your locomotive to lose power or run erratically. The frequency of
lubrication depends on your operating conditions.
2. AXLE LUBRICATIO : Two drops of oil should be placed on all four contact
points where the axle enters the gear box. An ultra light oil such as Hob-E-
Lube (#HL653) is recommended.
3. GEAR BOX LUBRICATIO : Under normal operating conditions, the gear
box should not have to be lubricated. However, you may want to
lubricate the gears after each 100 hours of operation by removing the six
screws on the bottom of the gear box to expose the gears and applying
moly grease by Hob-E-Lube to the gears on the axle only. Do not apply
grease to any electrical contacts inside the gear box as you may hinder
the electrical contacts required for smooth operation.
WHEEL/SLIDE SHOES
The Alco S4 switcher is equipped with twelve electrical pickup
points-six per motor truck. Each of these must be cleaned periodically
to ensure proper electrical contact with the track which will ensure
smooth operation of your locomotive. Clean all four wheels and the
bottom surface of the slide shoes periodically to ensure good
electrical contact with the track. A good indication that you need to
clean these contacts is flickering lights, non-operation of the smoke
unit, or a jerking motion of the locomotive.
MAI TAI I G A D SERVICI G YOUR ALCO S4 SWITCHER
1
2
GEAR BOX
2
1
1
2
2
1
MOTOR LIGHTS SMOKE SOUND
OFF
ON
4 5