USA Trains EMD GP38-2 User manual

EMD GP38-2
DIESEL LOCOMOTIVE
OW ERS MA UAL
USA TRAI S
662 Cross Street
MALDE , MA 02148, USA
www.usatrains.com
K UCKLE COUPLER I STALLATIO
This USA Trains locomotive 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 war-
ranty 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 exces-
sive use are also not covered under warranty. USA Trains reserves the right
to determine “excessive use”. Transportation costs incurred by the cus-
tomer are not covered under this warranty.
This Diesel locomotive 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 pre-
paid. USA Trains is not responsible for damage or loss during shipment.
2. Include a note explaining the problem and servicing you need per-
formed. 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 $15.00 U.S. currency to cover return postage. Any locomotives
returned 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
•
•
•
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

Dear Customer,
Congratulations on your purchase of this highly
detailed replica of the electro-motive (EMD) GP38-2.
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. Over 400 parts make up this model -
the level of detail found in brass locomotives costing thousands of dollars
for a fraction of the cost. 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
General Motor’s Electro-Motive division first introduced the GP38 in the
mid 1960’s as the need for medium-sized road power increased. On
anuary 1, 1972, EMD introduced the Dash 2 locomotive line and the GP38
was superseded by the GP38-2. This 2000 H.P. road engine was one of the
all-time best selling locomotives built by EMD - 1545 GP38-2’s were sold to
numerous railroads throughout North America.
The accurate reproduction of this locomotive by USA Trains will allow the
modeler to have his favorite railroad GP38-2 running among the other loco-
motives on his/her railroad.
HISTORY OF THE EMD GP38-2
FEATURES
• Powerful dual-motored 8 wheel Power Trac drive train
• Operating fan driven smoke units emit realistic diesel exhaust
• Directional red/green marker lights
• Front & rear directional headlights
• Metal handrails
• Interior cab lighting
• Opening cab doors
• Detailed cab interior with engineer and control panel with gauges
• Authentic detailing including diamond plate walkways, grating on
steps, window shades, sliding windows and MU connectors
• Expert decoration reproducing authentic paint schemes of your favorite
railroad
• Multiple road numbers for prototypical multi-unit operation
Please call our parts department for prices and availability or visit our
web site www.usatrains.com • Phone: [phone] • Fax: [phone]
ITEM No. PART No. DESCRIPTION
23 R22-136 TRACTION WHEELS WITH GEARS (2) (for rubber tires) $9.95
24 R22-112 TRUCK SIDEFRAME (2) (specify color) 8.95
25 R22-137 RUBBER TIRES (4) 4.95
26 R22-226 CYLINDERS (2) 3.50
27 R22-227 FUEL TANK (specify color) 8.95
28 R22-228 SIDE HANDRAILS (4) (specify color or undecorated) 14.95
29 R22-116 REPLACEMENT MOTOR ONLY (1) 22.95
30 R22-134 STIRRUP FOR SIDE FRAME (4) (specify color) 5.95
31 R22-118 TRUCK MOUNTING BLOCK (1) 3.50
32 R22-232 COUPLER MOUNTING BLOCK & PIVOT (no coupler) 6.95
33 R22-233 AIR HOSES (1 right, 1 left) 8.95
34 R22-234 COUPLER LIFT BAR WITH 4 HOLDERS (1) 1.00
35 R22-235 LIGHT BULB AND WIRE (
Cab ) 3.50
36 R22-236 LIGHT BULB AND WIRE (
Number Board ) 3.50
37 R22-000 MOTOR BLOCK BOTTOM PLATE 7.95
38 R22-476 SINGLE AIR HOSE (1) 2.95
R2021 SNOW PLOW 16.95
R50001 USA TRAINS SMOKE FLUID 7.95
R50002 USA TRAINS CONDUCTIVE LUBRICANT 10.95
7
11
18
22 202324 192526
8 9 10
12
13
14
15
16
17

Due to the high level of detail designed into the USA Trains GP38-2, some
simple assembly is required.
(1) M.U. Connectors (2)
Insert M.U. connector in frame as shown in diagram below.
(both ends)
(2) Fold Down Step (2)
Insert step into step base assembly and insert into end of frame as
shown in diagram below. (both ends)
(3) Coupler Lift Bar Assembly (2)
Insert 2 eye bolts onto each side of lift bar and insert all 4 eyebolts
onto frame as in diagram below. (both ends)
(4) Air Hoses (6)
Insert right and left air hoses (3) into frame and single air hose to right
of coupler as shown in diagram below. (both ends)
(5) Hand Rails - Sides and Ends (6)
Insert side and end handrails into frame as shown in diagram below
(6) Smoke Stacks
Insert (2) plastic or (2) metal stacks into smoke stack holes as shown
in diagram below.
OTE: If running with smoke units on, metal stacks must be used due
to heat of smoke unit. (See smoke unit operation next page).
(7) Truck Sideframe Stirrups (4)
Insert one truck side frame stirrup into each truck sideframe as shown
on the diagram below. Proper installation will cover the top two side
frame screws.
OTE: Apply pressure to middle top slotted piece to ensure
side frame will stay on during operation.
ASSEMBLY
4
2
1
63
5
7
55
ITEM No. PART No. DESCRIPTION
1 R22-201 FRONT DIESEL HORN
2 R22-202 ANTENNA
3 R22-203 SUNSHADE (specify color)
4 R22-204 WINDSHIELD WIPERS (4)
5 R22-131 SMOKE STACKS - PLASTIC (2)
6 R22-132 SMOKE STACKS - METAL (2)
7 R22-108 SMOKE UNIT
8 R22-208 DYNAMIC BRAKE (specify color)
9 R22-209 ROOF FAN w/ ROTATING FAN BLADE (specify color)
10 R22-130 BRASS LIFT RINGS (14)
11 R22-211 LENS COVER (1)
12 R22-212 LIGHT BULB AND WIRE (Headlight)
13 R22-213 NUMBER PLATE - 1 END (specify number)
14 R22-214 FRONT/REAR HANDRAILS (2) (specify color)
15 R22-215 FOLD DOWN END STEP (2)
16 R22-216 M.U. CONNECTOR (2)
17 R22-217 COUPLER SPRING & MOUNTING PLATE
18 R22-218 END STEPS (specify color) (2)
19 R22-114 TRUCK SIDEFRAME SPRINGS (8)
20 R22-135 METAL WHEELS WITH GEARS (2)
21 R22-115 REPLACEMENT MOTOR TRUCK (1)
22 R22-122 SLIDE SHOES & SPRINGS (4)
21 3 5,64
27
28
293031
33, 38
35
32
36
34
Apply Pressure Here

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 two fan driven smoke units which produces
”diesel exhaust” through the two stacks on the top side of the cab body.
The smoke generators require the periodic addition of smoke fluid in order
to operate properly. To add smoke, remove the stacks from the top of
the locomotive and add 25-30 drops of USA Trains smoke fluid (USA Trains
part # R50001) into each smoke generator hole. Never overfill the smoke
generator and promptly wipe up any excess smoke fluid that may have
spilled onto any painted surfaces. Place both metal smoke stacks back
on top of the locomotive, and begin operation. Smoke production will
begin when the fluid becomes heated. 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 GP38-2 locomotive.
CAUTIO -USE ONLY THE METAL SMOKE STACKS PROVIDED WHEN OPERAT-
ING SMOKE UNIT.
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.
OTE: It is not uncommon for the front stack to smoke more than the rear
stack due to the draft created by movement of the locomotive.
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
front motor truck and the fuel tank. (see diagram below)
OPERATIO
LUBRICATIO
Your locomotive was lubricated at the factory and under normal oper-
ating 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 electri-
cally conductive lubricant (USA Trains Part #R50002). Use only our conduc-
tive 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 con-
tact 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 lubri-
cate 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 GP38-2 units are 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 electri-
cal 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 GP38
1
2
GEAR BOX
2
1
1
2
2
1
MOTOR LIGHTS SMOKE SOUND
OFF
ON