USA Trains EMD GP7 Installation instructions

USA TRAINS
EMD GP7 & GP9 DIESEL LOCOMOTIVE
Assembly & Disassembly Instructions
USA TRAINS • P.O. BOX 100 • MALDEN, MA 02148 • USA • www.usatrains.com

2
ITEM PART DESCRIPTION PRICE
NO NO
1 R22-101 FRONT DIESEL HORN $2.50
2 R22-102 VENT PIPE (specify color) 2.25
3 R22-103 SUNSHADE (specify color) 2.50
4 R22-104 WINDSHIELD WIPERS (4) 2.50
5 R22-105 REAR DIESEL HORN 2.50
6 R22-106 DYNAMIC BRAKE (specify color) 18.95
7 R22-107 BRAKE CYLINDER (specify color) 12.95
8 R22-454 SMOKE UNIT (fan driven) 24.95
9 R22-109 LENS COVER (1) 2.50
10 R22-110 LIGHT BULB AND WIRE (Headlight) 3.50
11 R22-111 FRONT/REAR HANDRAILS (2) (specify color) 14.95
12 R22-112 COUPLER MOUNTING BLOCK & PIVOT (no coupler) 6.95
13 R22-113 COUPLER SPRING & MOUNTING PLATE 2.50
14 R22-114 TRUCK SIDEFRAME SPRINGS (8) 2.50
15 R22-115 REPLACEMENT MOTOR TRUCK (1) 32.95
16 R22-116 REPLACEMENT MOTOR ONLY (1) 22.95
17 R22-117 TRUCK SIDEFRAME (2) 8.95
18 R22-118 TRUCK MOUNTING BLOCK (1) 3.50
19 R22-119 CYLINDERS (2) 3.50
20 R22-120 FUEL TANK (specify color) 8.95
21 R22-121 SIDE HANDRAILS (4) (specify color or undecorated) 14.95
22 R22-122 SLIDE SHOES & SPRINGS (4) 4.50
23 R22-123 END STEPS (specify color) (2) 4.50
21 3 54
20
21
22
24
39
27
EMD GP7 & GP9 REPLACEMENT PARTS LIST
23
28
25
ITEM PART DESCRIPTION PRICE
NO NO.
24 R22-124 AIR HOSES (6) $8.95
25 R22-125 FOLD DOWN END STEP (2) 3.95
26 R22-126 COUPLER LIFT BAR WITH 4 HOLDERS (1) 1.95
27 R22-127 LIGHT BULB AND WIRE (
Number Board ) 3.50
28 R22-128 LIGHT BULB AND WIRE (
Cab ) 3.50
29 R22-129 ROOF FAN w/ ROTATING FAN BLADE (specify color) 3.95
30 R22-130 BRASS LIFT RINGS (14) 6.95
31 R22-131 SMOKE STACKS - PLASTIC (2) 2.95
32 R22-132 SMOKE STACKS - METAL (2) 2.95
33 R22-133 NUMBER PLATE - 1 END (specify number) 2.95
34 R22-134 STIRRUP FOR SIDE FRAME (4) (specify color) 5.95
35 R22-135 METAL WHEELS WITH GEARS (2) 9.95
36 R22-136 TRACTION WHEELS WITH GEARS (2) (for rubber tires) 9.95
37 R22-137 RUBBER TIRES (4) 4.95
38 R22-138 M.U. CONNECTOR (2) 2.9
39 R2021 SNOW PLOW 16.95
R50001 USA TRAINS SMOKE FLUID 7.95
R50002 USA TRAINS CONDUCTIVE LUBRICANT 10.95
1407-X004 MAIN CIRCUIT BOARD W/SWITCH PANEL (upgrade) 32.95
1406-X004RI SMOKE GENERATOR CIRCUIT BOARD (1) (fan driven) 22.95
676-X005 FRONT HEADLIGHT CIRCUIT BOARD 21.95
676-X008 REAR HEADLIGHT CIRCUIT BOARD 21.95
6
31,32
9
12
1315 3516 3417 141836,3719
7
8
29 30 33
10
11
38
26
Prices shown are prices in effect at time of printing.
Prices are subject to change without notice.

3
NOTE: Special care should be taken while handling your new USA
Engine. USA Trains are manufactured and assembled with great care
to ensure detail. Miss handling or improper cleaning may cause
damage to the paint finish and assembled parts.
Body screws are # 4 Phillips head screws 1/2 inch long.
Component screws are # 2 Phillips head screws 1/4 inch long.
Use a # 1 Phillips screwdriver and a # 0 Phillips screwdriver for smaller
screws, do not over tighten.
ATTACHING DETAIL PARTS
Some assembled parts are permanently attached and some are not.
Front and rear handrails, side handrails, cab handrails are press fit.
Coupler lift bar eyebolts front and rear must be glued, eye bolts should
be on lift bar before gluing. Two smoke stacks are not permanently
attached. Note when using the smoke units you must use the metal
smoke stacks. The smoke units must be turned off if not being used. Air
hoses and plastic parts are glued on when you assemble your new
engine. Great care must be taken not to get glue on the painted
surfaces.
ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
REMOVING ENGINE SHELL
Several wires are attached from the engine shell to the engine
components mounted to the frame. Remove fourteen # 4 1/2inch
long screws located under your engine frame/chassis holding the
engine shell. They are located under the front and rear truck assembly
and fuel tank. See details 2, 3, 4, and 5. You will have to place your long
shaft screw driver between the truck frame and motor housing to
remove these screws a total of 14 screws. After removing the 14 engine
shell screws, the engine shell and cab will lift off together. Pull upward
on the engine shell front and rear assembly. The cab and steps are
held with four outer body screws. See detail 6A.
NOTE: The cab slides over the engine shell. Leave this assembly
together. See details 6B and 7.
DETAIL 1
All metal handrails
and all metal detail
parts are not glued.
Coupler lift bar eye
bolts (4) front and
rear must be glued.
Put eye bolts on lift
bar before gluing.
Air hoses front and
rear press fit or glue.
DETAIL 2
DETAIL 3
Cab and engine shell
mounting screws (14 total)
Hidden recessed screws
under trucks

4
ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
REMOVING CAB
Remove Cab and two 1/4 inch cab light bracket screws from the Cab
shell with a # 0 screwdriver.
NOTE: Do not remove the step and frame assembly from the cab, the
door springs will break (see detail 7 below). To replace cab light
remove the cab rear wall. Carefully slide the wall out, you will have to
break the small hot glue joint first. This will allow you to get to the light
bracket. The bulb and wires are held in place by the bracket and screws.
DETAIL 4
Engine Shell mounting
holes (4)
Speaker/Fuel tank
mounting screws (2)
Fuel tank locator pins (2)
Speaker cable hole
DETAIL 5
Engine shell screw
location (14)
Truck mounting screw &
washer #4 1/2 inch long
Front & rear weight
mounting screws &
washers #4 1/2 inch long
Cab mounting
screws (4)
DETAIL 6A
Before removing cab
unscrew door springs
then slide cab off
Slide wall out
Wires for front
headlight
Wires for cab light
Slide cab off
DETAIL 7
Cab light bracket
and screws
DETAIL 6B
Cab locking tabs (4)

5
REMOVING HEADLIGHTS
To replace bulbs or circuit boards for marker lights, front and rear head-
light, remove two # 2 screws and carefully lift out circuit board assem-
bly. The lighting circuit boards are not the same. Refer to item part
numbers on the parts list on page 2 of this booklet.
SMOKE UNITS
Fan generated smoke units, circuit boards and main switch-board
assembly are assembled as a complete unit and are not interchange-
able with non fan driven smoke units. Refer to detail 9 for fan driven
smoke units. For engine with basic smoke unit refer to detail 10.
ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
Front light board # 676-008 Rear light board # 676-005
DETAIL 8A DETAIL 8B
Lighting circuit board mounting brackets and screws
DETAIL 9
Voltage regulator Voltage regulator
Front weight Rear weight
Cab rear wall
Cab wiring
Main control circuit
board and switches
Smoke regulator
circuit board
Smoke regulator
circuit board
Fan & smoke unit Fan & smoke unit
Engine shell
Engine chassis
Shell mounting points (14)
Motor power feed
cable wires
FAN DRIVEN SMOKE UNIT DIAGRAM

SMOKE UNITS
Smoke Unit # 672-X008R1, smoke regulator circuit board # 676-X001
may have to be replaced at the same time. See detail 10 non-fan
smoke units. Engine switch panel circuit board 672-X007R1. Remove
two screws and carefully slide circuit board and circuit board holder
out, please mark all wire connectors.
Circuit boards are clearly marked for connectors. We recommend
that you label all wires for their locations. This will help you when re-
attaching them later. All wires are color-coded and have different
lengths.
NOTE: One smoke unit circuit board is mounted to the engine shell and
the other to the engine chassis.
6
ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
NOTE: Some of the following steps may not be required. Carefully
consider what steps are needed before you make your repairs.
Several wires are attached from the engine shell to the engine frame
and other components. Tag all wires and label them for easy re-
assembly. it is recommended not to disconnect all wires, only
disconnect the ones required.
REMOVING FRONT AND REAR TRUCK ASSEMBLY
Remove truck mounting 1/2 inch # 4 screw and flat washer. See detail 6A.
Disconnect wire connectors, label each pair for proper replacement.
Note their location as wire length and connectors may not be
identical. See detail 12B.
Voltage regulator
& heat sink
Front weight
Rear weight
Cab rear wall
Cab wiring
Main control circuit
board and switches
676-X007R1
Smoke regulator circuit
board 676-X001
Pick-up shoe
power cable wires (2)
Smoke unit
672-X008R1
Smoke unit
672-X008R1
Rear circuit
board & wiring
Engine chassis
Motor power feed
cable wires
NON FAN DRIVEN SMOKE UNIT DIAGRAM
DETAIL 10

7
ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
PICK-UP SHOES
Pickup shoes and wires press against wheel axles for additional
contact surface. To replace these wires, you will have to remove the
truck bottom plate. Remove 6 screws from bottom plate. See detail 12A.
NOTE: If doing this step you may take time to lubricate the motor gears
and axles ends. You may consider replacing traction tires at this time
also. See detail # 11.
Before replacing motor bottom plate make sure bearings are seated flat
in bearing slots so plate will seat properly and flush with motor block. See
detail # 11.
Remove side frame stirrup first (press fit only not glued), then remove
truck sideframes mounted with 3 screws on each side. See details 12B.
DETAIL 12A DETAIL 12B
Truck wiring
Traction tires (2)
Pick-up shoes (2)
Truck motor Gear box (2)
Phorous bronze
pick-up wires (2)
Bearings (4)
Bottom plate
screws (6)
4 wire connector
for motor
2 wire connector
for pick-up shoes
Stirrup
mounting
point
DETAIL 11

8
ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
SERVICING
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. All main handrails must be removed and kept by the customer.
2. The locomotive must be packed in the original blue/red box with
the original styrofoam inserts and then packed in the original 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.
3. 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 serv-
ice 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 $25.00 U.S. currency to cover return postage.
Any locomotives returned in the continental U.S.A. will be pre-paid by
USA Trains.
4. Ship your item to: USA TRAINS
662 CROSS STREET
MALDEN, MA. 02148
LIMITED ONE YEAR WARRANTY
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
warranty registration card has been received by USA Trains. This war-
ranty 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 to determine “excessive use”. Transportation
costs incurred by the customer are not covered under this warranty.
USA TRAINS • PO BOX 100 • MALDEN, MA 02148, USA
www.usatrains.com