Topics

[DROOPING COUPLERS.]

If your trip pin hangs down and has a habit of catching on the ez-track turnouts causing derailments or car separation you might try a couple of things.

DROOPING COUPLERS.
               
1. DROOPING COUPLER (FIG.1).               
2. TURN CAR UPSIDE DOWN AND PLACE ON A MAINTENANCE CRADLE.               
3. REMOVE GEAR BOX LID (FIG.2).               
4. INSTALL KADEE 0.010 GRAY INSULATING FIBER WASHER ON COUPLER (FIG.2).       
5. FOR NEW CARS INSTALL KADEE 0.010 GRAY INSULATING FIBER WASHER ON COUPLER (FIG.3).       
6. REINSTALL GEAR BOX LID (FIG. 4).               
7. USING A KADEE #206 HO INSULATED MULTI-PURPOSE COUPLER HEIGHT GAUGE FOR HO STANDARD, CHECK CLEARANCE (FIG.5).
8. IF TRIP PIN IS BELOW FOOT PLATE, WITH BLUE BOX CARS ADD ONE KADEE 0.010 GRAY INSULATING FIBER WASHER AND ONE
   KADEE 0.015 RED INSULATING FIBER WASHER ON THE KING PIN BETWEEN THE FRAME AND TRUCK (FIG.6).
9. FOR TYCO BODY COUPLER UPGRADE, ADD TWO KADEE 0.015 RED INSULATING FIBER WASHER ON THE KING PIN BETWEEN THE
    FRAME AND TRUCK (FIG.7).
10. WHEN THE TRIP PIN IS ABOVE THE FOOT PLATE, CHECK FOR CLERANCE ON THE KADEE #321 BETWEEN-THE-RAILS CODE 100
    DELAYED-ACTION MAGNETIC UNCOUPLER (FIG.8).
11. CHECK FOR CLEARANCE ON THE EZ TRACK TURN OUT (FIG.9).

           
FIG.1


FIG.2


FIG.3


FIG.4


FIG.5



FIG.6
   


FIG.7


FIG.8


FIG.9

Stock Tyco car with Tyco truck and plastic wheel sets.



Stock Tyco car with Tyco truck and metal wheel sets.



Nine feet of track with one end elevated 2 inches. Cars set at top of elevation let free roll down, coast to stop.

[SoundTraxx 885840 Tsunami 2 TSU-BH1 2 Amp Digital Sound Decoder Install on a Bachmann EDM SD40-2 DCC onboard Diesel locomotive.]

SoundTraxx 885840 Tsunami 2 TSU-BH1 2 Amp Digital Sound Decoder Install on a Bachmann EDM SD40-2 DCC onboard Diesel locomotive.



1 each. Bachmann Loco Chassis Bottom (HO SD40-2 DCC NEW). ................Model: 609XX-00C02-C NEW



1 each. SoundTraxx TSU-BH1 Tsunami 2 EDM Digital Sound Decoder. .........P.N. 885840 EDM Diesel



1 each. SoundTraxx 28mm (1") Round Speaker. .........................................................Product Coad: 810153
        Dimensions: 28 x 4.5mm(D)
        Frequency Response: 320 Hz - 18kHz
        Power: 1 Watt (Nominal) 2 Watts (Peak)
        Impedance: 8 Ohms



1 each. Bachmann Fuel Tank with Speaker holes - Gray (HO SD40-2). ......................Model: 609XX-00M01- DCC-GRAY



1 each. Bachmann LED Front (HO SD40-2). .......................................................................Model: 6090X-LED-F

     

1 each. Bachmann LED Rear (HO SD40-2). ...............................................................................Model: 6090X-LED-R
.
         

2 each. Fuel tank cover screws. .......................................................................................P.N. 10471

1 each. Plastic dip 11OZ. ...................................................................................................P.N. 11203




TASK: BREAK IN THE MOTOR BRUSHES AND GEARBOXES

: BREAK IN THE MOTOR BRUSHES AND GEARBOXES. RUNNING THE ENGINES FORWARD FOR TWENTY
  MINUTES AT THREE DIFFERENT SETTINGS, THEN BACKWARDS FOR TWENTY MINUTES AT THREE
  DIFFERENT SETTINGS THIS WILL QUIET DOWN THE GEAR BOXES AND INSURE POSITIVE BRUSH
  CONTACT FOR GOOD LOW SPEED MOTOR CONTROL.


TASK: DISASSEMBLE DIESEL LOCOMOTIVE

: REMOVE FUEL TANK COVER.



: REMOVE SHELL RETAINING SCREWS, RETAIN SCREWS FOR REASSEMBLY.



: REMOVE SHELL.



: REMOVE BLACK PLASTIC PCB CLIPS FROM LEFT AND RIGHT TRUCK TABS, MOTOR TABS AND LEFT AND 
  RIGHT BACK TRUCK.
NOTE: BACHMANN DOES NOT ALWAYS FOLLOW THE NMRA COLOR CODING. RIGHT DOWN WIRE COLOR
            AND TAB FOR FUTURE REFERENCE.



: REMOVE FRONT SCREW FROM BACHMANN DCC DECODER AND RETAIN.



: REMOVE BACK SCREW FROM BACHMANN DCC DECODER AND RETAIN.



: REMOVE THE BLACK (-) REAR TRUCK WIRE AND THE RED(+) RIGHT REAR TRUCK WIRE.



: REMOVE THE BLACK (-) FRONT TRUCK WIRE AND THE RED(+) RIGHT FRONT TRUCK WIRE.



: REMOVE THE ORANGE (-) MOTOR WIRE AND THE RIGHT GREY (+) WIRE.



: REMOVE THE DECODER FROM THE CHASSIS TOP.



: REMOVE PLASTIC WIRE HOLDER.



: REMOVE THE MOTOR FROM THE LOWER CHASSIS.



: USING A FLAT TIPPED SCREWDRIVER REMOVE FRONT AND BACK TRUCKS



: INSPECT THE END OF THE UNIVERSAL JOINT HUB FOR SPLITTING OR SEPARATION OF THE UNIVERSAL
  JOINT AND WORM GEAR SHAFT. FOR REPAIR SEE https://www.bachmanntrains.com/home-usa/board/index.php/topic,38176.0.html



 
: DISCARD OLD BOTTOM CHASSIS MODEL: 6090X-00C02-A



TASK: REASSEMBLE DIESEL LOCOMOTIVE

: BACHMANN LOCO CHASSIS BOTTOM (HO SD40-2 DCC NEW). .........MODEL: 609XX-00C02-C NEW



: USING A DREMEL ROTARY TOOL WITH A SANDING DRUM ATTACHMENT WIDEN OUT THE SPEAKER
  HOLE LIP ON THE BACHMANN LOCO CHASSIS BOTTOM SPEAKER HOLE, SO THE SPEAKER SITS FLUSH
  WITH THE CHASSIS BOTTOM.




: INSPECT THE SPEAKER FOR PROPER CLEARANCE FROM SHORTING TO THE BOTTOM CHASSIS.



: APPLY THREE COATS OF PLASTI DIP RUBBER COATING ON BOTTOM CHASSIS, LET DRY IN BETWEEN
  COATS.



: SOLDER SPEAKER WIRES TO SPEAKER AS SHOWN TO PREVENT SHORTING TO BOTTOM CHASSIS.
  NOTE: USE FLUX ON ALL WIRES TO BE SOLDERED. TIN WIRES BEFORE INSTALLING WIRES TO DECODER.



: INSTALL SPEAKER INTO THE BOTTOM CHASSIS AND FUEL TANK COVER WITH TWO 10471
  COUNTERSUNK SCREWS.


 

: REMOVAL OF CAPACITORS AND DOGBONE SHAPED INDUCTORS ATTACHED TO THE MOTOR. IF
  INSTALLED, REMOVE THE THREE ORANGE CAPACITORS AND TWO GREEN DOGBONE SHAPED
  INDUCTORS. THE POSITIVE AND NEGATIVE LEADS SHOULD BE ATTACHED TO THE BRUSH CAPS
  DIRECTLY TO THE DECODER BOARD.





: SOUNDTRAXX TSU-BH1 TSUNAMI 2 EDM DIGITAL SOUND DECODER. .........P.N. 885840 EDM DIESEL



: ON THE BENCH ALL TABS ON THE FRONT END OF THE DECODER TO BE USED, POPULATE WITH SOLDER.



: ON THE BENCH ALL TABS ON THE BACK END OF THE DECODER TO BE USED, POPULATE WITH SOLDER.



: WITH THE DECODER AND LIGHT SHIELD IN PLACE, FIT THE LED FRONT MODEL: 6090X-LED-F AS
  SHOWN. OBSERVE THE
  CORRECT POLARITY OF THE LEDS AS INDICATED IN THE DIAGRAM BELOW. LARGE FLAG (-).
 



: REMOVE LIGHT SHIELD AND SOLDER THE LED FRONT MODEL: 6090X-LED-F ON TO THE DECODER.



: I FIT THE DRIVE SHAFTS INTO THE TRUCK GEARBOX UNIVERSAL JOINTS AND REINSTALL INTO THE
  LOWER BODY CHASSIS DRIVE SHAFT TUNNEL. RED WIRES (+) RIGHT HAND, BLACK WIRES (-) LEFT HAND.



: FIT THE DRIVE SHAFTS INTO THE MOTOR FLYWHEELS AND REINSTALL THE MOTOR INTO THE LOWER
  BODY CHASSIS.



: INSTALL CHASSIS TOP AND INSTALL FRONT LIGHT SHIELD AND DECODER ON THE TOP CHASSIS REUSING
  SCREWS. FOUR-TAB END FORWARD,  THREE-TAB END REARWARD. INSTALL THE BACK PLASTIC WIRE
  HOUSING.



: TUCK SPEAKER WIRES ALONG THE SIDES IN BETWEEN DECODER AND CHASSIS.
: SOLDER THE RED (+) WIRE TO THE S+ TAB,  THE BLACK (-) WIRE TO THE S- TAB.
NOTE: USE FLUX ON ALL WIRES TO BE SOLDERED. TIN WIRES BEFORE SOLDERING WIRES TO DECODER.



: TUCK THE FRONT TRUCK WIRES ALONG THE SIDES IN BETWEEN DECODER AND CHASSIS.
: SOLDER THE RED (+) WIRE TO THE RR TAB,  THE BLACK (-) WIRE TO THE LR TAB.
NOTE: USE FLUX ON ALL WIRES TO BE SOLDERED. TIN WIRES BEFORE SOLDERING WIRES TO DECODER.




: TUCK WIRES ALONG THE SIDES IN BETWEEN DECODER AND CHASSIS.
: AT THIS POINT A COMMON MISTAKE IS MADE. ON THE DECODER RIGHT IS (+) AND LEFT IS (- ). EXCEPT
  ON THE BACK END, THE MOTOR IS RIGHT (-) AND LEFT (+), BACKUP LIGHT IS RIGHT (-) AND LEFT (+).

IN FIG.1 SHOWS THE MOTOR AND BACK UP LIGHT WIRED BACKWARDS.

GREY MOTOR WIRE (+), SOLDERED TO MOTOR TAB M- (-).
ORANGE MOTOR WIRE (-), SOLDERED TO MOTOR TAB M+ (+).
BLUE BACKUP WIRE (+), SOLDERED TO BLUE BACKUP TAB BL (-).
YELLOW BACKUP WIRE (-), SOLDERED TO BLUE BACKUP TAB V+ (+).

WHEN TEST RUN FORWARD, THE HEAD LIGHT WILL TURN ON AND THE MOTOR WILL RUN BACKWARDS.
WHEN RUN IN REVERSE, THE BACKUP LIGHT WILL NOT TURN ON AND THE MOTOR WILL RUN FORWARD.

IN FIG.2 SHOWS THE MOTOR AND BACK UP LIGHT WIRED CORRECTLY.

GREY MOTOR WIRE (+), SOLDERED TO MOTOR TAB M+ (+).
ORANGE MOTOR WIRE (-), SOLDERED TO MOTOR TAB M- (-).
BLUE BACKUP WIRE (+), SOLDERED TO BLUE BACKUP TAB BL (+).
YELLOW BACKUP WIRE (-), SOLDERED TO BLUE BACKUP TAB V- (-).

NOTE: BACHMANN DOES NOT ALWAYS FOLLOW THE NMRA COLOR CODING. THE WIRE COLORS MAY
VARY ON THE MOTOR AND BACKUP LIGHT. ON THIS MODEL:
GREY MOTOR WIRE (+).
ORANGE MOTOR WIRE (-).
BLUE BACKUP WIRE (+).
YELLOW BACKUP WIRE (-).

NOTE: USE FLUX ON ALL WIRES TO BE SOLDERED. TIN WIRES BEFORE SOLDERING WIRES TO DECODER.



FIG. 1



FIG. 2

: SOLDER THE RED (+) RIGHT BACK TRUCK WIRE TO THE RR TAB, THE BLACK (-) WIRE LEFT BACK TRUCK
  TO THE LR TAB.
NOTE: USE FLUX ON ALL WIRES TO BE SOLDERED. TIN WIRES BEFORE SOLDERING WIRES TO DECODER.




TASK: TEST AND PROGRAM

: PLACE ON SERVICE TRACK ADDRESS 3, IN FORWARD MOVING THROTTLE FORWARD THE ENGINE
  SHOULD MOVE FORWARD WITH HEAD LIGHT ON BACKLIGHT OFF. IN REVERSE MOVING THROTTLE
  FORWARD THE ENGINE SHOULD MOVE IN REVERSE BACKUP LIGHT ON HEAD LIGHTS OFF.

: BEFORE INSTALLING THE SHELL, YOU CAN UPGRADE OR REPAIR YOUR COUPLER POCKETS. 
https://www.bachmanntrains.com/home-usa/board/index.php/topic,38183.0.html

: REMOVE FUEL TANK COVER.
: INSTALL SHELL WITH TWO 10157 SCREWS.



: INSTALL FUEL TANK COVER WITH TWO 10471 COUNTERSUNK SCREWS.







                                                                                          CV CHEET SHEET

IN ORDER TO KEEP ENGINE FLEET STANDARDIZED I USE A CHEAT SHEET FOR A PROGRAMING START POINT.

CV2 START VOLTAGE = ()

FOR NEW INSTALLS I SET UP CV2 START VOLTAGE VALUE TO MEET A STEP ONE THROTTLE, SPEED STEP 28 =  9 INCH PER 10 SECONDS TRAVELED REQUIREMENT ±.

           

EXAMPLE



TSUNAMI 2 TSU-BH1 2 AMP DIGITAL SOUND FOR ENGINE CONSISTS OF UP TO EIGHT ENGINES:

ONE SD40-2 ENGINE AT 15.3 OZ.
CV2 START VOLTAGE VALUE IS SET AT = 30
SPEED STEP 28 AT STEP ONE THROTTLE, 9 INCH PER 3 SECONDS TRAVELED.
SPEED STEP 128 AT STEP ONE THROTTLE, 9 INCH PER 3 SECONDS TRAVELED.

UNDER LOAD.

EIGHT SD40-2 ENGINES IN CONSISTS AT 122.4 OZ. TOTAL ENGINE WEIGHT PULLING 80 CARS TOTAL 440OZ.
CV2 START VOLTAGE VALUE IS SET AT = 30
SPEED STEP 28 AT STEP ONE THROTTLE, 9 INCH PER 13 SECONDS TRAVELED.
SPEED STEP 128 AT STEP ONE THROTTLE, 9 INCH PER 20 SECONDS TRAVELED.

EDM SD40 – 2, SINGLE ENGINE OPERATION:
SOUNDTRAXX 885840 TSUNAMI 2 TSU-BH1 2 AMP DIGITAL SOUND

***CV1 PRIMARY ADDRESS = ()
CV114 ENGINE EXHAUST CONTROL = 2
CV120 HORN SELECTION = 28. (LESLIE S3L)
CV123 PRIME MOVER SELECT (EMD 645 TURBO) = 5  
AUTOMATIC SOUNDS (CV198 = 6) (CV193 = 2) (CV194 =5)
CV198 = 2 AUTO-BELL
CV198 = 4 AUTO-BRAKE
CV198 = 6 AUTO BELL & AUTO BRAKE
CV193 = () BELL START RANGE ANYWHERE BETWEEN 1 AND 126 (CV193 MUST BE LOWER THAN CV194)
CV194 = () BELL ON TIME RANGE ANYWHERE BETWEEN 1 AND 255 (DURATION 1 TO 255 SECONDS)
          (CV194 MUST BE HIGHER THAN CV193)


EDM SD40 – 2, ENGINE CONSISTS OF UP TO EIGHT ENGINES:
SOUNDTRAXX 885840 TSUNAMI 2 TSU-BH1 2 AMP DIGITAL SOUND

****CV1 PRIMARY ADDRESS = ()
CV2 START VOLTAGE = 30
CV3 BASELINE ACCELERATION RATE = 29
CV4 BASELINE DECELERATION RATE = 2
CV10 EMF FEEDBACK CUTOUT = 126
CV114 ENGINE EXHAUST CONTROL = 2
CV116 DYNAMIC BRAKE RATE = 2
CV117 INDEPENDENT BRAKE RATE – 12
*CV120 HORN SELECTION = 28. (LESLIE S3L)
CV123 PRIME MOVER SELECT (EMD 645 TURBO) = 5
CV211 LOW-SPEED COMPENSATION = 255
CV212 BEMF FEEDBACK INTENSITY = 126
CV215 BEMF REFERENCE VOLTAGE = 125
CV220 CONSTANT BRAKE DISTANCE = 2
CV223 PRIME MOVER PITCH SHIFT = 88 (No. 2 CONSIST ENGINE) = 168 (No. 3 CONSIST ENGINE)
**AUTOMATIC SIGNAL, THE DECODERS IS SETUP (IN ORDER)
    CV31 INDEX 1 (READ ONLY) = 16
    CV32 INDEX 2 = 1
    CV258 CLICKETY-CLACK EFFECT = 0
**AUTOMATIC WHISTLE SIGNAL, THE DECODERS IS SETUP (IN ORDER)
  *CV31 INDEX 1 (READ ONLY) = 16
  *CV32 INDEX 2 = 1
  *CV407 AUTOMATIC WHISTLE SIGNAL FORWARD = 1
  *CV408 AUTOMATIC WHISTLE SIGNAL REVERSE = 2
  *CV409 AUTOMATIC WHISTLE SIGNAL STOP = 12 
*HEADLIGHT SET POINTS. (CV 57 OFF=0, ON =1) (CV 58 OFF=0, ON =2)
*AUTOMATIC SOUNDS (CV198 = 06) (CV193 = 2) (CV194 =5)
*CV198 = 2 AUTO-BELL
*CV198 = 4 AUTO-BRAKE
*CV198 = 6 AUTO BELL & AUTO BRAKE
*CV193 = () BELL START RANGE ANYWHERE BETWEEN 1 AND 126 (CV193 MUST BE LOWER THAN CV194)
*CV194 = () BELL ON TIME RANGE ANYWHERE BETWEEN 1 AND 255 (DURATION 1 TO 255 SECONDS)
                    (CV194 MUST BE HIGHER THAN CV193).


ACTIVATE THE QUIET START :

IF YOU WANT THE SOUND ENGINES ON THE LAYOUT TO START ON DEMAND, THE DECODERS IS SETUP CV114=2



NOTE: F5 FULL ENGINE SOUND START UP.
NOTE: F6 FULL ENGINE SOUND SHUTDOWN.



* ACTIVATED ON LEAD ENGINE.

** INDEX DESIGNATORS FOR MORE INFORMATION:
    https://www.bachmanntrains.com/home-usa/board/index.php/topic,38188.0.html
    https://soundtraxx.com/content/Reference/Manuals/Tsunami2/tsu2_diesel_usersguide.pdf

*** CHANGING FACTORY CAB NUMBER:
      https://www.bachmanntrains.com/home-usa/board/index.php/topic,38011.0.html

**** CV1 PRIMARY ADDRESS FOR CONSISTS ARE DONE IN GROUPS:
        (SD40-2 = 2) (GP40-2 = 4) (DD40AX = 3) (DD40AX-SD40-2-DD40AX = 5).


NOTE: CVs CAN BE QUICKLY RESET TO THEIR FACTORY DEFAULT VALUES USING THE FOLLOWING PROCEDURE.

1. TURN ON TRACK POWER TO THE DECODER.  WAIT 5 SECONDS THEN RETURN POWER TO THE DECODER.  IF YOU HAVE INSTALLED
A SOUNDTRAXX CURRENTKEEPER™ OR ANOTHER DEVICE THAT MAINTAINS TRACK POWER, ALLOW AT LEAST TWO MINUTES FOR
CHARGING BEFORE PROGRAMMING.

2. ENTER ONE OF THE FOLLOWING VALUES INTO CV 8 (MANUFACTURER ID) TO PERFORM A FULL OR PARTIAL CV RESET:

    CV8 MANUFACTURER ID
    CV8 TO 8  =  RESET ALL CVS
    CV8 TO 9  =  RESET CVS  1-128
    CV8 TO 10 = RESET CVS  129-256
    CV8 TO 11 = REST CVS 1.257-1.512
    CV8 TO 12 = RESET CVS 2.257-2.512
    CV8 TO 13 = RESET CVS 3.257-3.512

3. TURN OFF POWER TO THE DECODER. WAIT 5 SECONDS THEN RETURN POWER TO DECODER. IF YOU HAVE INSTALLED A
SOUNDTRAXX CURRENTKEEPER OR ANOTHER DEVICE THAT MAINTAINS TRACK POWER, ENSURE THAT THE DEVICE IS FULLY
DISCHARGED (USUALLY ABOUT 3-4 MINUTES) BEFORE RETURNING POWER.

4. WAIT ABOUT 10 SECONDS AFTER RETURNING POWER TO THE DECODER.  ALL LIGHTS (HEADLIGHT, BACKUP LIGHTS OR EFFECT
LIGHTS) AS WELL AS THE DECODER'S ERROR LIGHT, WILL FLASH 16 TIMES TO INDICATE CVS HAVE BEEN SUCCESSFULLY
RESET. TSUNAMI2 WILL RESPOND TO PRIMARY ADDRESS 3 AFTER ALL CVS OR CVS 1-128 HAVE BEEN RESET.

[EXAMPLES]

Recently I have been installing SoundTraxx 885840 Tsunami 2 TSU-BH1 2 Amp Digital Sound Drop in Decoders in my Bachmann Diesels and I noticed some CVs with decimals (CV1.407). 

The CVs with decimal numbers are not decimal numbers, they are Index designators.



The latest Decoders have so much information SoundTraxx added three index layers to store the additional CVs.

To access indexed CVs, CV31 Index 1 =16 (Read Only), *CV32 Index 2 = (), must be in front of any CV with a 1.,2. or 3. index designator in front of the CV number.
*CV32 Index 2 = 1 (Indexed CV page1)
*CV32 Index 2 = 2 (Indexed CV page 2)
*CV32 Index 2 = 3 (Indexed CV page 3)

     

EXAMPLES

All Indexed CVs in Indexed CV Page 1 has a 1. In front of the CV number.
CV1.407 Automatic Whistle Signal Forward
CV1.408 Automatic Whistle Signal Reverse
CV1.409 Automatic Whistle Signal Stop

Tsunami 2 Diesel User's Guide Rev. 1.2    Page 59 is where the Configuration Values are found.
CV1.407 Automatic Whistle Signal Forward =1
CV1.408 Automatic Whistle Signal Reverse = 2
CV1.409 Automatic Whistle Signal Stop = 12 

To Activate the Automatic Signals:
Drop the 1. In front of CV numbers when programing.
Program in order.
CV 31= 16
CV32 = 1
CV407 = 1
CV408 = 2
CV409 = 12

All Indexed CVs in Indexed CV Page 3 has a 3. In front of the CV number.
CV3.258 Clickety-Clack Effect 

Tsunami 2 Diesel User's Guide Rev. 1.2    Page 42 is where the Configuration Values are found.
CV3.258 Clickety-Clack Effect value = 0

To Deactivate the Automatic Signals:
Drop the 3. In front of CV numbers when programing.
Program in order.
CV 31= 16
CV32 = 3
CV258 = 0

[Upgrade and repair of pocket couplers on the Bachmann EDM SD40-2]

Upgrade and repair of pocket couplers on the Bachmann EDM SD40-2

:  2 EACH.        ACCURAIL #1017 STANDARD SIZE COUPLER BOXES.....................................P/N: 1017
:  2 EACH.        BACHMANN E-Z MATE COUPLERS .......................................................................P/N:78025
:                                                      OR
:                        WALTHERS HORN-HOOK COUPLERS(X-2F) .....................................................P/N:933-995
:                                                      OR
:                        KADEE No.148 WHISKER COUPLERS ...................................................................P/N:148
:                                                      OR
:                        WALTHERS PROTO MAX COUPLERS ....................................................................P/N:920-6002
:  1 EACH.        MICRO-MARK COUPLER GAUGE FOR HO STANDARD GAUGE ...................P/N:82824
:  1 EACH.        X-ACTO No. PRECISION KNIFE .................................................................................P/N: EPIX3201

Remove the body shell and check the metal deck for straightness. (If dropped the back deck gets bent in the up direction). It is soft metal; you can straighten it by hand.



Damaged coupler box

The coupler mounting screw is striped out. Enlarge the hole to fit one evergreen polystyrene 1/8 tube 0.125 dia.

Manufacture the replacement shaft using evergreen polystyrene 1/8 tube 0.125 dia. For pocket coupler insulation - Cut replacement shaft to fit flush with top of
coupler in place. Using a 2-56 tap, tap one end of the replacement shaft all the way to the shank of the tap.


Upgrading coupler box

Remove coupler cover and coupler.



With an ex-acto knife remove tabs and barrel as shown.


 
Using the Kadee #246 tap and drill set tap the hole with the 2-56 tap.



Using Accurail #1017 Standard Size Coupler Boxes.



Trim ends and install desired coupler with whiskers.



Install Coupler Box to shell with a 2-56x3/16  blk zinc phil pan/thrd MS 485-532-82 screw.




Check coupler for proper height using a Coupler Gauge for HO Standard Gauge.

[TALGO TRUCKS FIELD SERVICE KIT RTR RECOUPLING:]

How do I fix couplers? There are three different types of couplers shown find the one that look like yours and follow the pictures for that type.

TALGO TRUCKS FIELD SERVICE KIT RTR RECOUPLING:

:  2 EACH.        KADEE TALGO TRUCKS ADAPTORS ....................................................................P/N:212
:  2 EACH.        WALTHERS HORN-HOOK COUPLERS(X-2F) ....................................................P/N:933-995
:                                                      OR
:                        KADEE No.5 COUPLERS ..........................................................................................P/N: No.5
:                                                      OR
:                        KADEE No.148 WHISKER COUPLERS .................................................................P/N:148
:                                                      OR
:                        WALTHERS PROTO MAX COUPLERS ..................................................................P/N:920-6002
:                                                      OR
:                        BACHMANN E-Z MATE COUPLERS .....................................................................P/N:78025
:  4 EACH.        INTERMOUNTAIN 33" METAL WHEELSETS ........................................................P/N: W40050
:  1 EACH.        MICRO-MARK COUPLER GAUGE FOR HO STANDARD GAUGE .................P/N:82824
:  1 EACH.        ULTRA FLAT KRYLON RED OXIDE PRIMER ..........................................................P/N:51317
:  1 EACH.        X-ACTO No. PRECISION KNIFE ................................................................................P/N: EPIX3201
:  1 EACH.        SINGLE END PICK
:  1 EACH.        LABELLE 108 MULTI - PURPOSE LIGHT WEIGHT OIL (PLASTIC SAFE) ......P/N:98552-00108
:  1 EACH.        MICRO-MARK PAINT MASK FOR HO SCALE WHEELS ....................................P/N:86225

         

UPGRADED TALGO TRUCKS

:  TYCO TALGO TRUCK.
:  KADEE TALGO TRUCKS ADAPTOR.
:  INTERMOUNTAIN 33" METAL WHEELSETS.
:  KADEE No.5 COUPLERS.
:  ULTRA FLAT KRYLON RED OXIDE PRIMER.




TASK: DISASSEMBLE TRUCK.

:  USING A SINGLE END PICK PULL LOCK PIN BACK AND TWIST COUPLER COUNTERCLOCKWISE.



:  PULL COUPLER OUT.



:  SPREAD TRUCK ENDS OUT REMOVE WHEEL SET.



TASK: TALGOTRUCK GEAR BOX ASSEMBLY - USING KADEE No.5 COUPLERS.

:  USING A X-ACTO KNIFE REMOVE THE GEAR BOX TABS.


:  USING A SINGLE END PICK PULL LOCK PIN ARM BACK.



:  USING TWEEZERS INSERT KADEE No.634 CENTERING SPRING N0.5 STYLE IN TO THE
  GEAR BOX.



:  INSERT KADEE N0.5 COUPLER INTO THE KADEE No.634 CENTERING SPRING AND IN TO THE
  GEAR BOX.



:  RELEACE THE LOCK PIN TAB BY REMOVING THE SINGLE END PICK.



:  INSERT THE KADEE TALGO TRUCK ADAPTOR CROSSWISE IN GEAR BOX OPENING.



:  TURN AND PRESS DOWN THE KADEE TALGO TRUCK ADAPTOR 90°.





:  PRESS THE KADEE TALGO TRUCK ADAPTOR DOWN AND SNAP IN PLACE.



:  MOVE THE COUPLER FROM CENTER TO FULL RIGHT STOP AND RELEACE -THE COUPLER SHOULD
  RETURN TO CENTER.  MOVE THE COUPLER FROM CENTER TO FULL LEFT STOP AND RELEACE -THE
  COUPLER SHOULD RETURN TO CENTER.

 
Top view

Bottom view

TASK: TALGOTRUCK GEAR BOX ASSEMBLY - USING BACHMAN MARK II COUPLERS.

:  USING A X-ACTO KNIFE REMOVE THE GEAR BOX TABS.



:  USING A SINGLE END PICK PULL LOCK PIN ARM BACK.



:  USING FINGERS SPREAD OUT THE WISKERS ON THE BACHMAN MARK II COUPLER.



:  INSERT BACHMAN MARK II COUPLER INTO THE GEAR BOX.



:  RELEACE THE LOCK PIN TAB BY REMOVING THE SINGLE END PICK.



:  INSERT THE KADEE TALGO TRUCK ADAPTOR CROSSWISE IN GEAR BOX OPENING.



:  TURN AND PRESS DOWN THE KADEE TALGO TRUCK ADAPTOR 90°.




:  PRESS THE KADEE TALGO TRUCK ADAPTOR DOWN AND SNAP IN PLACE.



:  MOVE THE COUPLER FROM CENTER TO FULL RIGHT STOP AND RELEACE -THE COUPLER SHOULD
  RETURN TO CENTER.  MOVE THE COUPLER FROM CENTER TO FULL LEFT STOP AND RELEACE -THE
  COUPLER SHOULD RETURN TO CENTER.


Top view


Bottom view

TASK: TALGOTRUCK GEAR BOX ASSEMBLY - USING WALTHERS HORN-HOOK COUPLERS(X-2F).

:  USING A SINGLE END PICK PULL LOCK PIN ARM BACK.



:  USING FINGERS SPREAD OUT THE WISKERS ON THE WALTHERS HORN-HOOK COUPLERS(X-2F) TO
  INSURE COUPLER RETURN.



:  INSERT WALTHERS HORN-HOOK COUPLERS(X-2F) INTO THE GEAR BOX.



:  RELEACE THE LOCK PIN TAB BY REMOVING THE SINGLE END PICK.



:  INSERT THE KADEE TALGO TRUCK ADAPTOR CROSSWISE IN GEAR BOX OPENING.



:  TURN AND PRESS DOWN THE KADEE TALGO TRUCK ADAPTOR 90°.




:  PRESS THE KADEE TALGO TRUCK ADAPTOR DOWN AND SNAP IN PLACE.



:  MOVE THE COUPLER FROM STOP TO CENTER AND RELEACE -THE COUPLER SHOULD RETURN
  TO STOP.


TOP

BOTTOM

TASK: PANTING TRUCK ASSEMBLY

:  WASH TRUCK ASSEMBLY WITH SOAP AND WATER AND RINSE WITH WATER.



:  MASK OFF TRUCK KING PIN AND DECOUPLING ARM.



:  PAINT TRUCK ASSEMBLY.



:  AFTER PAINTING DE-MASK TRUCK KINGPIN AND DECOUPLING ARM.



:  FOR KNUCKLE COUPLERS LUBRICATE THE KNUCKLE PIN USING LABELLE 108 MULTI - PURPOSE
  LIGHT WEIGHT OIL.



TASK: PANTING WHEEL ASSEMBLIES

:  WASH WHEEL SETS WITH SOAP AND WATER AND RINSE WITH WATER.



:  MASK OFF WHEEL SETS.



:  PAINT WHEEL SETS.



:  AFTER PAINTING CLEAN AXLE ENDS.



TASK: WHEEL TO TRUCK ASSEMBLY.

:  INSERT WHEEL SET AXLE END INTO JOURNAL BOX.



:  SPREAD TRUCK SIDE FRAME ENDS OUT INSERT WHEEL SET AXLE END IN TO JOURNAL BOX.



NOTE: WITH PROPER INSTALLATION ALL COUPLERS WILL LINE UP.




TASK: COUPLER HEIGHT VERIFICATION.

:  USING A MICRO-MARK COUPLER GAUGE FOR HO STANDARD CHECK CLEARANCE.

NOTE: COUPLERS SHOULD HIT THE COUPLER GAUGE IN THE SAME PLACE WITH NO DROOP.




TASK: TRANSITIONAL CAR.

:  ONE TRUCK WITH A KNUCKLE CUPLER, AND ONE TRUCK WITH A HOOK HORN COUPLER.

NOTE: THIS ALOWS THE OPERATION OF ROLLING STOCK WITH KNUCKLE COUPLERS AND HOOK HORN
 

[NOTE:]

I purchased 25 new Bachmann SD40-2 engines prepping for my retirement. I inspected 25 SD40-2's, drive trains, 6  universal joints where split. I am in the aerospace industry and have all kinds of structural adhesives for gluing spars and stuff together. So, in the turbine shop I found a 30+ year old bottle of Loctite 271 thread locker. I'm in the kitchen, the oven is running about 200°F, this is where I get a lesson in crossover chemistry for model trains. Loctite likes a flat clean surface, the inner surface of the universal joint hub is flat enough, the outer surface of the worm gear shaft is flat enough, I cleaned off the universal joint hub and worm gear shaft with electro-wash cleaner degreaser (plastic safe) P/N: ES1210. Loctite likes oxygen starved places with tight fits, I put a drop of Loctite 271 in the universal joint hub and a drop on the worm gear shaft, with my thumb I pressed the universal joint hub onto the worm gear shaft flush with the bottom of the universal joint arms. Now you have a thin oxygen free layer of Loctite tightly between the universal joint hub and worm gear shaft. Now you let it cure overnight. However, I sped up the process so I could see the results. I took the gear drive and chucked it in the oven on the cookie sheet for 60 seconds at 200°F then pulled it out and let it cool. I tried to pull the universal joint and worm gear assembly apart with my fingers, I couldn't pull them apparat. 



Clean off the universal joint hub and worm gear shaft with the electro-wash cleaner degreaser (plastic safe) P/N: ES1210. Inspect the outer end of the universal joint hub for splitting or separation of the universal joint and worm gear shaft.


                                                                                         
Apply a drop of Loctite 271 in the clean universal joint hub.



Apply a drop of Loctite 271 drop on the clean worm gear shaft.



Inserted the worm gear shaft into the universal joint hub receptacle. Pressed the universal joint hub onto the worm gear shaft flush with the bottom of the universal joint arms, remove excess Loctite. Put the universal joint hub and worm gear assembly in the oven on the cookie sheet for 60 seconds at 200°F then pulled it out and let it cool. Inspect the universal joint for proper adhesion, Inspect the bearing for freedom of movement.

NOTE:  Do not allow any Loctite on the bearing, the bearing will
            seize up and not spin after curing!!



NOTE:  Loctite 271 is a high strength, low viscosity, red, methacrylate-based adhesive. It is a
            permanent solution. Once cured Removable by heating up parts to 500°F(260°C).
            If you screw it up, you can heat the assembly up to 500 °F which is the release temperature for
            the Loctite 271, clean it off with acetone and start over, or you can go to Bachmann Parts and buy
            their Worm Gear Assy. w/ driveshaft (Truck) (HO SD40-2) kit.



 

[Figuring Gradient percent and Adding Weight to Engines]

Figuring Gradient percent and Adding Weight to Engines

For figuring grades with sidings for helper Engines, I use a standard of an 7000ft long unit trains in Nevada scaled down to 1:87 scale, 80 ft. ± long. Running fast freight. I put No. 6 switches and sidings for helper Engines 10 ft. before the bottom of the ramp. I put No. 6 switches and sidings for helper Engines 20 ft. past the top of the ramp with a 7-inch (.583) Rise in elevation.

I use Handy Converter for Model Railroaders Version 17 CD: https://stanstrains.com/SoftwareHandyConverter.htm

Using the software Handy Converter for Model Railroaders CD:
Gradient percent: 2%
Rise in elevation: .583 (7 inches)
Run in length is 29.15 feet.

So, the total length including sidings is 60 feet. Starting with 10-foot flat run on level 1, a 29.15-foot ramp with a Rise in elevation of 7 inches and ending with a 20-foot flat run on level 2.

So, adding weight should increase the pulling power, right?

Trains get traction because of the immense weight of the Engines, and the friction generated between the metal wheel and metal rail head.  More weight equals more traction which requires more horsepower. On model trains you have a set horsepower. Providing the model train has room for additional weight (some due most don't), a limited amount of weight can be added as long you don't exceed your power-to-weight ratio and center of gravity. Our power-to-weight ratio formula is for every Bachmann motor listed:
Weight: not to exceed 15.2 oz. per motor.

Model: H63525-1, Model: 6090X-8812A-FS, Model: 6090X-8812A-FL, Model: 6090X-8812A, Model: 621XX-8812B

On the DD40AX's we are using, it does have more traction from adding weight. Our DD40Ax's didn't pull very good, so we added DD40AX sound value decoder and added weight for a gross weight 24 oz. this gave the DD40AX acceptable pulling power, which now is close to our Geniuses DDA40X's which have a gross weight of 26 oz. Sometimes it's not how much weight you add, it is where you put it that counts. The center of gravity should be halfway in-between the forward truck and the aft truck. If one truck is lighter than the other truck the lighter one will brake traction first, then the second one will brake traction. Applying 12.0 oz. at the forward truck center and 12.0 oz. at the aft truck center for a total of 24 oz. at the center of gravity. Applying the traction evenly across both sets of D-D trucks it increased the pulling power for me.
Running consists with four DD40AX engines at 96 oz. total engine weight. Pulling 70 cars at 525 oz. total car weight. For a total train weight of 621oz at 98 SMPH on a flat run. Each Motor pulls 77.62 oz.



When weighing engine make sure the engine is level between scales. Its ok getting the weight and balance closes but not perfect but we don't exceed ± 0.2 oz. between trucks.



Is there enough room for this?

1). DD40AX, has room for additional weight.



2). GP40 does not have room for additional weight.



On our GP40's we use the alternate method for adding weight.  We add another GP40 (same motor same chassis with the same weight 13.2 oz. each) and we keep adding GP40 until the engines quit braking traction, then add one more. 6 Bachmann GP40's at 79.2 oz. total engine weight with NCE BACH-DSL Decoders P/N: 05240139 pull 60 cars total 270oz. at 62 SMPH. Each Motor pulls 58.2 oz. The decoders start voltage CV2 is set to a value of 30. This allows all the engine to start at the same time in this type of consist which is very important for maximum wheel adhesion and pulling power at low speeds.
We set the CV's on all of the GP40's at the same time sitting on the track. At step one at 9in. per 10 sec. travel standard.
CV116 torque kick rate to a value of 2.
CV117 torque kick strength to a value of 12.
CV2 start voltage to a value of 30.

3). SD40-2 does not have room for additional weight.



On our SD40-2 we also use the alternate method for adding weight.  We add another SD40-2 (same motor same chassis with the same weight 15.2 oz. each) and we keep adding SD40-2 until the engines quit braking traction, then add one more. 6 Bachmann SD40's at 91.2 oz. total engine weight with NCE BACH-DSL Decoders P/N: 05240139 pull 80 cars total 440oz. at 65 SMPH. Each Motor pulls 88.5 oz. The decoders start voltage CV2 is set to a value of 30. This allows all the engine to start at the same time in this type of consist which is very important For maximum wheel adhesion and pulling power at low speeds.
We set the CV's on all of the SD40-2's at the same time sitting on the track. At step one at 7in. per 10 sec. travel standard.
CV116 torque kick rate to a value of 2.
CV117 torque kick strength to a value of 12.
CV2 start voltage to a value of 30.

NOTE: For maximum wheel adhesion at low speed, NCE uses CV116 torque kick rate and CV117 torque kick strength.

NOTE: For maximum wheel adhesion at low speed, The Bachmann SD40-2 Sound Value Upgrade (SoundTraxx TSU-BH1 Digital Sound Decoder) uses:
CV3 Baseline Acceleration Rate to a value of 29.
CV4 Baseline Deceleration Rate to a value of 2.
CV10 EMF Feedback Cutout to a value of 126.
CV211 Low speed Compensation to a value of 255.
CV212 BEMF Feedback Intensity to a value of 126.
CV215 BEMF Reference Voltage to a value of 125.
CV220 Constant Brake Distance Rate to a value of 2.

NOTE: The Bachmann GP40 Sound Value engines run just fine out of the box, just set the CV2 start voltage The same as the NCE start voltages, they run with pack just fine.
 
NOTE: The Bachmann SD40-2 Sound Value engines:
CV116 Engine Exhaust Control to a value of 2.
CV3 Baseline Acceleration Rate to a value of 29.
CV4 Baseline Deceleration Rate to a value of 2.


NOTE: Resalts will Vary.

I purchased 80+ new Bachmann engines - DD40AX, SD40-2 AND GP40's prepping for my retirement. I inspected 30 DD40AX's, 240 drive gears, 42 where split. Inspected 25 GP40's, 100 drive gears, 4 were split. Inspected 25 SD40-2's, 150 drive gears, 0 were split. I am in the aerospace industry and have all kinds of structural adhesives for gluing spars and stuff together. So, in the turbine shop I found a 30+ year old bottle of Loctite 271 thread locker. I'm in the kitchen watching my wife baking cookies, the oven is running about 200°F, this is where I get my lesson in crossover chemistry for model trains. Loctite likes a flat clean surface, the inner surface of the gear hub is flat enough, the outer surface of the wheel axel is flat enough, I cleaned off the gear hub and axel with electro-wash cleaner degreaser (plastic safe) P/N: ES1210. Loctite likes oxygen starved places with tight fits, I put a drop of Loctite 271 in the gear hub and a drop on the axel, with my thumb pressed the axel into the gear hub. Now you have a thin oxygen free layer of Loctite tightly between the hub and axle. Using the NMRA HO standards gauge, MARK IVb I check that the wheel width is correct, now you let it cure overnight. However, I sped up the process so I could see the results. I took the gear drive and chucked it in the oven on the cookie sheet with the cookies for 60 seconds at 200°F then pulled it out and let it cool. I tried to pull the gear drive apart with my fingers, its flipping magic I couldn't pull the gear drive apparat.   
 


Clean gear drive wheel assemblies with the electro-wash cleaner degreaser (plastic safe) P/N: ES1210. Inspect the outer end of the gear hub for splitting or elongation.
 


Holding each wheel pull away from each other.



 The wheel in a split hub will pop out.


                                                                                             
Apply a coat of Loctite 271 in the clean gear hub axle receptacle.



Apply a coat of Loctite 271 to the clean wheel axel.



Insert the wheel axle into the gear hub receptacle. remove excess Loctite.



Using the NMRA HO standards gauge, MARK IVb check that the wheel width is correct. 
Allow the repaired gear drive wheel assembles to cure overnight.



After running four DD40AX's for 4 years accumulating 50+ hours of run time, all gear drives repaired with Loctite 271 passed the pull test.

[D]

The included diagrams are what I used for installing four E-Z Command 5 AMP Power Boosters to the E-Z Command Dynamis DCC system. For every 50 to Ft of track one Bachmann E-Z Command 5 AMP power booster is fitted and the 50 Ft track section is isolated with track insulated rail jointers.
Equipment used:
1.    E-Z Command Dynamis DCC system..........................#36505
2.    E-Z Command Dynamis Pro Box..................................#36508
3.    E-Z Command Dynamis Handset.................................#36507
4.    E-Z Command Dynamis Wireless Receiver...............#36509
5.    E-Z Command 5 AMP Power Booster........................#44910
6.    3.5mm Headphone Jack Splitter 3.5 Audio 5 Way 6 Port
Female Connector Adapter(eBay).



7.    Short Red Power Wire - Old Style.                #BAC00002-B



8.    Short Red Power Wire - (Bare Wire).                #BAC00002-C



9.    Short Red Power Wire – NEW.                    #BAC00002-A











Wireless infrared receiver range upgrade:

Cut the Bachmann E-Z Command ® Dynamis ® Wireless receiver cable D in half or one end longer than the other. Attach a RJ45 8P8C CAT 6 Modular Plugs Network Cable Lan Connector End Internet US on each of the cut ends, ring out both harness for continuity wire by wire.

NOTE: No substitutions with RJ45 8P8C CAT 6 Modular Plugs Network Cable Lan Connector.



Connector B RJ45 8P8C, Nickel Plating; TIA/EIA 568-C.2 Verified; RoHS compliant. Network Speed: up to 10 Gbps.

NOTE: No substitutions with RJ45 8P8C, Nickel Plating; TIA/EIA 568-C.2 Verified; RoHS compliant. Network Speed: up to 10 Gbps.

Attach cable A and cable D together using Connector B.





Wireless infrared receiver placement:

Equipment used:
3M Command™ Picture Hanging Removable Interlocking Fasteners, 5/8" x 2 3/4" medium strips.
Place fastener strip on the back of a wireless receiver, place fastener strips on the walls as shown in the diagram 2"x 6" pattern. With an engine running on the track, walk around moving the wireless receivers around until the dead spots (no signal) are eliminated.



Wall A (North).



Wall B (Southwest).



Wall B (Southeast).



Wall C (East).



Wall D (West).





NOTE: Results may vary.

We are running four Bachmann E-Z COMAND®  5 Amp power boosters which have annoyingly loud cooling fans, it gets so loud it hurts your ears. You have to wear ear plugs with a noise canceling headset.     
We are installing Noctua NF-A6x25 Premium fan with Flow Acceleration Channels mounted on Anti-Vibration Mounts running at 1600 rpm in each booster today.



We started by removing the top of the booster and remove the fan in the back panel, back drill the screw holes. Cut the fan mount flush with a snap-off knife. Enlarge the four holes and install the 4x Anti-Vibration Mounts. 



Verified that the fan is pointed in the right direction (airflow out). Installed the fan on the 4x Anti-Vibration Mounts previously installed on the back panel. 
NOTE: Some fans have on the outer case arrows pointing airflow direction and rotation.



There are two options for low – nose speed settings:
(1). 2400 rpm low – nose Adapter (NA-RC10).
(2). 1600 rpm Ultra-low-nose Adapter (NA-RC12).



The fan has a three pin female connector while the booster has a two pin male connector with a tab. I broke the white tab off the two pin male connector, so the three pin female connector will plug in. 



Operationally check the fan for proper flow. Plugging in the female connector as shown, the fan will run in the right direction. Plugging it in on the other pin the fan will run backwards and you will be sad.
   


We installed the 1600 rpm Ultra-low-nose Adapter (NA-RC12).
         


Installing the cover and checking air flow one more time, using two 5 Amp power boosters we hooked up one booster per forty-two feet of track in an oval for a total of 84 feet. Running four DD40AX's eight motors total pulling 60 89' TOFC flatbeds loaded. Total train weight 32lbs the train was moving forty-two feet every 25 seconds at step 28 using a E-Z Command Digital Command Control system for two hours. The booster's inlet temperature was 75° with 15% humidity, outlet temperature of 82° with a deferential of 7°. We operate the train room between 62°min. to 79° max.
The four 5 Amp power boosters are sounding quite nice, you can't hear the boosters running anymore.

If you want automatic silencing and keeping an engine silent until activated, the Sound Value Decoder (SoundTraxx) is setup CV116 Engine Exhaust Control to a value of 02.  When step one is selected with the throttle the Sound works.

[REPLACEMENT TECHNIQUES:]

If your Doodle Bug hops, and pops going down the track making clicking sounds, your gears are split and need to be replaced.



REPLACEMENT TECHNIQUES:

1.) Loctite 271 threadlocker P/N:27121 can be used for adhering a 3D Printed gear to axle.

SPLIT GEAR FIELD SERVICE KIT:
:  1 EACH.    LOCTITE 271 THREADLOCKER (HIGH STRENGTH) ................P/N:27121                                   
:  1 EACH.    NMRA HO STANDARDS GAUGE (WITH RP-25 CONTOUR) ...MARK IVb
:  1 EACH.    ELECTRO-WASH CLEANER DEGREASER (PLASTIC SAFE) ......P/N:ES1210
:  1 EACH.    No. 50 DRILL BIT.
:  1 EACH.    No. 47 DRILL BIT.
:  2 EACH.    BALSA WOOD.
:  1 EACH.    MINIATURE GEAR AND WHEEL PULLER.
https://www.micromark.com/Miniature-Gear-Puller
:  1 EACH.    HO SCALE BACHMANN DOODLE BUG AXLE REPAIR KIT.
https://www.shapeways.com/product/ZXTD5WA4F/ho-scale-bachmann-doodle-bug-axle-repair-kit?optionId=248454086&li=marketplace

REPLACEMENT OF GEAR ON DRIVE WHEEL ASSEMBLIES:                                                     
:  PLACE MODEL BOTTOM SIDE UP, IN A FOAM CRADLE.
:  REMOVE SIDEFRAMES.
:  USING A 1.44 MM LONG SHAFT FLAT TIP SCREWDRIVER OR EQUIVELANT, INSERT SCEWDRIVER 
   IN BETWEEN THE COWCATCHER AND WHEEL POPING OFF THE GEARBOX COVER CLIP FROM THE 
   GEAR BOX TAB, SAME BOTH SIDES, REMOVE GEARBOX COVER.




:  REMOVE DRIVE WHEELS FROM GEAR BOX, CLEAN GEAR DRIVE WHEEL ASSEMBLIES WITH THE
   ELECTRO-WASH CLEANER.
:  USING THE MINIATURE GEAR AND WHEEL PULLER, REMOVE THE WHEEL WITH THE BLACK INSULATOR
   BUSHING AND SLIDE OFF THE SPLIT GEAR.

NOTE: THE HO SCALE BACHMANN DOODLE BUG AXLE REPAIR KIT COMES WITH FOUR 3D
             PRINTED GEARS. WE USED TWO KITS FOR TWO MODELS, WE WERE ABLE TO INSTALL FOUR,
             TWO PER MODEL, DESTROYED THREE LEARNING HOW TO INSTALL THEM.
            (1)    DO NOT PRESS FIT, THE GEAR WILL SPLIT. (3D PRINTED IN MATTE TRANSLUCENT PLASTIC)
            (2)    DO NOT USE TEMPERATURES OVER 200 DEGREES FAHRENHEIT.
            (3)    HAND DRILL IN STEPS (No. 50, 49, 48, 47). CAN SPLIT IF PUSHED TO HARD,PIECES CAN CHIP OFF ON
                   THE EXIT SIDE.

:  USING A HAND DRILL ENLARGE THE GEAR AXEL HOLE IN STEPS STARTING WITH A
   No. 50,49, 48 ENDING WITH A No. 47.



:  CLEAN GEAR AND GEAR DRIVE WHEEL ASSEMBLIES WITH THE ELECTRO-WASH CLEANER.
:  APPLY A COAT OF LOCTITE 271 IN THE CLEAN GEAR HUB AXLE RECEPTACLE.
:  APPLY A COAT OF LOCTITE 271 TO THE CLEAN WHEEL AXEL.
:  INSERT THE WHEEL AXLE INTO THE GEAR HUB RECEPTACLE. REMOVE EXCESS LOCTITE.

NOTE: THE GEAR WILL SLIDE ON EASY FOR A STRESS-FREE FIT.
             ON A BACHMANN GEAR WE WOULD PUT THE ASSEMBLIES IN A 200 DEGREES FAHRENHEIT OVEN FOR 1 MINUTE. SO,
             WE TRIED THIS WITH THE 3D PRINTED GEAR AND IT WORKED. HOWEVER, WE MISALIGNED ONE 3D GEAR. WITH THE
             BACHMANN GEARS YOU CAN HEAT UP TO 500 DEGREES FAHRENHEIT WHICH IS THE RELEASE TEMPERATURE FOR THE
             LOCTITE 271, BACHMANN GEARS CAN BE REMOVE AND REUSED. THE 3D PRINTED GEARS WILL DISINTEGRATE AT
             THIS TEMPERATURE MAKING THEM A SINGAL USE.
 
:  REINSTALL THE WHEEL TO THE AXLE.
:  USING THE NMRA HO STANDARDS GAUGE, MARK IVb CHECK THAT THE WHEEL WIDTH IS CORRECT.
:  USING THE BALSA WOOD MAKE A CENTERING JIG FOR THE 3D PRINTED GEAR ON THE AXEL.
:  ALLOW THE REPAIRED GEAR DRIVE WHEEL ASSEMBLIES TO CURE OVER NIGHT (24 HRS).
:  PLACE THE WHEEL AXLE ASSEMBLIES IN THE GEAR BOX, BE CARFUL WITH THE WHEEL CONTACT ARMS   
   THEY DAMAGE EASLY. REINSTALL THE GEARBOX COVER AND SIDEFRAMES.



:  TEST RUN.

[Activate the Automatic Sound:]

Activate the Automatic Sound:
If you want Automatic Bell and Whistle, the Sound Value Decoder (SoundTraxx) is setup CV198=6, CV193=2, CV194=11.  When step one is selected with the throttle the Automatic Bell and Automatic Whistle works. When step three is selected with the throttle the Automatic Bell shuts off. When step one is selected with the throttle the Automatic Whistle works. Forward step one is selected with the throttle the Automatic Whistle sounds two long whistles and when stopped one short whistle. Reverse step one is selected with the throttle the Automatic Whistle sounds three short whistles and when stopped one short whistle.   
 
CV198=4 Automatic - Bell
CV198=2 Automatic - Whistle
CV198=6 Automatic - bell and Whistle
CV193-() Bell Start range anywhere between 1 and 126. CV193 must be lower than CV194.
CV194-() Bell off set point time must be higher than CV193.

Removing Factory Cab Numbers on model trains:
Step 1). Cut a piece of paper towel the size of numbers to be removed, two layers. Place over numbers.
Step 2). Apply using a Q-tip, Micro Sol MI-2 (Red lettering on bottle) liberally.



Step 3). Let soak for ten minutes, keep moist using a Q-tip.
Step 4). Remove the paper towel, using a Q-tip dipped in Micro Sol MI-2 gently rub off numbers and clean off debris using the dry end.



Step 5). Repeat step 1 thru 4 until all numbers are completely removed.
Step 6). Apply desired decals and set with Micro Sol MI-2 using directions on the bottle.
Step 7). Dilute one part Micro Flat MI-3 to three parts water, Using a soft paint brush apply over Decal.

 

[CV2 START VOLTAGE = ()]

We purchased 25 new Bachmann-EMD SD40-2 DC/DCC Union Pacific diesel locomotives and 2 Bachmann-EMD SD40-2 w/DCC & Sound Union Pacific diesel locomotives. The idea was to take eight new SD40-2 out of the box, hook them up to eighty 50' high cubes and run them up and down 2% grades in the pacific northwest layout. Using eight new SD40-2 out of the box worked about as good as a screen door on a submarine. This is a list of defects we found in some of the units new out of the boxes:
1). Plastic shell is warped from being removed from the mold to soon causing the back end to warp up.
2). Back coupler sets 1/8 of an inch too high over rolling stock couplers.
3). Wheels in the rear truck don't move, power train problems.                 
4). Motor sounds like a really loud marble grinder. You need to run it up to step 8 to start moving.
5). You can't add sound, there is no place for a speaker, unless you involve a machine shop.

Corrective action:
 
1). Plastic body shell is warped, Back coupler sets 1/8 of an inch too high.

https://www.bachmanntrains.com/home-usa/board/index.php/topic,38183.msg279429.html#msg279429

2). Wheels in the rear truck don't move.
                 
I disassembled the chassis to see why the wheels in the rear truck do not move, the universal joint and the driveshaft was disconnected and lying at the bottom of the driveshaft tunnel.

https://www.bachmanntrains.com/home-usa/board/index.php/topic,38176.msg279393.html#msg279393

3). Motor sounds like a really loud marble grinder.

Removed the body shell and DCC decoder board with no sound.
Installed NCE BACH-DSL Decoders P/N: 05240139 installed with no sound.

https://ncedcc.zendesk.com/hc/en-us/article_attachments/200500099/BachDv35.pdf



Adjusted CV's
CV116 torque kick rate to a value of 2.
CV117 torque kick strength to a value of 12.
CV2 start voltage to a value of ().

CV2 START VOLTAGE = ()

FOR NEW INSTALLS I SET UP CV2 START VOLTAGE VALUE TO MEET A STEP ONE THROTTLE, SPEED STEP 28 =  9 INCH PER 10 SECONDS TRAVELED REQUIREMENT ±.

           

EXAMPLE



4). You can't add sound, there is no place for a speaker.

You can Upgrade your Bachmann DC/DCC SD40-2 Diesels with a Soundtraxx TSU-BH1 Tsunami 2 EDM Drop in Digital Sound Decoder for Bachmann Diesels.

https://www.bachmanntrains.com/home-usa/board/index.php/topic,38200.msg279496.html#msg279496

[DDA40X/E-Z Track sound dampening.]

I like operating in a big 45 x 15+ room with no windows, with stairs going down in the middle of the plywood floor.  I like to run heavy trains on HO scale E-Z Track, No.1 main four Bachmann DD40AX with eight motors pulling 60 to 100 cars with Intermountain 33" Metal Wheel sets at 100 smph.  No.2 main four Bachmann DD40AX with eight motors pulling 60 to 100 cars with Intermountain 33" Metal Wheel sets at 101 smph going the opposite direction on 170 feet of E-Z Track with supper elevated curves, it gets so loud it hurts my ears. Unfortunately, when metal wheel set were introduced, the metal wheel sets on metal rails produced a high pitched frequency in the E-Z Track molded plastic roadbed which is very unpleasant to listen to. You have to wear ear plugs with a noise canceling headset.
     
Due to the fact that the material in the HO scale E-Z track molded plastic roadbed has approximately a noise reduction coefficient (NRC) of 0.00, the best that can be done is mask the noise.

DDA40X/E-Z Track sound dampening.
Woodland scenics O scale track-bed ST1476 directly placed on the ply wood floor, the modified HO scale E-Z Track molded plastic roadbed drilled with No.# 25 holes in the road bed. This is done to remove the high pitch sound and keep the low pitch sound.



DDA40X/E-Z Track sound dampening test 02, rolling stock with engine sound muted.
Woodland Scenics O scale track-bed ST1476 directly placed on the ply wood floor, the modified HO scale E-Z Track molded plastic roadbed is drilled with alternating No.# 25 holes in the road bed. This is done to remove the high pitch sound and keep the low pitch sound. With engines sounds muted, you can hear sound levels of the wheel sets on the rails. Rolling stock modifications:

Accurail Roller Bearing Trucks P/N: 165.
Intermountain 33" Metal Wheelsets P/N: W40050.

The train runs up from step 0 to step 28 on the first lap. On the second lap the train maintains 101 scale miles per hour (smph). On the third lap the train coasts down from step 28 to 0.

I was surprised this brought down the noise of the rolling stock to where you could have a normal conversation with the trains running in the background, it does not hurt your ears anymore. No more ear plugs, no more noise canceling headsets, however the engines are really loud now.

Adjusting DD40AX sound levels:

We took each consist of four Bachmann DD40AX Sound Value Equipped Prime Movers and adjusted the CV's

Engine No.1:

CV33 F0(f) Output Location to a value of 01.
CV34 F0(r) Output Location to a value of 02.
CV115 Horn Selection to a value of 02. (Leslie RS5T)
CV130 Bell Volume Control to a value of 64. 
CV131 Exhaust Volume Control to a value of 70.
CV133 Dynamic Brake Volume Control to a value of 150.

Engine No.2, No.3, No.4:

CV33 F0(f) Output Location to a value of 00.
CV34 F0(r) Output Location to a value of 00.
CV115 Horn Selection to a value of 02. (Leslie RS5T)
CV129 Horn Volume to a value of 00.
CV130 Bell Volume Control to a value of 00.
CV133 Dynamic Brake Volume Control to a value of 150.

The DD40AX Engines No.1, No.2, No.3, No.4 are placed on the programing track he sets the CV2 start voltage to a value of 00 on all of them at the same time. He sets the CV5 Vmax to a value of 00 on all of them at the same time.
The DD40AX Engines No.1, No.2, No.3, No.4 are placed on the main line with 60 89 foot TOFC flat cars in tow, at step 1 the DD40AX's are pulling the 60 89 foot TOFC flat cars smoothly, he takes the consist of 4 DD40AX's pulling 60 89foot TOFC flat cars up to step 28.

DDA40X/E-Z Track sound dampening test 03, rolling stock with engine sound.
Adjusting Bachmann DD40AX sound levels: Woodland Scenics O scale track-bed ST1476 directly placed on the ply wood floor, the modified HO scale E-Z Track molded plastic roadbed is drilled with alternating No.# 25 holes in the road bed. This is done to remove the high pitch sound and keep the low pitch sound. With engines sounds on, the train runs up from step 0 to step 28 on the first lap. On the second lap the train maintains 101 scale miles per hour (smph). On the third lap the train coasts down from step 28 to 0.

DDA40X/E-Z Track sound dampening test 04, Fast forty sandwich.
Adjusting Bachmann DD40AX Sound Value Equipped Prime Movers sound levels for a Fast forty sandwich: Woodland Scenics O scale track-bed ST1476 directly placed on the ply wood floor, the modified HO scale E-Z Track molded plastic roadbed is drilled with alternating No.# 25 holes in the road bed. This is done to remove the high pitch sound and keep the low pitch sound. With engines sounds on, CVs set to:

Engine No.1:

CV33 F0(f) Output Location to a value of 01.
CV34 F0(r) Output Location to a value of 02.
CV115 Horn Selection to a value of 02. (Leslie RS5T)
CV130 Bell Volume Control to a value of 64.
CV133 Dynamic Brake Volume Control to a value of 150.

Bachmann SD40-2 Engine No.2:

NCE BACH-DSL Decoder P/N: 05240139

CV5 V max to a value of 00
CV33 F0(f) Output Location to a value of 00.
CV34 F0(r) Output Location to a value of 00.
CV116 torque kick rate to a value of 2.
CV117 torque kick strength to a value of 12.
CV2 start voltage to a value of 98

Bachmann DD40AX Engine No.3:

CV33 F0(f) Output Location to a value of 00.
CV34 F0(r) Output Location to a value of 00.
CV115 Horn Selection to a value of 02. (Leslie RS5T)
CV129 Horn Selection to a value of 00.
CV130 Bell Volume Control to a value of 00. 
CV133 Dynamic Brake Volume Control to a value of 150.

The DD40AX Engines No.1, No.3 are placed on the programing track. CV2 start voltage to a value of 00 on all of them at the same time. CV5 Vmax to a value of 00 on all of them at the same time.

The train runs at step 28 maintaining 103 scale miles per hour (smph).

Now the Engines are sounding quite nice, however the four Bachmann 5 Amp boosters have annoyingly loud cooling fans.
       
We installed a Noctua NF-A6x25 Premium fan with Flow Acceleration Channels mounted on Anti-Vibration Mounts running at 1600 rpm in each booster.



Now the 5 Amp boosters are sounding quite nice, you can't really hear the boosters running anymore and the trains sound like the real ones zipping along.

For future layout applications:
HO scale E-Z Track molded plastic roadbed drilled with No.# 25 holes, will sit on a Woodland scenics O scale track-bed ST1476 track-bed.
For train yards the HO scale E-Z Track molded plastic roadbed drilled with No.# 25 holes, will sit on a Woodland scenics ST1477 track-bed super sheet.
The E-Z Track and track-bed sits on Homasote® 440 sound barrier for best sound dampening.



NOTE: The DD40AX sound value decoder CVs can be quickly reset to their factory default values using the following procedure.
1. Place the locomotive on a powered section of track. Program CV 30 to 2 (or CV 8 to 8) using either Service Mode or Operations Mode.
2. Cycle power to the decoder by turning power to the track off and then back on.
3. After power is restored to the track, there should be no indication of activity other than the power LED turning on for a period of 6 seconds. If sound comes on immediately upon restoring power, the
    decoder did not reset. Repeat steps 1 and 2. (Bachmann DD40AX Sound Value decoders do not have a power LED).
4. Once the 6-second period has elapsed, the sound should come on and the headlight, backup light will blink 16 times indicating that the CVs were successfully reset.
5. Tsunami sound value decoder should now respond to short address 3 just as it did when it was new.