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DCS Proto-Sound 2.0 Diesel/Electric Locomotive Upgrade Kit, Installation Manual, Page: 19 / 44

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DCS Proto-Sound 2.0 Diesel/Electric Locomotive Upgrade Kit Installation Manual Download Page 19

Soldering Speaker Connections

-Solder the yellow and
white wires (U) to the
speaker (H) making sure
to get the polarity
correct, ) and
white(-)

-Connect speaker plug to
harness plug (white) with
yellow & white wires
coming from the 12-Pin
Chassis Harness (Y).

CAUTION: If either
wire shorts to the
speaker frame, the PS-
2 electronics will be
damaged.

PS-2 Upgrade Kit Installation Guide

19

Summary of Contents for Proto-Sound 2.0 Diesel/Electric Locomotive Upgrade Kit

Page 1: ...ge enough to house the electronics The instructions herein are generic in nature and will not provide the installer with specific installation details for specific locomotives Consult the individual item s operator s manual for specific instructions on how to disassemble the locomotive prior to installing the upgrade kit This product is not covered by a warranty unless installed by an M T H Author...

Page 2: ...ecting Motor Ground Pickup Wires Connecting Lights Connecting Smoke Unit To The Harness Wire Management Short Circuit Prevention Conventional Operation Warranty Coverage Service Options Limited 90 Day Warranty Installing The Battery Recharging Jack Volume Pot Installing The Tach Reader Bracket Installing The Flywheel Tach Tape Mounting The Tach Reader To The Tach Bracket Self Recharging Battery Tr...

Page 3: ...ging Jack Hardware 2 J Ditch Lights 2 K Interior Lights L Overhead Blinking Light M 6 32 x 6mm Screws 3 N 6 32 Nuts 3 O 6 32 x 8mm Screw P Shrink Tubing Q Wire Management Coil R Wire Ties 6 4 S Foam Tape T Wire Nuts 2 U Speaker Plug V Smoke Unit Wire Harness W 8 Pin Chassis Harness X 5 Pin Motor Harness Y 12 Pin Chassis Harness A Proto Sound 2 0 Circuit Board AE 0000010 AE 0000011 AA PS 2 Heat Sin...

Page 4: ...h Reader Bracket IH 0000389 FFF Tach Tape BE 0000151 H Speaker BF 0000034 I AA NiCad Battery Pack BG 4000003 II Battery Charging Jack BC 1000004 III Battery Charging Jack Hardware PS 2 Upgrade Kit Installation Guide 4 EE Marker Light Green E Marker Light Red ...

Page 5: ... 0000027 S Foam Tape V Smoke Unit Wire Harness N 6 32 Nuts TP MS00075 K Interior Lights T Wire Nuts BI 4500003 O 6 32 x 8mm Screw IA 0000050 L Overhead Blinking Light P Shrink Tubing R Wire Ties Q Wire Management Coil PS 2 Upgrade Kit Installation Guide 5 ...

Page 6: ... W 8 Pin Chassis Harness X 5 Pin Motor Harness Y 12 Pin Chassis Harness PS 2 Upgrade Kit Installation Guide 6 ...

Page 7: ...ers Drill Drill bits 1 8 5 32 Drill bit 3 8 or or de burring tool Electrical Tape Razor Saw Proto Sound Battery Charger M T H Part number 50 1019 What Is An ESD As ESD safe work area is an area set aside in your workshop that is electrically grounded and includes anti static mats and grounding straps ESD Mat Work Only in an ESD Safe Zone Grounding Strap 7 ...

Page 8: ...ltage lighting boards will work under DCS with no modifications If the non powered trailing unit is equipped with lighting ie back up light that is connected to the powered unit through a harness you can use that existing harness to connect those lights up to the PS 2 kit This kit does not provide connections for Proto Coupleres in non powered dummy units although it does include two PS 2 Proto Co...

Page 9: ...connected bulbs if equipped Note Note If any of the above items are missing or not in working order procure the required parts before continuing It might be helpful to label the Front and rear of the chassis as a reminder which direction the engine should first move when powered up Note Before beginning installation see discussion on page 27 on wire management which should be planned as you procee...

Page 10: ... Whistle any other electronics and harnesses Speaker save mounting hardware Existing couplers save the T bars springs and c clips Any lights including the headlight and marker LEDs if present These will likely be mounted inside the body shell Do remove the volume pot or smoke unit ON OFF switch if present used on Proto Sound 1 models If your locomotive does not have a volume pot order BI 0000040 v...

Page 11: ... PS 2 components The major components are the PS 2 board PS 2 Heat Sink Bracket the speaker and the rechargeable battery pack The speaker can often be installed in the fuel tank if your locomotive is so equipped leaving the chassis areas in front of between and behind the motors for the remaining PS 2 equipment This Premier Line GG 1 features no fuel tank so the speaker must be mounted onto the ch...

Page 12: ...er there is NO warranty once the bag is opened NOTE Use ESD safe work area and procedures when handling the PS 2 board Make sure the PS 2 board is firmly inserted into the plastic mounting bracket If not gently push the board into the bracket until fully captured by the bracket DO NOT REMOVE THE BOARD FROM THE BRACKET Place the components on the chassis floor in the best position given the space I...

Page 13: ...rd with plastic mounting bracket A metal heat sink bracket AA speaker and battery from the chassis and place on an ESD safe area on your workbench Removing the motors trucks will help protect them from Any stray metal chips when drilling mounting holes Drill the holes as marked with the proper drill size A 5 32 bit will be required for the PS 2 plastic mounting bracket A and heat sink bracket AA U...

Page 14: ... 2 of the screws M and nuts N Apply white thermally conductive grease to the bridge rectifier on the PS 2 board Mount the PS 2 plastic mounting bracket Apply white thermally conductive grease to bridge rectifier the mounting spot for the metal heat sink bracket PS 2 Upgrade Kit Installation Guide 14 ...

Page 15: ...nstalls in the same location as the original engine coupler Install the proto couplers C onto the existing locomotive trucks or coupler mount locations using the existing hardware Be sure to route the coupler wire harness through the chassis floor as shown The front truck Proto Coupler connector attaches to the black purple harness from the 12 Pin chassis harness Note Use coupler insulator CC as r...

Page 16: ...T ELEMENT VOLUME POT SMOKE SWITCH TACH READER SMOKE UNIT HARNESS 12 PIN CHASSIS HARNESS 7 PIN CHASSIS HARNESS 8 PIN CHASSIS HARNESS 4 OHM 3 WATT SPEAKER SPEAKER SPEAKER OVERHEAD BEACON MARKER LIGHTS GREEN DITCH LIGHT 1 FRONT PROTO COUPLER CAB INTERIOR LIGHTS FRONT MARS LIGHT FRONT HEADLIGHT WIRE NUT MARKER LIGHTS RED DITCH LIGHT 2 REAR PROTO COUPLER REAR MARS LIGHT REAR BACKUP LIGHT PS 2 CIRCUIT B...

Page 17: ...PS 2 Board Connections 5 PIN 4 PIN 12 PIN 8 PIN 2 PIN 7 PIN PS 2 Upgrade Kit Installation Guide 17 ...

Page 18: ...same mounting hardware for the original speaker Install the speaker H into the previous speaker mounting location if applicable using the existing hardware Re use the existing smoke unit switch Solder one blue wire from Pin 10 of the 12 Pin Chassis Harness to smoke unit switch center pin Many locomotives featuring a smoke unit switch have engraved ON OFF on the floor Choose the appropriate pin for...

Page 19: ...ing sure to get the polarity correct yellow and white Connect speaker plug to harness plug white with yellow white wires coming from the 12 Pin Chassis Harness Y CAUTION If either wire shorts to the speaker frame the PS 2 electronics will be damaged PS 2 Upgrade Kit Installation Guide 19 ...

Page 20: ...age to the board and may affect operation The battery pack connector comes pre mounted to the recharging jack and battery pack cable It plugs into the PS 2 Circuit board as indicated by the arrow Mount the 2 Pin battery recharging jack II to chassis floor using hardware III as shown on the right Insert the spacers III between the recharging jack board and the chassis floor to prevent the rechargin...

Page 21: ...ble sided foam tape S on the chassis floor in the location established previously Secure the AA rechargeable Ni Cd battery pack I using the double sided foam tape Solder the red blue and gray volume pot wires to the volume pot Red to the center terminal and blue and gray to the outside terminals Use the double sided tape to secure the battery pack to the chassis floor Connect the battery harness t...

Page 22: ... Cut bracket straps Spread the Tach Reader bracket apart and slip between the flywheel and motor for engines equipped with Mabuchi or similar motors Push the bracket all the way onto the top of the motor The small tabs extending down will lock onto motor casing Installing Tach Tape Onto Motor Flywheel Clean the flywheel with a cleaning solution and then install the tach tape FFF to the flywheel di...

Page 23: ...to the tach reader bracket the distance between the tach reader and the flywheel should be between the tach reader and the flywheel should be between 5mm 1 5mm Unsolder the tach reader from the circuit board at the four tach reader prongs Once unsoldered resolder with the proper gap between the reader and board Check the distance between the flywheel and tach reader Adjust if necessary as detailed...

Page 24: ...ect the black wires from the 7 Pin Chassis Harness to chassis ground Connecting Lights Install the Ditch Headlight Marker Mars Overhead Blinking Cab Interior bulbs into the proper engine wire harness locations as seen in the diagram on page 16 and the instructions on page 25 On RailKing diesel locomotives the headlight and backup light are usually a screw or bayonet based bulb inserted into a brac...

Page 25: ...d on your model 8 All loose purple wires need to be connected Notice on Pin 2 of the 12 Pin Chassis Harness that there are two purple wires Route one wire to the front and the other to the rear of the engine Using one of the yellow wire nuts tie all the loose purple wires in the front of the engine Front Coupler Headlight Cab Interior Light Mars Light Ditch Light etc together Using the remaining y...

Page 26: ...e no longer present since the PS 2 hardware will be managing the smoke unit heating elements and motor The heating elements MUST be isolated from the electronics on the board or the PS 2 board will be permanently damaged see alternate cut line Green Wire Gray Wire Follow the above wiring directions to the smoke unit motor CRITICAL STEP Use a razor saw to cut the bottom of the smoke unit circuit bo...

Page 27: ...e Brown wire from the smoke unit wiring harness to one pad and the Purple to the other the pads are interchangeable Soldering to the trace for each end of the element is also acceptable Connecting The PS 2 Harness To The Smoke Unit Cont d Wire Management Short Circuit Protection Route the wires around the motor and chassis such that the wires will not be pinched when the body is installed Use piec...

Page 28: ...oves in the forward direction If the two motors in a twin motored unit appear to be fighting each other reverse the white and yellow motor wires on one motor If the engine starts in reverse reverse the yellow and white wires to both motors If the engine does not move the battery most likely needs to be charged Press the whistle button and verify the horn test sound The sound is not a normal horn b...

Page 29: ... a large mainline steam engine ie 4 8 4 Northern for example will find that the locomotive cannot run at the same scale speed as other engines and that the chuff rate will not be properly timed with the driver revolutions This is because the driver sizes of the two different locomotives are drastically different from one another Follow the illustrations on the following pages to learn how to searc...

Page 30: ...ve you are upgrading Go to the Sound Sets page of the Proto Sound 2 0 Website www protosound2 com upg soundsets htm to search for the correct sound set for your Fill out the appropriate search fields to search for your locomotive It is not necessary to fill out all the fields PS 2 Upgrade Kit Installation Guide 30 ...

Page 31: ...oad it to your computer Select your locomotive from the search results by clicking on the appropriate photo Scroll to the bottom of the page and right click on the bottom sound file link to download the file to your computer You will be prompted for the location where you want to save the file prior to the download beginning PS 2 Upgrade Kit Installation Guide 31 ...

Page 32: ...ff press and release the Bell button again The bell will continue to ring from the time you turn it on until you press and release the button again to turn it off To sound the whistle firmly press the Horn Whistle button The whistle will sound for as long as you continue to depress the button It will stop when you release the button Your train is programmed to start in neutral The train will alway...

Page 33: ...Bells from Neutral only 1 Horn 3 Bells 1 Horn 5 Bells from Neutral only Activating Proto Sound 2 0 Conventional Mode Features Proto Sound 2 0 features are activated by sequences of Bell and Horn button pushes described below Please read the full descriptions of each feature before using it To use these buttons to activate features rather than to blow the horn or ring the bell you should tap the bu...

Page 34: ...0 has disabled operator control over the Horn and Bell buttons until the full PSA sequence is complete After waiting about 30 seconds for that sequence to run press the Direction button again to trigger the second sequence of PSA After about 30 seconds press the Direction button again to trigger the third PSA sequence Again after allowing about 30 seconds for that sequence to run press the Directi...

Page 35: ...PSA can be triggered from Neutral It will operate the same as if triggered while in motion except that at the conclusion of the PSA the engine will depart in the next direction of travel as opposed to the direction it was Traveling before entering Neutral Proto Coupler Operation This locomotive is equipped with one or more coil wound Proto Couplers for remote uncoupling action Because Proto Couple...

Page 36: ...the engine will run more slowly at a given throttle voltage when speed control is on than when it is off you should adjust the throttle to a lower power level for operation with speed control off to avoid high speed derailments When speed control is off the volume will drop to allow for better low voltage operation put the engine in neutral then quickly tap the transformer s Horn button one time t...

Page 37: ...l Direction Lock Two Horn Blasts Repeat to Return to Normal Condition indicates change is made Reset To Factory Default To override the settings you currently have assigned to the engine and reset it to its factory defaults while in Neutral tap the Horn button quickly once followed by five quick taps of the Bell button allowing approximately second to lapse between each quick button press Two horn...

Page 38: ...es Recharge If the sounds are improved at the end of the 15 minute test charge the batteries charge has run down and can be recharged There are a number of ways you can do this Leave the engine in neutral with track voltage at 10 12 volts for 6 7 hours so the batteries can fully recharge if your engine has a smoke unit be sure it is turned off Use M T H s battery recharger sold separately that plu...

Page 39: ...e the coupler FYS starts The Proto Coupler won t let the engine uncouple on the fly The coupler does not fire or stay coupled When I press the whistle button the bell sounds Reverse the transformer leads You may be pressing the button too quickly Try pressing the whistle horn button more slowly taking approximately one full second to fully depress the button You may be pressing the button too quic...

Page 40: ...ition Follow the procedure in the Lock into a Direction section Engine speed must be below 10 scale mph approx 10 volts or less in conventional mode Proto Sound 2 0 volume is set too high Turn the volume control knob on the bottom of the chassis counter clockwise to reduce the volume Check to be sure the battery is installed and fully charged See the Self Charging Battery Back Up section The batte...

Page 41: ...disables the reversing unit whenever FYS is enabled This way the engine remains still at its stop as the operator cycles through the FYS sequences FYS is programmed to start ringing the bell at that point After approximately 12 rings of the bell it will automatically turn off Because FYS must control various effects in each sequence Proto Sound 2 0 takes control of these sound effects until you ex...

Page 42: ...upler and the spring washer and the coupler to the T Bar and truck bolster The insulator prevents the coupler wiring from contacting and short circuiting against the truck s axle Failure to insert the insulator could permanently damage the coupler and PS 2 board Shown above is the coupler unassembled Shown here is the insulator attached to the truck and coupler Ensure that the part of the insulato...

Page 43: ...if available Return Authorization number if required by the service center a copy of your sales receipt and a full description of the problem must be included to facilitate the repairs Please include the description regardless of whether you discussed the problem with a service technician when contacting the Service Center for your Return Authorization service mth railking com Limited 90 Day Warra...

Page 44: ...ervising use examine the hobby transformer and other electronic equipment periodically for conditions that may result in the risk of fire electric shock or injury to persons such as damage to the primary cord plug blades housing output jacks or other parts In the event such conditions exist the trains set should not be used until properly repaired Do not operate your layout unattended Obstructed a...

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