Cushion 50 Foot PS-1 Box Car Assembly Instructions
Body assembly:
Place the retainer valve and line on the “B” end of the body. Start with the center pin on the valve line; press it in just part of the way. Then, while keeping
the line straight, press in the other two pins just part way. Finish by pressing in the center pin and two other pins all the way.
Carefully cut the side ladders from their sprues. Place the ladder with the offset at the top. Press in the top pegs first until the curved end of the runner
touches the body surface. Press directly on top of the pegs only. Now, press in the remaining pegs to match the top ones. Note: The pegs have a taper
and should be pressed in until only the straight portion is showing. “Helpful Hint:” set all the pegs in place, then turn the body over on a flat surface.
Press down gently to apply equal pressure to all the pins.
Carefully cut the end ladders from their sprues. Fit them into their holes and press in the top pegs until the curved tips of the runners touch the body
surface. Press in the remaining pegs until they match the top. Be sure the runners are even and level, and press only on the top of the pegs.
Lay stirrups in place on underframe before attaching underframe to shell body.
Body to Chassis: Note the orientation of the brake wheel end of the body (“B” end) to the chassis. The two rods point to the B end and the air tank and
AB valve are opposite. The cone shaped end of the piston points to the B end. Make sure the tabs of the airline are in their notches on the floor (they
cannot be put in place after the body is attached). Slightly spread the body sides and fit the chassis in place. It should snap in place and be even with
the bottom edge of the body. The small tabs on the sides of the floor will be recessed into slots on the inside of the body.
Slide the rod from the bell crank between the coupler box and the floor runner under the truck into the slot in the chassis bolster cross beam. Turn it
over (which hooks the “L” end into the slot) to bring the square tab up to the slot in the floor. Hook the small lip of the tab up into the slot. The tab should
fit flush with the bottom of the floor. Slightly twist the brake wheel rod to bring the gear housing up to the rectangular hole. Press in the housing until it
snaps into the hole. Then press the pin at the center of the rod into its place.
Place the brake step into its mounting holes and press in the pins until the brackets touch the body surface. This captures the retainer valve line and
the brake wheel rod and chain.
Make sure the rod on the side of the draft gearbox sets inside of the oval of the attached cut lever.
Turn the brake wheel end (the B end) of the body toward you. Place the roof walk along the top of the car body, orienting the notch in the pegs to your
right. Starting at the B end, run your finger down the roof walk, pressing evenly so the roof walk does not get bumpy. The pegs should snap into place
(the pegs will not “snap” in if they are not positioned correctly). Carefully fit the end bracket pins into their holes and press them in until the brackets are
against the surface. Use a small flat tool or your finger nail to apply the pressure.
The sliding doors are installed by inserting them through the door openings at an angle of about 30 degrees. Hook the top guide bar behind the right
side of the door opening. The clip on the bottom left corner of the door can now be fitted into the lower left corner of the opening. Rotate the door
counterclockwise until it snaps into place. The door should slide easily without binding.
Test the car using our #205 or #206 coupler height gauges to check for the correct coupler height.
©2009 Kadee
®
Quality Products Co. e-mail: [email protected]
Kadee
®
Quality Products Co.
673 Avenue C
White City, OR 97503-1078
U.S.A.
http://www.kadee.com e-mail: [email protected]
The Coupler People
®
