ASSEMBLY
IMPORTANT: Before assembling remove burrs
or flash (if any) from all parts. Burnish (polish)
all friction bearing surfaces with #231 Greas-em
dry graphite lubricant.
To assemble the coupler follow the illustrations in
these instructions. Secured lid to the gearbox with the
#2 x 3/8" screw. Add a “puff” of our #231 Greas-em
into the draft gear box. Make sure the coupler flexes
back and forth freely.
MOUNTING
Use the #829 #1-Scale or #880 G-Scale coupler
height gauge to determine the coupler mounting
height.
Having selected the Kadee
®
Coupler best suited for
your application, turn car over and place Coupler
with Draft Gear Box in position, directly on the car
centerline. Look for obstacles which might prevent
Gear Box from laying flat in position. (NOTE: The
#
789
#
1789
Lid
Coupler
centering
springs
Coupler
Draft gear box
BODY MOUNTED COUPLER WITH EXTENDED
GEAR BOX ASSEMBLY INSTRUCTIONS
Contains:
2 ea. Couplers, 2 ea. Draft Gear Boxes, 2 ea. Draft
Gear Box Lids, Centering Springs, Knuckle Spring,
#4 x 1/2" screws, #4 x 3/4" screws, #2 x 3/8" screws,
and white plastic .010" shims.
The Kadee® #830 (G) or #820 (#1) body mounted
Coupler with standard Draft Gear Box are used
when there is ample room and for tighter radius
curves. The 789 or 1789 couplers do not swing as
far as the #830 or #820 Couplers so they are most
effectively operated on track with a larger radius.
For maximum performance, it is important that the
Coupler be mounted at the correct height, directly
on the cars' centerline. Note: If the car is going to be
changed to metal wheels this should be done first
since it may change the coupler height.
Please read through instructions carefully and
completely before proceeding.
protruding European style bumper cushion which
some LGB™ cars have, must be removed for
proper clearance. Pulling straight out and removing
half may be enough or it should be cut off as close
to the car as possible). It might be helpful to hold the
Coupler Assembly in place & check distance from
center of Coupler to top of rail using the appropriate
coupler height gauge. Once you have established
this measurement, you can determine if you must
shim Gear Box down or cut the underbody to raise
the Coupler Draft Gear Box.
If Coupler mounting surface is uneven, or too high
from the track, make one or more plastic shims to
support the Coupler Assembly. In many cases, you
can place shims on, or between, the center sills and
end sills of the car underframe to provide a solid
base for the Gear Box. Temporarily mount shims,
then set Draft Gear Box assembly in place and
mark location of mounting holes on shims. Remove
shims and drill 3/32" hole for the #4 screws in the
marked locations. Remount shims in their original
position, this time using screws to hold them solid.
If Coupler mounting surface is too low, the
underframe must be cut to raise the Coupler to the
proper height. Carefully lay out the area to be cut
so the Gear Box will be level, centered and at the
correct height. It may be best to remove most of the
material with a chisel or small saw. leaving finish
material which can be carefully removed with a fine
file until desired fit and depth is achieved. Placing
shims between the truck bolster and the car body
bolster to raise the car is an alternative to cutting
the car body underframe for some cars. Drill 3/32"
holes and secure the couple using the #4 screws.
