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

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DIESEL/ELECTRIC
LOCOMOTIVE UPGRADE KIT
INSTALLATION MANUAL
2nd Edition
Compatibility
This Proto-Sound 2.0 Diesel/Electric Locomotive Upgrade Kit is compatible with any AC
or DC Powered locomotive equipped with a DC can motor(s) and motor flywheel(s). The
locomotive must be large 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.
WARNING:
Authorized Conversion Center.
PLEASE READ BEFORE USE AND SAVE FOR REFERENCE

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

  • Page 1 2nd Edition Compatibility This Proto-Sound 2.0 Diesel/Electric Locomotive Upgrade Kit is compatible with any AC or DC Powered locomotive equipped with a DC can motor(s) and motor flywheel(s). The locomotive must be large 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.

  • Page 2: Table Of Contents

    Table of Contents ................... Contents Of The Kit. Required Tools................................... Upgrading Multiple-Unit Diesels Locomotive Inspection & Review ..........................Preparing The Chassis For the Upgrade ......... Installing The PS-2 Components Onto the Chassis Mounting The PS-2 Board..............Installing The Proto-Couplers............... PS-2 Chassis Wiring Diagram...............

  • Page 3: Contents Of The Kit

    Contents Of The Kit A) PS-2 Board and Plastic Bracket III) Battery Charging Jack Hardware (2) AA) PS-2 Heat Sink Bracket J) Ditch Lights (2) B) Mars Light (2) K) Interior Lights L) Overhead Blinking Light C) Proto-Coupler (2) M) 6/32 x 6mm Screws (3) CC) Coupler Insulator (2) N) 6/32 Nuts (3) D) Backup Light...
  • Page 4 (G) Headlight (E) Marker Light- Red EE)Marker Light - Green (H) Speaker BF-0000034 (F) 7-Pin Chassis Harness w/Tach Reader (I) AA NiCad Battery Pack BG-4000003 (FF) Tach Reader Bracket IH-0000389 (II) Battery Charging Jack BC-1000004 (FFF) Tach Tape BE-0000151 (III) Battery Charging Jack Hardware PS-2 Upgrade Kit Installation Guide...
  • Page 5 (J) Ditch Lights (Q) Wire Management Coil (R) Wire Ties (K) Interior Lights (L) Overhead Blinking Light (S) Foam Tape (M) 6/32 x 6mm Screws IA-0000027 (T) Wire Nuts (BI-4500003) (N) 6/32 Nuts TP-MS00075 (U) Speaker Plug (O) 6/32 x 8mm Screw IA-0000050 (V) Smoke Unit Wire Harness (P) Shrink Tubing...
  • Page 6 (W) 8-Pin Chassis Harness (X) 5-Pin Motor Harness (Y) 12-Pin Chassis Harness PS-2 Upgrade Kit Installation Guide...

  • Page 7: Required Tools

    Required Tools - Soldering iron - ESD safe work area - White thermally conductive grease - Screw drivers, Philips #2 & #00 - Wire cutters - Drill - Drill bits (1/8”, 5/32”) - Drill bit (3/8” or ½”) or de-burring tool - Electrical Tape - Razor Saw - Proto-Sound Battery Charger (M.T.H.

  • Page 8: Upgrading Multiple-Unit Diesels

    This kit does not provide connections for lights in non-powered (dummy) units. Non-powered Proto-Sound One units with constant- voltage 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.

  • Page 9: Locomotive Inspection & Review

    Inspection & Review Before beginning the installation, Inspect the engine to be upgraded and verify the following are in good working order: - Pick-up rollers - Motor w/flywheels - Smoke unit (if equipped) - Speaker mounting hardware Note: Before beginning - Volume pot installation, see discussion - Coupler mounting hardware,...

  • Page 10: Preparing The Chassis For The Upgrade

    Preparing The Chassis For The PS-2 Upgrade Before you can install the PS-2 components into your locomotive, any existing sound boards or reversing units must be removed. The PS-2 Kit contains all the necessary electronics your locomotive requires to operate. Some existing mounting brackets may be utilized during the installation of the PS-2 components.

  • Page 11: Installing The Ps-2 Components Onto The Chassis

    Installing The PS-2 Components Onto The Locomotive Chassis Once the existing electronic components have been removed from your locomotive, begin locating the best mounting position for the PS-2 components. The major components are the PS-2 board, PS-2 Heat Sink Bracket, the speaker and the rechargeable battery pack.

  • Page 12: Mounting The Ps-2 Board

    Mounting The PS-2 Board -Remove the PS-2 Board (A) from the sealed anti-static bag -Verify PS-2 board is securely inserted into its plastic mounting bracket. NOTE: If you are not a participating MTH Authorized Service Center there is NO warranty once Make sure the PS-2 board is firmly inserted the bag is opened into the plastic mounting bracket.
  • Page 13 Mounting The PS-2 Board Cont’d - Once you have determined the best locations for mounting the PS-2 Board bracket (A), metal heat sink bracket (AA), battery pack (I), and battery charging jack (II), mark the chassis floor locations using a pencil or silver marker so you can drill the holes in the proper locations.
  • Page 14 Mounting The PS-2 Board Cont’d - Mount the plastic mounting bracket (A) containing the PS-2 board using 2 of the screws (M) and nuts (N) Mount the PS-2 plastic mounting bracket - Apply white thermally conductive grease to the bridge rectifier on the PS-2 board.

  • Page 15: Installing The Proto-Couplers

    Mounting The PS-2 Board Cont’d - Secure the metal heat sink bracket (AA) to the bridge rectifier using screw (O) Note: If screw is too long, cut it down so it does not hit the relay -Secure the heat sink bracket to the chassis floor using screw (M) and nut (N).

  • Page 16: Ps-2 Chassis Wiring Diagram

    PS-2 Chassis Wiring Diagram PS-2 Upgrade Kit Installation Guide...
  • Page 17 PS-2 Board Connections 5 PIN 7 PIN 4 PIN 12 PIN 2 PIN 8 PIN PS-2 Upgrade Kit Installation Guide...

  • Page 18: Installing The Chassis Harness

    Installing the Chassis Harnesses, Speaker & Smoke -Attach 12, 8, 7, and 5- Pin Chassis Harnesses to the PS-2 board (A) noting that each plug is polarized and has a different number of pins. Take care to insert the correct plug into the correct connector on the PS-2 board.

  • Page 19: Soldering Speaker Connections

    Soldering Speaker Connections -Solder the yellow and white wires (U) to the speaker (H) making 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).

  • Page 20: Installing The Battery, Recharging Jack & Volume Pot

    Installing The Battery, Recharging Jack and Volume Pot -Plug the 2 pin battery pack connector into the PS-2 board. CAUTION: Position the battery pack close enough to the PS-2 board so it does NOT require lengthening of the battery pack or battery recharging port harnesses.
  • Page 21 -Solder the wires from the 12-pin chassis harness to the existing volume pot. Red wire to the center terminal, blue to one outer terminal and gray to the other outer terminal. Note: Volume pot not required for command operation. Solder gray and red wires together to get full volume in Solder the red, blue and gray volume pot wires to the...

  • Page 22: Installing The Tach Reader Bracket

    Installing Tach Reader Bracket -Based on the motor type, install the tach reader mounting bracket (FF). The bracket is snapped into place on a Mabuchi or similar motor by spreading it open and sliding it under the flywheel. It may be necessary to use tape or epoxy glue to hold the bracket in position.

  • Page 23: Mounting The Tach Reader To The Tach Bracket

    Mounting Tach Reader To Tach Reader Bracket -Insert the tach reader into the tach reader bracket. -The gap between the optical sensor and flywheel should be 0.5mm (0.022”)-1.5mm (0.060”); 0.75mm (.030”) is optimum. When inserted into the tach reader bracket, the distance between the tach -If the gap is too large, decrease the reader and the flywheel should be between tach reader space between reader and...

  • Page 24: Connecting Motor, Ground & Pickup Wires

    Connecting Motor, Ground & Pickup Wires -Solder the yellow and white wires from the 5-pin motor harness to the motors. As noted on page 10, observe the wire color code of the previous electronics to ensure both motors turn in the same direction. If the engine starts out in the reverse direction, you will later need to reverse the yellow and white wires to the motor.
  • Page 25 Connecting Lights (cont’d) 1. Connect the Front Headlight with blue connector (G) to blue connector with sky blue & purple wires. Install the Rear Backup Light with green connector (D) to the green connector with green & purple wires. 2. Connect Marker light with yellow connector to the yellow connector with orange w/white stripe &...

  • Page 26: Connecting Smoke Unit To The Harness

    Connecting The PS-2 Harness To The Smoke Unit -Soldering Gray and Green wires to Green Wire the smoke unit fan motor. If the smoke unit motor terminals are Gray Wire hooked up backward, the impeller will spin in reverse and fail to pump out the smoke.

  • Page 27: Wire Management/Short Circuit Prevention

    Connecting The PS-2 Harness To The Smoke Unit Cont’d -Solder the heating pads together at both sides on the top of the board by adding more solder. Then solder the Brown wire from the smoke unit wiring harness to one pad and the Purple to the other (the pads are interchangeable).

  • Page 28: Testing The Ps-2 Installation

    -Fire the coupler using the combination signal in conventional mode or the digital signal with the DCS remote. -Press the direction button and verify the engine stops. -Press the direction button again and verify the engine moves in reverse direction and that the headlight and back-up lights work properly.

  • Page 29: Loading Proto-Sound 2.0 Files Into Locomotive

    PS-2 Conversion File for your engine type. Programming can only be accomplished with the M.T.H. DCS Digital Command System and the free DCS Loader Program. Both the Loader Program and the PS-2 Conversion Files can be found on the Proto- Sound website (www.protosound2.com).
  • Page 30 STEP 1: Go to the Sound Sets page on the Proto-Sound website 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 STEP 2: Fill out the Search Fields to find the locomotive you are upgrading.
  • Page 31 STEP 3: Click on the photo of the engine you are upgrading. Select your locomotive from the search results by clicking on the appropriate photo. STEP 4: Scroll to the bottom of the page and right click the Proto-Sound 2.0 Conversion File link to download it to your computer.

  • Page 32: Proto-Sound 2.0 Operation Instructions

    Conventional PS-2 Operation This manual contains the operating instructions for Proto-Sound 2.0 in conventional mode only. Instructions for accessing DCS command mode features accompany the DCS Remote Control System equipment. Activating Features Throttle To increase or decrease track voltage, and therefore train speed, turn the throttle control knob.
  • Page 33 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 buttons very quickly with a ½-second pause between button presses.
  • Page 34 Passenger Station Announcements (PSA) Your engine is equipped with a sound package of passenger station announcements that you can play when you pull into a station. Each sequence described below will play as long as it is left on, randomly generating sounds, but be sure to allow approximately 30 seconds between the button pushes described below to allow the PSA sufficient time to run through each sequence.
  • Page 35 Tips on Using PSA • You can terminate PSA at any time by turning off power to the track for 15 seconds. • You do not have to be in Forward to use PSA. At the conclusion of the full sequence, the train will pull away from the station in whatever direction you were going when you activated the feature.
  • Page 36 Front Coupler: To fire the front coupler (if your engine has one), quickly tap the Bell button once followed by four quick taps of the Horn button, allowing approximately ½ second to lapse between each quick button press. The sound of the lift bar and air line depletion will play, and the knuckle will be released.
  • Page 37 Locking Locomotive Into a Direction You can lock your engine into a direction (forward, neutral, or reverse) so that it will not change directions. To do this, put the engine into the direction you want (or into neutral to lock it into neutral), run it at a very slow crawl (as slowly as it will move without halting), and quickly but firmly tap the Horn button once followed by three quick taps of the Bell button, allowing approximately ½...

  • Page 38: Self-Recharging Battery

    Self-Charging Battery Back-Up The two special AA 2.4 NiCad Battery Pack recharges continuously during train operation and should last for up to five years. The batteries are dry battery that should not leak or cause any damage to your engine. Depending upon when your engine was built, they may need to be charged right out of the box.

  • Page 39: Troubleshooting

    Troubleshooting Proto-Sound® 2.0 Problems Although Proto-Sound 2.0 has been designed and engineered for ease of use, you may have some questions during initial operation. The following table should answer most questions. If your problem cannot be resolved with this table, contact M.T.H.
  • Page 40 Cab Chatter Remedy Sometimes the Cab Chatter sounds Cab Chatter plays only in neutral at don’t play. random intervals. Lock-out Remedy I can’t get the engine to run after I The engine is locked into the neutral power up the transformer. It sits still position.
  • Page 41 Remedy Once in FYS, the engine doesn’t go So that FYS effects can be as realistic into reverse. Proto-Sound 2.0 as possible, 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.

  • Page 42: Coupler Insulator Installation

    PS-2 Upgrade Kit- Coupler Installation A plastic insulator, item CC in the parts list of your Proto-Sound 2.0 Upgrade Kit, has been included with the rest of your PS-2 Upgrade Kit parts. Shown above is the coupler unassembled. This insulator should be inserted between the coupler and the spring, washer and the coupler to the T-Bar and truck bolster.

  • Page 43: Service & Warranty Information

    Service & Warranty Information How to Get Service Under the Terms of the Limited Warranty When you suspect an item is defective, please check the operator's manual for standard operation and trouble-shooting techniques that may correct the problem. Additional information may be found on the M.T.H.
  • Page 44 CAUTION: ELECTRICALLY OPERATED PRODUCT: Not recommended for children under 10 years of age. M.T.H. Recommends supervision with children ages 10-16. As with all electric products, precautions should be observed during handling and use to reduce the risk of electric shock. WARNING: When using electrical products, basic safety precautions should be observed, including the following: Read this manual through before using this device.

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