Lionel ElectroCoupler Upgrade Kit Instruction ManualTable of contents Congratulations! Congratulations on your purchase of the Lionel ElectroCoupler Upgrade Kit!These couplers are

72-4141-2501/04

LionelElectroCoupler

Upgrade KitInstruction Manual

Table of contents

Congratulations!

Congratulations on your purchase of the Lionel ElectroCoupler Upgrade Kit! These couplersare activated by commands from your CAB-1 Remote Controller, so you can release the

couplers anywhere on your layout without an Uncoupling Track section.

A Command Control Upgrade is necessary for ElectroCoupler operation.

Follow the steps in this instruction manual to replace the magnetic couplers on your diesellocomotive or your steam locomotive’s tender. For more specific instructions about yourparticular locomotive, see the owner’s manual for that product.

Two ElectroCouplers Kits are required for diesel locomotives.

Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive 3-8

Installing ElectroCouplers on your early GP-9 diesel locomotive 9-13

Installing ElectroCouplers on your more recent GP-9 diesel locomotive 14-17

Installing an ElectroCoupler on the tender (steam locomotives) 18-19

Limited Warranty/Lionel Service 20

2

Note!

Note!

The following Lionel marks may be used throughout this instruction manual and are protected under law.All rights reserved.

Lionel®, TrainMaster®, Odyssey®, RailSounds®, CrewTalk™, TowerCom™, DynaChuff™,StationSounds™, Pullmor®, ElectroCoupler™, Magne-Traction®, CAB-1 Remote Controller®,PowerMaster®, Lionel ZW®, ZW®, PowerHouse®, TMCC®, Lionelville™, Lockon®

Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive

1. Remove the body. Refer to the locomotive’s manual for the location of the body screws.

2. Remove the Phillips-head screw from the recessed hole in the bottom of the truck. Referto Figure 1.

3

Figure 1. Screw locations (underside of the truck)

C-420 SD-60/70 Dash-9

Removethis

screw

Removethis

screw

3. Locate and remove the pick-up roller mounting screw on the top of the truck. This screwis visible in front of the motor through the slot in the frame. The pick-up wire is attachedto this screw. Refer to Figure 2 on page 4.

With this screw removed, the pick-up roller assembly will disengage from the truck.Note!

Installing ElectroCouplers on your C-420, Dash-9, SD-60, or SD-70 diesel locomotive (continued)

4. Dash-9 Locomotives only. Position the truck as if the locomotive was travelingstraight forward so that a second screw is visible through the slot in the frame, thenremove this screw. Refer to Figure 3.

4

Figure 2. Pick-up roller screw

Removethis

screw

Removethis

screw

Figure 3. Extra screw on Dash-9 locomotives

Remove this screw

C-420 Dash-9 SD-60/70

Motor

Motor

Motor

Frame Frame Frame

Motor

Frame


5. Lift the truck away from the frame.

6. Compress the washer and the spring under the C-clip, then remove the C-clip with a pairof needle-nose pliers. Carefully release the spring and washer after the clip is removed.Refer to Figure 4.

Carefully release the spring and washer to avoid launching them off the post. Werecommend wearing safety glasses.

5

Figure 4. Components on the retaining post

Caution!

C-Clip

Washer

Spring

Washer

RetainingPost


6

Figure 5. Pilot removal

7. As illustrated in Figure 5, remove the pilot from the truck. Allow the retaining post to dropout of the truck far enough to remove the old coupler and to install the ElectroCoupler.


7

8. Slide the entire coupler out through the pilot.

9. Insert the ElectroCoupler and its two wires through the front of the pilot and under themounting boss.

10. Push the retaining post through the hole in the shank of the ElectroCoupler.

11. Pass the ElectroCoupler wires up through the round hole in the pilot, then reinstall thepilot.

12. Slide the metal washer, the spring, and the fiber washer (in this order) down the retainingpost as illustrated in Figure 6.

13. Compress the spring and washers, then re-install the C-clip.

Carefully release the spring and washer to avoid launching them off of the post.We recommend wearing safety glasses.

14. Route the coupler leads through the frame. The wires should follow the truck’s pick-upwires.

15. Insert the ends of the ElectroCoupler wires into the two-pin connector that was includedwith the upgrade kit.

16. Plug the connector into the circuit board as illustrated in Figure 7 on page 8.

The location of this connection will vary.

Caution!

Figure 6. ElectroCoupler installation

C-Clip

Fiber Washer

Spring

Washer

RetainingPost

Note!


17. Carefully bundle the wires together and keep them clear of the motor and truck guides.

18. Reposition the motor. Be sure that there are no gaps between the motor mounting plateand gear box.

19. Reinstall that motor screw on the bottom of the truck.

20. Replace the pick-up roller screw. Pass the screw through the metal washer with the pick-up wires and then the insulating grommet. On the bottom on the truck, reposition thepick-up roller so that the roller is seated on the plastic insulating surface.

21. Dash-9 locomotives only. Replace the extra screw on the top of the truck. Refer backto Step 4.

22. Repeat this process for the other ElectroCoupler.

23. Reinstall the body, taking care not to pinch any wires between the frame and the body.

8

J3

J8

Figure 7. Plugging in the connector

Front

Rear

Installing ElectroCouplers on your early GP-9 diesel locomotive

1. Remove the body of the locomotive. Refer to your owner’s manual for the location of thebody screws.

2. Remove the screw from the bottom of the motor truck, then lift it away.

To release the rear truck, remove the retaining clip from the mounting pin, then liftaway the truck.

3. Compress the washer and the spring under the retaining clip, then remove the retainingclip with a pair of needle-nose pliers. Carefully release the spring and washer after theclip is removed. Refer to Figure 8.

The spring and washer will launch off the truck if you are not careful. Eyeprotection is recommended.

9

Caution!

Figure 8. Removing the magnetic coupler

C-Clip

Washer

Spring

Washer

RetainingPost

Note!

Installing ElectroCouplers on your early GP-9 diesel locomotive(continued)

10

4. At this point, the retaining post will drop down. Simply remove the retaining post andslide the magnetic coupler through the pilot.

5. Slide the ElectroCoupler and the two wires through the pilot and under the mountingboss.

6. Push the retaining post through the ElectroCoupler’s shank.

7. Slide on a washer, the spring, and then another washer. Refer to Figure 9.

Figure 9. Installing the ElectroCoupler

C-Clip

Fiber Washer

Spring

Washer

RetainingPost


8. Compress the washers and spring and replace the retaining clip.


9. Route the coupler wires up through the frame through the openings shown in Figure 10.

11

FU

LL

RS

SIG

NA

L

RU

N

LCR

U

PR

OG

Figure 10. Routing the wires through the frame

Caution!


10. Reposition the truck, motor and the spring plate, then replace the screw on the undersideof the motor truck.

To install the rear truck, reposition the truck and install the retaining clip.

11. Repeat steps 2 through 10 for the other truck.

12. Notice that the ends of the ElectroCoupler wires are fitted with crimped metal ends. Cutoff and strip the end of one wire from each of the ElectroCouplers. In other words, eachElectroCoupler should have one wire with a crimped metal end and one wire with astripped end.

13. Identify the method of connection for your locomotive and connect the ElectroCouplerwires (one from each coupler) as discussed below.

Black wires with a wire nutOn some locomotives, the ends of all the black wires are bundled in a wire nutconnection. Refer to Figure 11. Remove the wire nut from the bundle and twist thestripped ElectroCoupler wires (one from each coupler) with the bundled wires. Replacethe wire nut to secure the connection.

Soldered connectionsOn other locomotives, the ends of all the black wires will be connected to a solder lugmounted to the frame in front of the electronics boards (beside the motor). Refer toFigure 12 on page 13. Solder the two stripped ElectroCoupler wires (one from eachcoupler) to the solder lug. Alternately, you may choose to loosen the solder lug screw,wrap the wires around the post, and gently tighten the screw.

14. Locate the two-position female connector packed with your ElectroCoupler. Insert theremaining two ElectroCoupler wires (with crimped ends) into the connector as illustratedin Figure 11.

12Figure 11. Wire connections

Wire nutRearElectroCoupler

FrontElectroCoupler

Metalprojections

Tabs

Note!


15. Plug the two-pin connector into the bottom portion of the connector mounted to thecircuit board.

The position of the connector may be different in your locomotive. Consult yourowner’s manual.

13

• Be sure the crimped metal projection is inserted so that it snaps in place below the connectortabs.

• Looking at the side of the connector with the tabs, the rear ElectroCoupler should be insertedinto the right slot and the front ElectroCoupler should be inserted into the left slot.

Be sure to position the couplers in these slots for proper functioning.Note!

16. Be sure that the wires are clear of the motor and truck guides. We recommend that youbundle the wires neatly with twist ties or tape for added protection.

17. Replace the body and the body screws, taking care not to pinch any wires between theframe and the body.

Figure 12. Plugging in the connector

Note!

FRONT/CAB

Solder lug

14

Installing ElectroCouplers on your more recent GP-9 diesel locomotive

1. Remove the body of the locomotive. Refer to your owner’s manual for the location of thebody screws.

2. Remove the screw from the bottom of the motor truck, then lift it away.

To release the rear truck, remove the retaining clip from the mounting pin, then liftaway the truck.

3. Compress the washer and the spring under the retaining clip, then remove the retainingclip with a pair of needle-nose pliers. Carefully release the spring and washer after theclip is removed. Refer to Figure 13.


Caution!

Figure 13. Removing the magnetic coupler

C-Clip

Washer

Spring

Washer

RetainingPost

Note!

15

Installing ElectroCouplers on your more recent GP-9 diesel locomotive(continued)

4. At this point, the retaining post will drop down. Simply remove the retaining clip andslide the magnetic coupler through the pilot.

5. Slide the ElectroCoupler and the two wires through the pilot and under the mountingboss.

6. Push the retaining post through the ElectroCoupler’s shank.

7. Slide on a washer, the spring, and then another washer. Refer to Figure 14.

Figure 14. Installing the ElectroCoupler

C-Clip

Fiber Washer

Spring

Washer

RetainingPost

16


8. Compress the washers and spring and replace the retaining clip.


9. Route the coupler wires up through the frame through the openings shown in Figure 15.

FU

LL

RS

SIG

NA

L

RU

N

LCR

U

PR

OG

Figure 15. Routing the wires through the frame

Caution!

17


10. Reposition the truck, motor and the spring plate, then replace the screw on the undersideof the motor truck.

To install the rear truck, reposition the truck and install the retaining clip.

11. Repeat steps 2 through 10 for the other truck.

12. Locate the two-position female connector packed with the ElectroCoupler. Insert the twoElectroCoupler wires (with the crimped ends) into the connector as illustrated in Figure16. Be sure that the crimped metal projections snap in place below the connector tabs.

The two wires from the rear coupler go into one connector while the two wiresfrom the front coupler go into the other. For each coupler, the wires areinterchangeable between the right and left positions.

13. As illustration in Figure 16, plug in the connectors.

14. Be sure that the wires are clear of the motor and truck guides. We recommend that youbundle the wires neatly with twist ties or tape for added protection.

15. Replace the body and the body screws.

Note!

Figure 16. ElectroCoupler connections

Front oflocomotive

Rear of locomotive

Metalprojections

Connectortabs

Rearcouplerwires

Frontcouplerwires

Note!

Installing an ElectroCoupler on the tender (steam locomotives)

1. Remove the body of the tender. Refer to your owner’s manual for the locations of the bodyscrews.

2. Remove the speaker-mounting screws. Refer to Figure 17 on page 19. Remove theRailSounds circuit board, if necessary.

3. Remove the truck-mounting screw that was located beneath the speaker to release thetruck.

4. Compress the spring under the retaining clip, then remove the retaining clip with a pair ofneedle-nose pliers. Carefully release the spring after the clip is removed.

The spring will launch off the truck if you are not careful. Eye protection isrecommended.

5. At this point, the retaining post will drop down. Simply remove the magnetic coupler.

7. Slide the ElectroCoupler and the two wires under the mounting boss.

8. Push the retaining post up, then slide on the spring.

9. Compress the spring, then press on the retaining clip.

The spring will launch off the truck if you are not careful. Eye protection isrecommended.

10. Reposition the truck, then reinstall the truck-mounting screw.

11. Route the coupler wires up through the frame, passing through the slot at the rear of theframe.

12. Reposition the speaker, then reinstall the speaker-mounting screws.

13. If there is a two-pin connector mounted to the circuit board, insert the twowires into the two-pin connector that was included with your upgrade kit. Refer to theright-hand portion of Figure 11 on page 12 and disregard the “FRONT” and “REAR”designations to make these connections. Plug the two-pin connector into the bottomportion of the connector mounted to the circuit board.

If the two-pin connector is not present, you will find a black and a brown wire.Remove the wire nut to free the wires. Cut off the ends of the ElectroCoupler wires, thenstrip the wires back about 1/4”. Connect each ElectroCoupler wire with one tender wire. Werecommend that you twist and solder the wires together, or you may install wire nuts for themost secure connections. Wrap the wires with electrical tape to avoid short circuits.

14. Be sure that the wires are clear of the body. We recommend that you bundle the wires neatlywith twist ties or tape for added protection.

15. Reinstall the tender body.

18

Caution!

Caution!

19

IInstalling an ElectroCoupler on the tender (steam locomotives)(continued)

Figure 17. ElectroCoupler installation

Truck mounting screw

Electrocouplerwires

Speaker mounting screw

Magnetic coupler

Retainingclip

Spring

Armature

Retainerclip postWhite Connector

Limited Warranty/Lionel Service

T his Lionel product, including all mechanical and electrical components, moving parts, motors andstructural components, except for light bulbs, is warranted to the original consumer-purchaser, for one

year against original defects in materials or workmanship when purchased through an authorized Lionelmerchant.

This warranty does NOT cover normal wear and tear, light bulbs, defects appearing in the course ofcommercial use, or damage resulting from abuse or misuse of the product by the purchaser. Transfer of thisproduct by the original consumer-purchaser to another person voids this warranty. Modification of this productvoids this warranty.

Any warranted product which is defective in original materials or workmanship and is delivered by theoriginal consumer-purchaser to Lionel L.L.C. or an authorized Lionel L.L.C. Service Center, together with proof oforiginal purchase will, at the option of Lionel L.L.C., be repaired or replaced, without charge for parts or labor. Inthe event the defective product cannot be repaired, and a replacement is not available, a refund of the originalpurchase price will be granted. Any products on which warranty service is sought must be sent freight or postageprepaid, as transportation and shipping charges are not covered by the warranty.

In no event shall Lionel L.L.C. be liable for incidental or consequential damages.Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above

exclusion may not apply to you.This limited warranty gives you specific legal rights, and you may have other rights which vary from state

to state.

Instructions for Obtaining ServiceIf service for this Lionel L.L.C. product is required, bring the item, along with your dated sales receipt and

completed warranty information to the nearest Authorized Lionel Service Center. Your nearest Lionel ServiceCenter can be found by calling 1-800-4-Lionel, or by accessing our Website at www.lionel.com.

If you prefer to send your product back to Lionel L.L.C. for repair in Michigan, you must first call 586-949-4100 or FAX 586-949-5429, or write to Customer Service, P.O. Box 748, New Baltimore, MI 48047-0748, stating what the item is, when it was purchased and what seems to be the problem. You will be senta return authorization letter and label to ensure your merchandise will be properly handled upon receipt.

Once you have received your return authorization and label, make sure that the item is packed to preventdamage during shipping and handling. We suggest that you use the product’s original packaging. Thisshipment must be prepaid and we recommend that it be insured.

Please make sure you have followed all of the above instructions carefully before returning anymerchandise for service. You may choose to have your product repaired by one of our Authorized Lionel ServiceCenters after its warranty has expired. A reasonable service fee will be charged.

Warranty InformationPlease complete the information below and keep it, along with your dated sales receipt. You must present

this and your dated sales receipt when requesting warranty service.

Name ________________________________________________________________________

Address ______________________________________________________________________

Place of Purchase ________________________________________________________________

Date of Purchase ________________________________________________________________

Product Number ________________________________________________________________

Product Description ______________________________________________________________

©2004 LIONEL L.L.C., CHESTERFIELD, MI 48051-2493UNITED STATES OF AMERICAPRINTED IN U.S.A.

Documents

Lionel ElectroCoupler Upgrade Kit Instruction ManualTable of contents Congratulations! Congratulations on your purchase of the Lionel ElectroCoupler Upgrade Kit!These couplers are