This installation documentation is for the N-scale Kato F40PH. The Amtrak version of this model features a slightly different internal configuration, most notably the lack of directional markers as found in the Metra and ONP versions. This installation uses the K0D8-C decoder and was performed by TCS.
Shown above the Kato EMD F40PH locomotive prior to installation.
To remove the shell, lift from the front and release the clips along the side that clip it in place. It may be necessary to use a small screwdriver to release the sides.
Shown here the original light board to be removed.
To remove the original board, start by removing the plastic retaining clip shown here.
With the retaining clip removed, lift the motor contacts upward as shown. Then slide the board forward slightly to release it from the other clip.
Shown here with the original board removed.
To convert this model to DCC, it is required that the track power rails that run along the model be insulated. To remove them, start by releasing this plastic piece from both ends of the chassis.
Shown here with the track power rails removed.
We use Kapton tape wrapped around the rails to insulate the motor from the track power. This is REQUIRED!
Note the locations of the motor contacts on each rail, then wrap the tape around each rail one full revolution, ensuring that the joint in the tape is toward the inside of the body and not against the motor pickup.
Reinstall the track power rails and plastic covers.
Next, place the decoder into place and slid it backwards into the rear clip to hold it in place.
Once the decoder is properly seated, fold the motor contacts down to touch the K0D8-C decoder.
The plastic retaining clip can be re-used to hold the motor contacts onto the decoder and hold the decoder itself in place.
Optionally you can solder the contacts to the board as shown. TCS recommends this method as it offers a more reliable connection.
Your Kato N-scale F40PH is now TCS-equipped and ready to roll!
Important Soldering Tip
Please do not use any flux either liquid or paste on the mother board. Over time, the acidic properties of liquid or paste flux will begin eating away at the fiberglass PCB and will damage it. Use only Rosin-core solder or no-clean flux approved for electronics use.
TCS recommends the use of Kester "44" Sn63 Pb37, .015" diameter Rosin-core solder. Kester part number 24-6337-0007.
You can order this solder from the following retailers:
Digikey - PN:KE1110-ND
Techni-Tool - PN:488SO6775
Other solder tips
When stripping wire, only strip a tiny little bit of the insulation. Strip no more than a 1/32 of an inch. When the wire gets tinned with solder, the insulation will shrink back more. Try to not expose any more wire than half the length of the solder pad at most. In no case should solder or exposed wire wire ever be outside the boundary of the the solder pad you are attaching a wire to.
Click here for important information on properly Stripping and Tinning wire