This installation is for a HO-Scale Kato SD40 using a TCS WOW121-Diesel Decoder and AK-MB1. This install was performed by TCS.
HO-Scale Kato SD40 prior to WOW121-Diesel Decoder, AK-MB1, and UNIV-SH1-C installation.
To start off this install, we must first remove the front and rear couplers and their housings. Once that is complete, the shell will lift off of the chassis.
Do this by holding the fuel tank with one hand and lifting the shell off by pressing up underneath the end platforms with your other hand.
With the shell off, we can now remove the factory light board. First remove any wire clips and disconnect the wires from the board.
PLEASE NOTE: All the wires have been unclipped prior to taking the above photo.
Once the wires are loose, the factory light board can easily be unscrewed from the motor mount.
Make sure to hold onto the two screws as they will be used to secure the AK-MB1 back in place.
Now with the factory light board removed, we can now mount the AK-MB1 with the two screws removed earlier.
Next, solder your motor and pickup leads to the AK-MB1.
In order to fit the UNIV-SH1-C and illuminate the rear light, we need to do some easy prep work.
Start this by removing the shell weight and rear light optic.
With the shell weight and rear light optic removed, we can now clip flush the two gray stands that supported the end of the optic near the center of the shell.
Next, we cut the rear light optic shorter and glue an led to its newly cut end.
Once complete, we can now mount our UNIV-SH1-C WOWSpeaker Kit to the top of the shell.
Double sided tape or glue works well to keep the speaker from rattling around.
Next, we need to attach our headlight leads to the front and rear headlight pads on the AK-MB1.
For the installers convenience, the lighting pads already feature onboard current limiting resistors for LED's that Atlas and Kato models typically use.
Lastly, we need to solder our speaker leads to the AK-MB1 and plug in our WOW121 decoder.
With all three main components mounted, we can now close up the locomotive and reinstall the coupler assemblies.
Be sure to be mind full of wire routing and reassembly of the shell as to not damage or foul the installation.
You have now installed a TCS WOW121-Diesel Decoder, AK-MB1, and UNIV-SH1-C into your HO-Scale Kato SD40.
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 then a 1/64 of an inch. When the wire gets tinned with solder, the insulation will shrink back more. Try to not expose any more wire then 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