This installation is for a HO Scale Broadway Limited EMD SD40-2 using a TCS WOW121 Diesel Decoder, AK-MB1 Motherboard with built in Keep Alive® and a High Bass WOWSpeaker kit.
HO-Scale Broadway Limited EMD SD40-2 shown prior to installation.
To start off this install, we must first remove the front and rear coupler screws highlighted above and their housings. With the couplers removed, while gently pulling outwards at each end and along each side of the frame, lift the shell off of the frame. Take care to release the handrails as you lift off the shell so they don't break.
The Broadway Limited EMD SD40-2 shown with the shell off.
Remove the screws and wires from the original lighting board and remove it from the chassis. Keep the small original light distribution boards for reuse.
With the lighting board removed, snip the connectors off and trim, tin or lengthen the wire leads as needed and using small lengths of TCS 3/32" and 3/64" shrink tubing, insulate these solder leads.
Remove the two screws located underneath the chassis and release the speaker mount from the frame. Save the screws for reuse.
With the speaker frame removed, using foam double sided tape, mount the AK-MB1 motherboard to the frame and with the included wiring diagram as your guide, solder the track and motor leads to it. Reattach the front Led distribution board.
With the speaker assembly free, remove the three screws holding the frame together and remove the speaker. This will be replaced. Save these screws for reuse.
Remove the inner ring from the (right side, facing forward) speaker frame. Insert the WOWSound High Bass speaker into this frame half (speaker facing out) and using a small amount of CA glue, wick the glue around the speaker frame edge to seal it in place. We set this frame face down on a sheet of wax paper to facilitate the gluing process. NOTE: You must be very careful to avoid getting glue on the speaker cone. Glue on the speaker will ultimately cause it to produce no sound and fail.
When it is dried, reassemble the speaker frame and reattach it to the chassis being careful to properly route the rear lighting and speaker wires. Solder these wire leads along with the rear LED to the motherboard according to the included wiring diagram.
The installed speaker assembly show from the right side, facing forward. Solder the front LED assembly to the motherboard. TCS motherboards include on board current limit resistors for LED use. There is no need to apply external resistors for LED use.
You can now plug in your WOW121 decoder. Close up the locomotive and reinstall the coupler assemblies. Your Broadway Limited EMD SD40-2 is now WOWSound 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 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