This installation is for a HO Scale Broadway Limited E3 / E6 using a TCS WOW121 Diesel Decoder, AK-MB1 Motherboard with built in Keep Alive®, motor mount, UNIV-SH3-C WOWSpeaker kit, and 28mm High Bass Speaker.
HO-Scale Broadway Limited E3 / E6 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, gently pull outwards on each side of the frame, lift the shell off of the frame. Take care to release the ladders as you lift off the shell so they don't break.
The Broadway Limited E3 / E6 shown with the shell off. Remove the wires from the original lighting board, remove the four screws and remove it from the chassis. You can also remove the rear electronic board and other components along with the front cab section.
With the lighting board components removed, clip off the connector ends, trim, trim 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 all the screws from the top of the plastic platform and set it aside. It will need to be modified to accommodate the new speakers.
Shown with the platform removed. The existing speakers and rubber gaskets beneath them can be discarded.
Using a sharp blade or cutting tool, remove the portions highlighted above in red. On the rear of the board, ensure you do not cut the screw holes off. With this complete, the remaining platform sections can be replaced with the saved screws.
The locomotive shown ready to accept the motherboard and new speaker components.
Using foam and double-sided tape, mount the motor mount to the frame. Then using the same tape, secure the AK-MB1 to the motor mount as shown. Solder the track and motor leads to the motherboard according to the included wiring diagram.
On the bottom of the cab section, there is a lighting board for the front headlight and marker lights. Highlighted in red are two small resistors that must be bridged as TCS motherboards include on board current limit resistors for LED use. There is no need to apply external resistors for LED use. To bridge them, simply solder a small piece of wire across the resistor ends as shown. With this complete, the cab section can be reinstalled.
You can now solder the front LED lighting wire leads to the AK-MB1 as according to the included wiring diagram.
With the 20mm WOWSound speaker inserted into the UNIV-SH3-C, set this assembly face down on the the front platform as shown and using a small amount of hot melt glue, secure this to the plastic platform. If your speaker enclosure installation covers the portholes on the enclosure, we recommend adding new port hole(s) similar to the original porting. Be sure that the new portholes are the same size and amount of the original and are vented freely into the locomotive We have found introducing a port of the correct size greatly increases the volume and sound quality of the installation. Too much or too little porting decreases the sound quality. 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.
To prepare the new WOWSound 28mm Hi Bass speaker for installation, carefully remove the plastic cover from the speaker rim, exposing the adhesive underneath.
With the speaker prepared, place it centered face down onto the rear speaker opening. Press it for a good secure fit.
To utilize both speakers in this installation, they must be wired in series. This means that one lead will go from one speaker pad to one solder point on the front speaker. The lead from the other solder point will go directly to the rear Hi Bass Speaker. The final lead connection will go from the second solder point on the Hi Bass Speaker back to the remaining speaker pad on the motherboard. This, in effect, creates a 'loop' from the motherboard through each speaker back to the motherboard.
Now with the High Bass two-speaker setup on board: to maximize the sound output, place a barrier tape over the open ports in the shell.
You can now plug in your WOW121 decoder.
Lastly, in order to keep the wires neat and prevent possible shorts, lace the wires into a bundle using lacing cord, which is a wax impregnated string used for wire bundling and making harnesses. There are many choices of lacing cord available from Digikey www.digikey.com. We use part number 802534B BK032-ND
Close up the locomotive and reinstall the coupler assemblies. Be sure to be mindful of wire routing and reassembly of the shell as to not damage or foul the installation. Your Broadway Limited E3-6 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