Jonathan,

Thanks for responding.  I'm helping a friend out with the loco.  It is in a 2008 vintage K4.  The decoder is a factory installed Tsunami.  Going the warranty route is off the table.  The loco has been upgraded using a secondary TCS FL4 decoder to support a tender backup light, cab light and working marker lights.  When I got the loco for testing, all the sounds and lighting worked, but there was no movement.

First, I visually checked the gearing and it all looks good (i.e., no cracked axle or idler gears).  I then checked the running gear and it all works silky smooth.  Since I had to remove the motor to perform these test, I also bench tested the motor by attaching it to a DC power source.  The motor barely ran and emitted smoke almost immediately.

I then attached the loco's DCC motor leads to a Sagami can motor I keep handy for decoder testing.  The motor ran as expected in both directions.  This confirms the decoder is still functional.  Thus, my determination that the factory motor was "cooked."

Tom

Folks,

I have one of the newer Spectrum K4's and the motor is "cooked."  Is anyone aware of any aftermarket remotoring kits?  I checked the NWSL web site and couldn't find any direct replacement kits listed.  I'm hesitant to purchase a Bachmann replacement for it because the loco has relatively little run time on it and I have to wonder how long an identical replacement will last.  Any help is appreciated.

Tom

You have a couple of options, but you will need to do the sound installation yourself.  ESU LokSound offers a couple of different sound sets you could use. You will need to check their web site to listen to the sound samples.  Or, what I did was install a SoundTraxx Tsunami TSU-750 GE Cummins Diesel decoder.  My story for using the Cummins diesel sound was that the railroad had modernized the unit by replacing the old motor with a more powerful and reliable diesel.

For my installation, I hardwired the decoder.  I did this in part because I changed the headlight to a 0603 SMD LED and also added a backup light (again using a 0603 LED).  There is adequate room on the plastic tray above the motor to mount the decoder.  I installed a mini oval speaker in the passenger compartment.  I mounted it to the floor near the baggage compartment bulkhead.  I did have to trim the first few rows of seats to make room for it.  I essentially cut away the seat portion nearest the isle and left The outer seats nearest the window in tact.  I then added a few figures in those seats.  This makes the speaker nearly invisible.

Good luck,

Tom

Fred,

My experience, if you talk to someone in person the service is wonderful.  If I send e-mail or leave voice mail, I never get a response.

Tom

Thanks for this is timely information.  I just had cracked gear failure on my Shay this past Tuesday during my monthly operating session.

Tom

Here is what has worked for me.  I weigh all my cars at 4 oz regardless of car length.  (Some longer cars may already be over that weight, and that is OK.)

I have a large home layout with two steep helper grades.  One of these grades twists and turns for over 50 actual feet as it climbs from the lower deck to the upper deck on my layout.  The other is a multi-turn helix.  I run up to 35 car coal trains on these grades with rear end helpers.  I find the consistent weight of the cars promotes very smooth operations.  The weight is heavy enough to keep the cars on the rails except for the "heavy handest" helper crews who attempt to push way too hard.  You also don't have to worry about having too heavy of cars at the rear of the train dragging cars off the rails ahead of them.

Tom

One of the branch lines on my layout has a 15" radius curve.  I did this on purpose to represent the remnant of a logging line that dated to the late 1890s.  The Bachmann 3 truck Shay goes around it regardless or orientation of the drive shaft.  I can't say that it likes it, but goes around it.  However, I did have to install a guard/guide rail next to the inside of the curve rail to keep it from derailing.  Without it, the lead truck wanted to "walk" up over the outside rail.   The branch uses code 55 rail, so that may also be part of the issue.

Tom

I received the promised replacement set of replacement wheelsets from Bachmann today.  As I inspected them for cracks just to be sure no defective ones were received in this shipment, I noticed that the design of the gear has changed a bit.  The thickness of the plastic axle portion on the "short side" nearest the gear has been visibly increased.  I didn't check the dimensions with a micrometer, but it appears to be twice as thick as the former casting.  I am sure this is intended to prevent the splitting in this location that would work its way all the way to the drive gear.  When the actual gear splits that is when the mechanism binding and erratic operations takes place.

The longer side of the axle casting appears to be the same thickness as the original ones.  I surely hope they recalculated the plastic's shrink rate and allowed for it.  I had several of my original axle castings crack on the long side as well, but none of these splits went all the way to the gear.

At this point, I am cautiously optimistic.  But, only time will tell if the problem has been adequately addressed.  However, at least it appears that Bachmann is trying to correct the problem.

Tom

I recently communicated with the folks at NWSL.  They indicated they have received some request for aftermarket replacement axle gears for the GE 44 toner.  However, demand thus far has been less than what they need to make this a priority project/product for them.

Tom

I called and spoke to the Bachmann Parts Department manager today.  A very pleasant lady.  Bachmann is sending me 4 replacement wheelsets to replace the cracked ones I just received from my recent on-line order.  A satisfactory "adjustment" was also made on the two drives I purchased from their on-line store back in December that were received with cracked gears.

It is too bad we are having to deal with this cracked gear problem.  I have Kato, Kato/Stewart, and Athearn locos that are decades old and I've never had a cracked gear.  Some smart mechanical engineer needs to do a better calculation on the shrink rate for these gears and build some tolerance in to account for it.

Regards,

Tom

To say that I am completely dissatisfied with Bachmann and its parts and service department at this point is a gross understatement.  After a month they have still not responded to my service ticket about receiving two DCC ready complete drives from their on-line store that arrived with 7 out of 8 cracked axle gears.

So, while waiting for my warranty issue to be acknowledged (let alone resolved), I ordered and paid for 2 sets of replacement wheelsets from the on-line store (I want to run them at my monthly operating session next week).  Well today the replacements I paid for arrived.  Much to my displeasure, 4 of the 8 replacement wheelsets arrived with cracked axle gears.  This is really troubling because in my order I requested that the replacement gears be inspected for cracks prior to shipment.  Obviously, this was not done.

In retrospect, I should have known better.  As I look closely at the parts photo shown in the on-line store I see where it shows cracked gears. 

Regards,

Tom

Andy,

Yes, the 4 functions of the TCS FL4 can be programmed to recognize forward and reverse direction.  Go to the TCS we site and look at the section for manuals.  The FL4 manual shows what CVs need to be set to which values to control this.  It also provides on instructions for getting them to flash in an alterating manner.

Also take a look at the advanced programming features manual.  It provides instructions on how to remap the function control keys.  For example, you can map the FL4s lighting functions to be activated by pressing the bell button.  In essence, pressing bell would activate both the bell and flashing ditch lights.  Turn the bell off, and the flashing will stop.

If things don't work out as you expect on the first try, don't worry.  You can simply reporgram the FL4 to factory settings and start the programming fresh.

Tom

Yes, your understanding is correct. 

Tom

Normally, something like this wouldn't bother me too much.  However, the fact that 12 cents worth of plastic is keeping from using/enjoying a considerable investment in Tsunami decoders/speakers and a significant amount of modeling time is downright annoying.  For now, I've got two very expensive static display models.

Tom

Sadly, I just encountered the same malady.  In December I purchased two new DCC-ready GE 44 ton chassis from the Bachmann on-line store to upgrade my older Western Maryland units to DCC with Tsunami sound.  I just completed both units this evening and during test running I discovered that they seemed to bind and then surge ahead only to bind and surge again repeatedly.  Obviously, this is not normal.

Upon closely inspecting the drives, much to my dismay, I discovered that one unit had all 4 drive axles/gears split.  The second unit had 3 of its 4 axles/gears split. 

Needless to say, I have submitted a service ticket to Bachmann for corrective action.

Tom