A. Attaching the Drive Unit to the Chassis

The rear of the Chassis should be trial fitted to the new drive unit's frame. By tipping the Chassis at an oblique angle where the rear of the Chassis and the rear of the drive unit touch; fit the two together. Once the rear sections are engaged, swing the front of the Chassis down over the drive unit, make sure that the wires are not in the way, by pulling them up through the Chassis. The sound pickup followers' base will be just in front of the motor and above the front drivers' electrical contact tube. As everything clears out of the way press the Chassis onto the drive unit. Once in place, the front screw on the pilot section and the screw in the rear hook section can be inserted and fastened. Note: in some cases there is no hole in the rear hook section, but there is a boss in the Chassis which will accept a screw, you will have to drill the 1/8" hole if it is missing. With these two screws in place it is time for the electrical hookup through the Chassis.

B. Electrical Connections

The drive units' pig tail wires (not stripped), pilot truck wires, and the Superstructure's light and smoke unit wires (Usually red and white) must be attached. From the note you made previously in the electrical test you should identify which of the pilot wires is attached to which of the drive unit's wires. The smoke unit/light wires are not current dependent, therefore can be attached to either pigtail (it's nice to match colors; i.e., white to white, then red to black). Two pieces of shrink tubing are provided for the pigtails to insulate your soldered connections. Slip the shrink tubing over the pigtails prior to connecting the wires. After the soldering is complete, slide the shrink tubing over the joint, apply heat from a lighter or match to shrink the tubing to a snug fit.

C. Reassembly of the Locomotive

The steam chest, cylinders, and drive rod assembly should be put in place on the pilot section. Make sure the steam chest is in firmly and sitting square. The drive rods should be attached to the center drivers' drive pin. If a spacer has been provided the drive rod is placed on the spacer between the two washers. The Hex-head screw should have either loctite or an adhesive applied to the threads, then inserted and gently tightened down.

The locomotive superstructure should be placed up-side-down into some kind of cradle or cushion. The Chassis carries a 3/4 pound cast-iron weight which should be reattached or replaced with a weight of about two to four pounds. Once this is done check the wire placement, tuck everything inside, make sure no wires are going to rest in an area which could cause any problems; i.e., near the drive gears, sound switch, etc. Place the drive unit up-side-down onto the superstructure, starting with the rear of the drive unit, fitting the sound unit on/off switch through the superstructure end plate, checking that no wires are protruding. It may take a little jockeying around but finally lower everything into place. Check that all of the screw holes line up (use a stiff piece of wire, or 1/16 rod). Insert the two screws into the bottom of the Cab. Square up the steam chest aligning on the boss protruding from the smoke box. Insert one of the side tanks in the slot in the side of the boiler. Line up the rear screw hole using a short piece of wire through all of holes in the pieces, start the screw into the front hole, but do not tighten. Fit the steam line into the small `fork' on the tank, remove the wire from the rear hole, insert the screw, tighten both screws. Repeat for the other side. Place the long screw into the center of the steam chest, tighten. Turn the locomotive over, insert the smoke box braces.

D. Testing the Assembled Drive Unit Place the locomotive on a section of powered track. Run the locomotive slowly, a little quicker, then at all speeds. If there is any knocking, it is probably the side rods and main rods touching and some spacers may be needed.