YARDBIRD CLASSIC TRAINS
Assembly Instructions

Installing the D1130 Smoke unit kit in the Mantua Pacific / Mikado type locos

8/21/10 - **PLEASE NOTE**:  The new smoke units we have in stock come with two long black leads instead of shorter yellow and brown leads.  This eliminates the need for the two short add-on wires.  On the new units, the black lead in the very middle of the unit replaces the yellow one, and the black lead close to the edge of the unit replaces the brown one.


Fig. 1 - Drilling the new hole
Fig. 2 - Continuing the hole into the boiler
Fig. 3 - Threading the boiler hole
You will want to sort out all pieces prior to beginning the installation.  The first step is to remove the front pilot truck from the loco.  Measure back exactly 3/8" on the frame (center to center) from the hole going through the steam chest and mark for a new hole.  I use a hard metal scribe to make a pilot mark.  Using a 5/64" bit, drill a hole in the center of the frame.  Be careful to keep the drill at the a right angle to make sure the hole is properly aligned (see Fig. 1).  After drilling completely through the frame, let the drill bit protrude and mark the center of where the hole should be on the bottom of the boiler.  Next, remove the boiler from the frame and proceed to drill the boiler hole approximately 1/2" deep, as shown in Fig. 2.  After those holes are completed, remove the 5/64" bit and re-drill the hole through the frame using a 3/32" bit.  This will allow the screw to turn without binding.  Then, using the self threading screw provided, thread the boiler hole to accept the new screw (Fig. 3)

Fig. 4 - Drilling out the smokestack
Fig.5 - Slip in the smoke unit
Fig.6 - Attaching the wires
Next, using a 3/16" bit first, carefully drill out the smokestack hole, as shown in Fig. 4.  (If you are working on a Mikado, you will need to remove the smokestack ring on the very top of the stack).   After that, use the 3/64" bit and re-drill the hole to the needed size.   Now slip the new smoke unit in place as shown in Fig. 5.   Apply a few drops of super glue on the shaft sides, then carefully slide the unit in place.   After the glue sets up, you are ready to wire the unit in.  *The leads supplied on the smoke unit are not long enough to reach to the motor, so we have supplied two smaller leads to attach to them.  These may be connected by twisting or soldering to the ends of the leads, making sure that they are covered with electrical tape or other insulating material.  Fig. 6 shows this step. *(10/12/06 - with the new units, this step may be skipped as the leads are long enough to reach) 

Fig. 7 - Hooking the wires up to the motor
Fig. 8 - Fasten the frame to the boiler
Fig. 9 - Touching up the paint
There are basically 2 ways to connect the wires to the motor.   One is to solder the leads to the brushes or brush pegs, and the other is to slip the wire ends under the brush springs as shown in Fig. 7.   If you solder the leads, be careful not to overheat the pegs, which can cause loosening.  If you slip them under the brush springs, you will want to be careful as the brushes can slip out when the tension is released from the springs.   Caution: Make sure to hook the lead in the center of the unit to the ungrounded side of the motor.  After hooking up the wires, make sure they are out of the way by applying a piece of electrical tape, securing them to the boiler bottom.  Next, replace the boiler, making sure the wires are not touching the gears, etc.  Using the longer screw and washer, fasten the frame to the boiler with the new hole, as shown in Fig 8.  Finally, you may want to touch up the paint around the new unit to match.  After the front truck, etc. are reinstalled, your locomotive is ready to test.

Fig. 10 -The installed smoke unit in operation
Of course you will want to bench test your new installation.  If everything was properly done, your locomotive is ready to run with the new unit smoking strongly.  You will need only a few drops of smoke liquid to make this unit work.  These units normally smoke for approximately 30 minutes after oiling.  The realism added to your model will be well worth the effort of the installation!


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