Thank you Tom for letting me know that other users are reporting that V100 locomotives which uses these same 117993 Telex couplers are also letting go of towed carriages. Clearly, this shows the problem is more wide-spread that what I have experienced myself.
I have done more investigation and am beginning to have a better understanding of the problem. I have also been corresponding with Mr. Frank Mayer of Marklin Service to try to see what they can do to help. To save me re-typing the rather long explanation of the problem (in case anyone is interested), I have copied below my latest email to Mr. Mayer for your information.
While I appreciate that not all members are as keen as me on Telex couplers, I find this one of the most enjoyable aspect of Marklin trains. I bought my first Telex locomotive, a first generation digital 3665 BR260 diesel shunting loco. in the mid 80s and I loved it! So when I came across the 117993 with NEM fitting, I was very keen to fit these to the rest of my locos. And when they work, they works so well. The coupling and uncoupling is so smooth and realistic. Its just a pity that there seems to be a production fault in 117993s which in my case, show a very high failure rate. In addition to solving my problem, I also wanted to raise this issue with Marklin to try to see if they can fix this problem so that 117993 will work properly.
Anyway, I hope this information helps for anyone who is interested and I will keep you posted on my correspondence with Marklin.
Dear Mr. Mayer,
Thank you for your email.
I can send you the locomotive but I feel this is not necessary. The reason is that I have been doing a number of checks to try to understand the problem, as detailed below.
A bit of background information would help here. I initially purchased 3 units of 117993s. I installed the first 117993 in my 3681 BR220 diesel locomotive. It worked superbly well; the coupling and uncoupling was very smooth, and it was totally reliable when pulling carriages in that it never lets go - I have attached some photos of this installation - see files with names beginning 1 to 3.
I fitted the second 117993 in my 37951 BR03 steam locomotive and that worked perfectly too - see photos 4 to 6. Encouraged, I bought another 10 units of 117993, planning to fit them to all of my other NEM coupler pocket equipped locomotives.
The third locomotive I fitted a 117993 to was a 37768 BR216 diesel. The coupling & uncoupling worked fine except that the 117993 would sometimes let go of the carriages being towed without any un-coupling signal sent to the 117993. Since emailing you, I have tried the remaining stock of my 117993 couplers one by one on my 37768 BR216 and 3681 BR220 locomotives and have found that of the 11 I had left, 5 units of 117993 works perfectly - i.e. couples & un-couples perfectly, and never lets go of carriages being towed - I fitted one of these to my 37768 BR216 diesel - see photos 7 to 9.
The fact that the good 117993s work perfectly on either of these locomotives and the defective 117993 lets go of carriages when tested on either/both of these locomotives show that the problem is not due to the locomotive or the mounting; the fault is clearly in the 117993 couplers.
Of the remaining 6 units of 117993, I found that:-
a) One is faulty in that the uncoupling pin sticks in the up uncoupled position so that the 117993 does not couple even after the uncoupling signal is turned off. In fact, if I use a tooth-pick to push the pin down to the couple position, it takes quite a few prods to get it down after which it will couple with carriages. But once the uncoupling signal current is applied to it to uncouple, the uncoupling pin still stay up after the uncoupling signal current is turned off and it refuses to couple to carriages - in other words, the uncoupling pin sticks and does not move up and down freely;
b) 5 units of 117993 couples and uncouples fine but lets go of towed carriages.
As such, it is clear that the issue here is simply that the defective rate of 117993 is extremely high. In my case of having bought 13 units of 117993s, 6 units (46%) are faulty as listed above. Further more, the fact that good units of 117993 works perfectly on each of my locomotives while the defective ones lets go on all my locomotives show the problem is not due to the locomotive or its NEM mounting. Clearly, this means there is no need for me to send my locomotive together with faulty 117993 units to you.
I did some more investigation to understand how the faulty 117993 would let go of carriages. What I did was fit one of the defective 117993 onto a 37661 E52 locomotive. However, I did not wire the 117993 to the decoder - see photos 10 to 12 - you will see that the 117993's wires are not connected but is tied to the top of the locomotive. This means that while the 117993 will couple to carriages, there is no way to send current to the 117993 to uncouple it. What I found was that after coupling carriages to the 117993, the coupling is very secure; you can pull on the carriages repeatedly and the carriages will not let go, as how it should be. However, once the locomotive pulls the carriages for 1 or 2 circuits of my layout, the 117993 will let go of the towed carriages! After letting go, the 117993 looks normal in the coupled position; i.e., the uncoupling pin is in the lowered position. I initially thought that what is happening is that the carriages coupling bar is riding up & slipping over the top of the 117993's coupling hook. But an adjustment to raise the NEM mounting does not help, and the angle of the bar is identical to the other perfectly working 117993s on the other locomotives.
To investigate further, I applied a very small piece of double sided adhesive tape (sellotape that sticks on both sides) and stuck this onto the inside of the tow hook of the 117993. I then coupled on the carriages and sent the locomotive round the layout. What I found was that after 2 or 3 circuits, the 117993 uncoupling pin had worked its way to the up uncoupling position. I can see this as the double sided tape is preventing the carriages from being let go so easily. Of course, if the locomotive continues to go round the layout, eventually, the carriages will be released and the coupling pin will go back down into the coupling position.
Clearly, what is happening is that with these defective 117993 units, ongoing & varying towing torque being applied to its coupling hook while towing carriages round the layout will eventually cause the uncoupling pin to move up by itself thus uncoupling and letting go of the towed carriages. The fact that this happens even with the defective 117993s fitted but unwired (i.e. no uncoupling current can be applied to the 177993) means the fault has to be a mechanical issue inside the 117993.
Let me suggest this. I will send you all 6 of my defective 117993 units. When you receive them, please fit them onto a test locomotive and use it to pull carriages round a layout. You will find that of the 5 units that lets go, it will let go when it is not meant to. Note that you need to test it pulling carriages, not just by tugging on the carriages to see if it lets go. For some reason, it will only let go if the towing torque is fairly constant but varying. I have found that once the towing torque is eased, the uncoupling pin, having worked its way half way up, will fall back down once the towing torque is eased. So to test it properly, you must let the locomotive pull the carriages round a flat layout for a number of circuits.
As for the final defective 117993, you can see immediately that it is faulty in that the uncoupling pin sticks in the upper position.
I apologise for the length of this email but I wanted to make everything clear. Please let me know your views on my suggestion.
Thank you again for your help and look forward to hearing from you.