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Offline TrainIride  
#1 Posted : 10 December 2016 11:04:00(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Hello Friends,

After the purchase of this mysterious and intriguing model,
I decided to restore its youth, as it was in 1959.

mn3024a.png

Thank you to marklincafe website for these 1958 catalog extracts:

01_mn3024_cata58.jpg

02_mn3024_cata58b.jpg
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Offline TrainIride  
#2 Posted : 10 December 2016 11:20:46(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
An interesting point:

This model has reversing lights :

03_mn3024_cata58c.jpg
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Offline TrainIride  
#3 Posted : 10 December 2016 11:48:30(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
So,

let's start.

When I first put the lady on tracks, when feeding AC current, the loco was not moving.
I heard buzzing noise, lights blinking, well something wrong...

I thought it was a faulty reversing unit spring.

So I removed the loco body and saw this supernatural thing,
taking place instead of the reversing unit:

HPIM5823.JPG


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Offline jvuye  
#4 Posted : 10 December 2016 11:50:15(UTC)
jvuye

Belgium   
Joined: 01/03/2008(UTC)
Posts: 2,881
Location: South Western France
Originally Posted by: TrainIride Go to Quoted Post
So,

let's start.

When I first put the lady on tracks, when feeding AC current, the loco was not moving.
I heard buzzing noise, lights blinking, well something wrong...

I thought it was a faulty reversing unit spring.

So I removed the loco body and saw this supernatural thing,
taking place instead of the reversing unit:

(snip repeated image)


yep! 3 rail DC.
Very popular in France Laugh

Edited by moderator 07 February 2017 02:25:11(UTC)  | Reason: Not specified

Jacques Vuye aka Dr.Eisenbahn
Once a vandal, learned to be better and had great success!
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Offline TrainIride  
#5 Posted : 10 December 2016 11:56:41(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
using a 9V DC battery between pickup shoe and wheels,
in one direction, and then in the other, showed me this weird component
was a kind of rectifier that was selecting one of the motor coils, depending on the current direction.
The wheels were turning OK in both directions with the DC current.

So let's remove this and see what's left in the loco :

HPIM5824.JPG

HPIM5826.JPG




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Offline TrainIride  
#6 Posted : 10 December 2016 12:01:08(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: jvuye Go to Quoted Post
Originally Posted by: TrainIride Go to Quoted Post
So,

let's start.

When I first put the lady on tracks, when feeding AC current, the loco was not moving.
I heard buzzing noise, lights blinking, well something wrong...

I thought it was a faulty reversing unit spring.

So I removed the loco body and saw this supernatural thing,
taking place instead of the reversing unit:

(snip repeated image)


yep! 3 rail DC.
Very popular in France Laugh


Hi Jacques,

Do you know what it is exactly ? a relay, a rectifier ?

Edited by moderator 07 February 2017 02:26:02(UTC)  | Reason: Not specified

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Offline TrainIride  
#7 Posted : 10 December 2016 12:29:44(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Give her back a heart:

fahrtrichtungsschalter #20824 needed

mn3024_notice_a.jpg

Done !

HPIM5844.JPG
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Offline river6109  
#8 Posted : 10 December 2016 12:58:07(UTC)
river6109

Australia   
Joined: 22/01/2009(UTC)
Posts: 14,716
Location: On 1965 Märklin Boulevard just around from Roco Square
all the numbers you see on the spare part list you must add a "0" at the end your spare part number than becomes 208240

John
https://www.youtube.com/river6109
https://www.youtube.com/6109river
5 years in Destruction mode
50 years in Repairing mode
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Offline TrainIride  
#9 Posted : 10 December 2016 13:16:49(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: river6109 Go to Quoted Post
all the numbers you see on the spare part list you must add a "0" at the end your spare part number than becomes 208240

John


Thank you John for the information,

now I have this table to fill ....

service_manual_10b_small.jpg
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Offline TrainIride  
#10 Posted : 10 December 2016 13:22:01(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
And now the thing that intrigued me a lot.

20824 or 208240 wiring is like this :

marklin-circuit.jpg

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Offline TrainIride  
#11 Posted : 10 December 2016 13:30:41(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
But it's written in then catalog that this model has reversing lights.

And the reversing unit has only one switch Blink .

So, how did Märklin engineers do to reverse lights and loco direction with only one switch ?

After many enquiries on internet
(and I would like to thank all the people who have posted these informations)
I found the documentation.

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Offline TrainIride  
#12 Posted : 10 December 2016 13:35:08(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE

The solution is described in chapter 13.2
of the Märklin Service Manual Handbook:

service_manual_13_2_small.jpg
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Offline TrainIride  
#13 Posted : 10 December 2016 13:39:36(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
which leads to this :

reverse_motor_and_lights.jpg

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Offline TrainIride  
#14 Posted : 10 December 2016 13:54:36(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
So, to summarize this,
we use the opposite motor coil to feed current to the light bulbs.

Regarding documentation, it can only be done with old motor coils,
maybe because of a lower impedance.

The current for the bulbs must be lower than the current for the motor.
This way, the current fot the bulbs can be considered as a "leakage current"

With more recent motors, the magnetic field mus be totally cancelled.

So for the 3024 :
mn3024_wiring.jpg
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Offline TrainIride  
#15 Posted : 10 December 2016 16:18:40(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Well,

this problem solved, let's continue with the beginning ...BigGrin

mn3024_box_a.jpg

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Offline TrainIride  
#16 Posted : 10 December 2016 16:26:44(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
To remove the body


The loco has two sides BigGrin

Side 1
Side 2

They are different

Side 1 is where the body is labelled "1" and where the chassis has the selector for catenary feeding

mn3024_side1_selector.jpg
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Offline TrainIride  
#17 Posted : 10 December 2016 16:44:25(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Gently remove each bulb holder by turning the front screw.

The screws from each sides have different part numbers :

mn3024_bulb_holders_notice.jpg

Do not mix them !




On side 1, the body has a small center hole :

HPIM5818.JPG




On side 2, the body has a wider center hole :

HPIM5816.JPG



On side 2, the body fits in a chassis kind of nose:

HPIM5815.JPG



So to remove the body, it is necessary to slide the body horizontally a bit to extract the nose:
This one is a bit damaged ....

HPIM5813.JPG




On side 1 chassis, there is no nose:

HPIM5812.JPG
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Offline TrainIride  
#18 Posted : 10 December 2016 16:56:36(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
The two sides from the chassis :

mn3024_chassis_sides.jpg

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Offline jvuye  
#19 Posted : 10 December 2016 18:15:46(UTC)
jvuye

Belgium   
Joined: 01/03/2008(UTC)
Posts: 2,881
Location: South Western France
Originally Posted by: TrainIride Go to Quoted Post
Originally Posted by: jvuye Go to Quoted Post
Originally Posted by: TrainIride Go to Quoted Post
So,

let's start.

When I first put the lady on tracks, when feeding AC current, the loco was not moving.
I heard buzzing noise, lights blinking, well something wrong...

I thought it was a faulty reversing unit spring.

So I removed the loco body and saw this supernatural thing,
taking place instead of the reversing unit:

...




yep! 3 rail DC.
Very popular in France Laugh


Hi Jacques,

Do you know what it is exactly ? a relay, a rectifier ?


A double diode (=rectifier) in fact. To make it compatible with 3 rail DC systems (e.g. JEP)


Jacques Vuye aka Dr.Eisenbahn
Once a vandal, learned to be better and had great success!
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Offline jvuye  
#20 Posted : 10 December 2016 18:20:30(UTC)
jvuye

Belgium   
Joined: 01/03/2008(UTC)
Posts: 2,881
Location: South Western France
Originally Posted by: TrainIride Go to Quoted Post
So, to summarize this,
we use the opposite motor coil to feed current to the light bulbs.

Regarding documentation, it can only be done with old motor coils,
maybe because of a lower impedance.

The current for the bulbs must be lower than the current for the motor.
This way, the current fot the bulbs can be considered as a "leakage current"

With more recent motors, the magnetic field mus be totally cancelled.

So for the 3024 :
mn3024_wiring.jpg


In fact, it uses the dual wound coil as a "poor" (= inefficient) 1:1 transformer. Wink
Jacques Vuye aka Dr.Eisenbahn
Once a vandal, learned to be better and had great success!
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Offline TrainIride  
#21 Posted : 10 December 2016 19:23:15(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Hi Jacques,

thank you for these informations !

Best regards
Joël
Offline TrainIride  
#22 Posted : 10 December 2016 19:26:57(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Well, now the body :

Inside, no contact plate for the catenary power !!! Blink

I did not find any information on this. Crying

So If you have one ....

mn3024_body_inside.jpg

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Offline TrainIride  
#23 Posted : 10 December 2016 19:36:23(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
and now replacing wear parts...

Well , everything ?? Smile

The loco has certainly run a lot (under DC current), considering all the brushes dust inside .

I did not recognise between the two brushes, which was the copper mesh, and which was the graphite Scared

HPIM5846.JPG



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Offline TrainIride  
#24 Posted : 10 December 2016 19:40:26(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
then, after a little make-up :

HPIM5855.JPG



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Offline TrainIride  
#25 Posted : 10 December 2016 19:59:25(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
By the way, let us talk about the brushes now.

#60030 and now 600300

the question is :

"is there a special place for the copper mesh ?"


HPIM5857.JPG




The answer is "YES" found in the Service Manual:

service_manual_07_6_1_small.jpg




There is a straight spring for the graphite one that press to the notch.
There is a bent spring that needs to enter in the mesh center.


HPIM5868.JPG


HPIM5870.JPG
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Offline TrainIride  
#26 Posted : 10 December 2016 21:39:25(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Now replacing the front and back couplers.

#201331 or now 2013310

MN213310.jpg

the flat spring will press (enough ?) upon the front wheels to avoid derailment .

mn3024_coupler_install.jpg

Due to the shape of these front gears,
the wheels will follow the coupler direction, and vice versa

mn3024_frontwheels_bottom.jpg

mn3024_frontwheels_top.jpg
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Offline TrainIride  
#27 Posted : 10 December 2016 21:53:41(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
...And the new pickup-shoe

the unavailable #7174 is replaced by a #212010

even if the pickup shoe previously mounted on the loco seemed inappropriate,
the new one look a bit too long, (hoping this is the good part number, I had it in a box without reference)

The old locomotive uses a very thin contact plate to collect the current from shoe.

MN212010.jpg

HPIM5861.JPG


mn3024_pickup_a.jpg


mn3024_pickup_b.jpg


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Offline jvuye  
#28 Posted : 11 December 2016 11:19:50(UTC)
jvuye

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Joined: 01/03/2008(UTC)
Posts: 2,881
Location: South Western France
You're heading in the right direction....
So far your "trip of discovery" is perfect.
I suppose that when you cleaned the rotor you also cleaned the gear train that's behind it.
You'll soon have earned your Certificate of Aptitude for Official Vintage Märklin Maintenance and Repair Engineer!
Wink Smile
Jacques Vuye aka Dr.Eisenbahn
Once a vandal, learned to be better and had great success!
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Offline Unholz  
#29 Posted : 11 December 2016 11:48:12(UTC)
Unholz

Switzerland   
Joined: 29/07/2007(UTC)
Posts: 1,392
Location: Switzerland
I agree with Jacques - although I don't have one of these models, this thread is better than any instruction manual. ThumpUp
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Offline TrainIride  
#30 Posted : 11 December 2016 13:23:35(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: jvuye Go to Quoted Post
You're heading in the right direction....
So far your "trip of discovery" is perfect.
I suppose that when you cleaned the rotor you also cleaned the gear train that's behind it.
You'll soon have earned your Certificate of Aptitude for Official Vintage Märklin Maintenance and Repair Engineer!
Wink Smile


Hi Jacques,

It is an honor for me to be selected for this C.A.O.V.M.M.R.E diploma ! Cool
Thank you very much !

Of course I cleaned the rotor gear, and the other ones around.
Unfortunately, I did not take a picture of it.
When I saw the 7 teeth gear condition, I told myself, "well, let's go to the dentist " BigGrin .
But it seems that in spite of its used state, everything is turning round...

We will see, with the future tests on tracks.

If not, it will be shown in the future "Troubleshooting" chapter.

Best Regards
Joël



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Offline TrainIride  
#31 Posted : 11 December 2016 13:31:03(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: Unholz Go to Quoted Post
I agree with Jacques - although I don't have one of these models, this thread is better than any instruction manual. ThumpUp


Thank you so much !
I have spent time to gather these informations and to make a synthesis,
so I wanted to share them on the Forum
that gave me the Vintage Märklin Repair Fever RollEyes

Don't hesitate to [THANK/LIKE] my posts BigGrin

Best Regards
Joël
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Jayxxup
Offline jvuye  
#32 Posted : 11 December 2016 14:47:15(UTC)
jvuye

Belgium   
Joined: 01/03/2008(UTC)
Posts: 2,881
Location: South Western France
Originally Posted by: TrainIride Go to Quoted Post
.....
... When I saw the 7 teeth gear condition, I told myself, "well, let's go to the dentist " BigGrin .
But it seems that in spite of its used state, everything is turning round...

We will see, with the future tests on tracks.

If not, it will be shown in the future "Troubleshooting" chapter.

Best Regards
Joël

Hi Joël
If you need some of these old 3 pole rotors with large or small flat commutators, let me know.
I have a pile of them here, recovered from 5-pole (hi-efficiency Wink Wink ) conversions.
Just tell me the number of teeth on the gear.
Cheers
Jacques

Jacques Vuye aka Dr.Eisenbahn
Once a vandal, learned to be better and had great success!
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Offline TrainIride  
#33 Posted : 11 December 2016 15:55:47(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: jvuye Go to Quoted Post

...
Hi Joël
If you need some of these old 3 pole rotors with large or small flat commutators, let me know.
I have a pile of them here, recovered from 5-pole (hi-efficiency Wink Wink ) conversions.
Just tell me the number of teeth on the gear.
Cheers
Jacques



Thank you Jacques, Yes, I am interested.
it is very nice.

If the rotor is malfunctioning, I'll let you know.

Best Regards
Joël
Offline kamstutz  
#34 Posted : 11 December 2016 21:27:47(UTC)
kamstutz

United States   
Joined: 27/03/2015(UTC)
Posts: 192
Location: Orlando, FL
Originally Posted by: TrainIride Go to Quoted Post
Originally Posted by: jvuye Go to Quoted Post
You're heading in the right direction....
So far your "trip of discovery" is perfect.
I suppose that when you cleaned the rotor you also cleaned the gear train that's behind it.
You'll soon have earned your Certificate of Aptitude for Official Vintage Märklin Maintenance and Repair Engineer!
Wink Smile


Hi Jacques,

It is an honor for me to be selected for this C.A.O.V.M.M.R.E diploma ! Cool
Thank you very much !

Of course I cleaned the rotor gear, and the other ones around.
Unfortunately, I did not take a picture of it.
When I saw the 7 teeth gear condition, I told myself, "well, let's go to the dentist " BigGrin .
But it seems that in spite of its used state, everything is turning round...

We will see, with the future tests on tracks.

If not, it will be shown in the future "Troubleshooting" chapter.

Best Regards
Joël





Joël - I too lust after the C.A.O.V.M.M.R.E diploma, but first I'll have to stop skipping classes on this forum (such as the thread you started) and return to the workbench. Many thanks for documenting the process you went through - both informative and entertaining (since I like to see vintage toys live again too.)

Kurt

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Offline TrainIride  
#35 Posted : 14 December 2016 20:47:43(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: kamstutz Go to Quoted Post

Joël - I too lust after the C.A.O.V.M.M.R.E diploma, but first I'll have to stop skipping classes on this forum (such as the thread you started) and return to the workbench. Many thanks for documenting the process you went through - both informative and entertaining (since I like to see vintage toys live again too.)

Kurt


Hi Kurt.

Thank you for being interested in my posts,

For sure you will have your diploma soon Smile .

To like resuscitating vintage toys is the first requirement to enter this school.
So you have already your first level ThumpUp

Best Regards
Joël
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Offline TrainIride  
#36 Posted : 14 December 2016 20:52:05(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Page 47 of the 1959 catalog...

...where we can see Lady E18 ( but in blue dress #3023)

mn3023_overhead_1959.png (2,217kb) downloaded 82 time(s).

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Offline TrainIride  
#37 Posted : 14 December 2016 20:59:11(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Well,

I wanted to take pictures of the wiring inside, but I found that the pictures were not clear enough.

So I decided to create drawings to explain the method.

1. At first, we need to solder a pair of wires on each poles of the reversing unit.
It is easier to to this before installing it, and by this way,
we do not have to touch the reversing unit too much.

1_inverter_4_wires.jpg


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Offline TrainIride  
#38 Posted : 14 December 2016 21:02:53(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
2. we need to solder the black wire of the reversing unit on the catenary switch :


2_connect_inverter.jpg

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Offline TrainIride  
#39 Posted : 14 December 2016 21:07:15(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE


3. we need to connect the motor coils to the reversing unit.

For each coil, a test must be done to see in which direction the wheels are turning :


3_connect_motor.jpg
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Offline TrainIride  
#40 Posted : 14 December 2016 21:11:41(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
4. the lights.

Once we have located which coil is which direction,
we can connect respectively the corresponding bulbs to the opposite coil Blink

And that's it !

4_connect_lights.jpg


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Offline TrainIride  
#41 Posted : 17 December 2016 16:23:20(UTC)
TrainIride

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Location: FRANCE
Now the wiring diagram is clearer,

Let us have a look to the inside.
Not a lot of wires, thanks to the common ground chassis ThumpUp

1_new_wiring_inside.JPG
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Offline TrainIride  
#42 Posted : 17 December 2016 16:28:10(UTC)
TrainIride

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Posts: 1,912
Location: FRANCE
Even if the reversing unit is "viewable",
You can understand it is better to solder on it before installing :

2_reversing_unit.JPG



See the two pair of wires upon the reversing unit poles:

5_two_pairs_of_wires.JPG
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Offline TrainIride  
#43 Posted : 17 December 2016 16:31:33(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE


The motor coils wires left after dismounting the rectifier were too short.
I used heat shrink tube to insulate the connections with the reversing unit cables.

3_shrink_tube.JPG

4_shrink_tube.JPG

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Offline TrainIride  
#44 Posted : 17 December 2016 16:33:30(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE

The wires for the light bulbs were soldered this way:

7_solder_front_bulbs.JPG

6_solder_rear_bulbs.JPG
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Offline TrainIride  
#45 Posted : 17 December 2016 16:39:35(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Now the wiring is finished,

just a look at some outside details



The "Bicycle" logo on sides 1 and 2 :

8_bicycle.JPG


"MARKLIN E18 35" on one side :

9_marklin_e1835.JPG


"3024E18 35" on the other side :

10_3024_e1835.JPG
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Offline TrainIride  
#46 Posted : 17 December 2016 16:41:20(UTC)
TrainIride

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Posts: 1,912
Location: FRANCE
The Lady is now ready to run !!


11_ready_to_run_a.JPG


12_ready_to_run_b.JPG
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Offline TrainIride  
#47 Posted : 17 December 2016 16:46:43(UTC)
TrainIride

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Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
A bit noisy, maybe because of the rotor gear teeth Smile ,

And great both flashing lights when reversing due to this special wiring.
Both coils are "opened" during this transition, so both coils are feeding current to the bulbs...

And see how the loco appreciates wide radius C-track turnouts !!









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Offline DB Fan  
#48 Posted : 17 December 2016 18:04:51(UTC)
DB Fan

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Joined: 01/03/2016(UTC)
Posts: 265
Location: Colorado
Great video. Thanks for sharing the restoration from start to finish. Very helpful.

Robert
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Offline TrainIride  
#49 Posted : 17 December 2016 18:26:07(UTC)
TrainIride

France   
Joined: 23/10/2010(UTC)
Posts: 1,912
Location: FRANCE
Originally Posted by: DB Fan Go to Quoted Post
Great video. Thanks for sharing the restoration from start to finish. Very helpful.

Robert


Thank you very much Robert !

Best Regards
Joël
Offline foumaro  
#50 Posted : 18 December 2016 04:28:17(UTC)
foumaro

Greece   
Joined: 08/12/2004(UTC)
Posts: 4,420
Location: Attiki Athens Greece
A seminar work,congratulations.ThumpUp
thanks 2 users liked this useful post by foumaro
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