Rebuilding Märklin 33043,  DRG 80 030 to digital with Märklin 60760 conversion set

Updated 05.06.2012

This small steam engine is a very nice model, compact, heavy and rather detailed. I have three of these locomotives, 80 007 from 2866, 33042 MM2000 and 33043 80 030 museum locomotive. This locomotive was equipped with a tailor made Delta decoder.

The prototype was made in Germany, in 1928-1929.  39 of these nice locomotives were made.  They were in traffic until 1965.  420 kW, 54,4 metric tons, 9.670 mm long.

Preparation for conversion:
Remove the Delta decoder and the motor.  I left the wire from the pick-up shoe, and soldered it to the decoder later on.

Motor:
Installation of the motor itself is very simple. After removal the old motor and the Delta unit, make sure that all mechanical functions, like the transmission, wheel axles and the rods, are good and that the locomotive is clean.  Install the new motor parts.  Before inserting the brushes, make sure once more that everything rotates perfect.  If required, oil the rotating parts very carefully.  Do not use too much oil, as this may harm the operation of the locomotive.  The noise suppressors are installed on a small test circuit board, in the front LH corner, under the light circuit board.

Decoder:
The decoder is installed in a decoder holder, Märklin spare part number 456200. After very carefully removing the rubber cover around the decoder, I soldered a brown/green wire to the free solder pad next to the gray wire.  This is an unofficial f3 function output, which I used as interior light, connected to a smd LED on top of the motor, via a 1.200 Ohm resistor.

Decoder adjustment:

Max. speed:
The Br 80 had a maximum speed of 45 km/h.  The 60760 decoder has 14 speed steps, so the closest I get with the Central Station is 48 km/h, at speed value 18 of 63 on the CS scale. I have set the speed scale under "Edit Locomotive" and "Properties" to 48 km/h, and when 45 km/h is indicated in the CS screen, the actual speed is very close, approx. 45,5 km/h in forward direction and a little lower in reverse direction.
I think that 13 "usable speed steps" are more than enough for a locomotive with 45 km/h maximum speed.

Acceleration and braking delay:
Both these values are set to 19,987 seconds.  I do not understand these figures, as the actual times are certainly not close to 20 seconds.

Interior light
I wanted to use the f3 (unofficial) for something, so I installed a smd LED and a 1,5 kOhm resistor on a small test circuit board.  The board is installed on top of the motot with some sticky green stuff.

Front and rear light:
Some time ago a light printed circuit, Märklin spare part number 240120, was available for these locomotives.  As far as I know this is no longer available.  It is rather easy to make one by cutting the Delta decoder into pieces.  See below photo.  I just removed the DIP-switch to the right of the IC and cut it with a small hacksaw and grinded off a bit with my Dremel and a flat grinding stone.



After removing the smd components, I soldered a small "jumper" (orange arrows) to the board, later to be soldered to the orange (+ to lamps) wire from the decoder.
The brown arrow is where I solder the brown (ground) wire to the decoder, after carefully scraping off the coating on the circuit board.

The yellow arrow indicates where the yellow wire from the decoder will be connected.  This copper lead is first mechanically cut off from the grounding screw hole, to the left of the arrow
The gray arrow shows where the gray wire from the decoder will be soldered. The protective coating must be removed from both soldering points.  The copper leads are coloured with the respective colours, to indicate the current flow.  Note that the orange connections are going via the jumper under the circuit board to the upper side, to both lamps.

This photo shows the light print temporary installed in the locomotive.

Parts used for the conversion:
Märklin no. Pcs. Description
60760 1 Conversion set with fx decoder
456200 1 Decoder holder
610080 2 Bulbs, front lights
- 1 Light circuit board, cut from Delta decoder
- 1 smd LED for interior light
- 1 1,5 kOhm resistor for the LED
- 1 small piece of test circuit board

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