This installation is for a HO-Scale Kato VO-660 Phase 2 using a TCS WOW101-Diesel Decoder and KA4. This install was performed by TCS.


Important Soldering Tip:
Please do not use any flux either liquid or paste on the mother board. It will damage it. Use only Rosin core solder approved for electronics use.
We recommend to use only Kester "44" rosin core, SN63PB37, .015" diameter, part number 24-6337-0007.
This can be ordered from Techni-Tool under Techni-Tool part number 488SO157

http://www.techni-tool.com

HO-Scale Kato VO-660 Phase 2 prior to WOW101-Diesel Decoder, KA4, and UNIV-SH4-C installation.

To start off this install, we must first remove the front and rear couplers and their housings. Once that is complete, the shell will lift off of the chassis.

Do this by holding the fuel tank with one hand and lifting the shell off by pressing up underneath the end platforms with your other hand

 

With the shell off, we can now remove the two screws on top of the board as indicated above in blue.

Next, remove the wires and the original lighting board while retaining the lights for reuse.
Trim and tin the wires.



Remove the front weight screw (highlighted in red in the small photo) and remove the front weight.
In this installation, we chose to trim this weight to just beyond the screw hole (shown as a blue bar in the above photo), and reinstall it into the shell to retain as much weight as possible.



We also shortened the original lighting leads, added a 1/6w 1K ohm resistor soldered inline to the cathode, and then hot glued them in place onto the end of the existing light tubes. Next, mount the KA4 in the shell, directly behind the LED, using hot glue or double sided foam tape to firmly affix it in place.

Now that the KA4 in place, securely mount the 25 X 14mm speaker into the SH4-C Speaker Enclosure and using foam double sided tape attach the speaker enclosure to the top of the shell. With the KA4 and speaker assembly in place we can wire them both to the rear WOWSound harness.

Plug the KA4 into the WOW101 and using double sided foam tape, securely mount the WOW101 decoder to the top of the shell.

Solder the track, motor, and lighting wires to the WOW101 harness, insulating as necessary as well as mounting and wiring gluing the rear LED just like we did the front LED (including the 1/6W 1K ohm resistor on the cathode).
See the wiring diagram provided in the decoder literature for complete wiring instructions.
We chose to add Kapton tape over the motor leads to hold the wires in place and to insure proper insulation.

Lastly, in order to keep the wires neat and prevent possible shorts, lace the wires into a bundle using lacing cord, which is a wax impregnated string 
used for wire bundling and making harnesses. There are many choices of lacing cord available from Digikey www.digikey.com
We use part number 802534B BK032-ND

Now you can close up the locomotive and reinstall the coupler assemblies. Be sure to be mindful of wire routing and reassembly of the shell as to not damage 
or foul the installation. Your Kato VO-660 Phase 2 is now WOWSound equipped and ready to roll!

 



Other solder tips: When stripping wire, only strip a tiny little bit of the insulation. Strip no more then a 1/64 of an inch. When the wire gets tinned with solder the insulation will shrink back more. Try to not expose any more wire then half the length of the solder pad at most. In no case should solder or exposed wire wire ever be outside the boundary of the the solder pad you are attaching a wire to.
Click here for important information on properly Stripping and Tinning wire

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