How To Install an ESU LokSound Select Micro DCC Decoder into a Kato SD45

gatrhumpy Dec 25, 2015

  1. gatrhumpy

    gatrhumpy TrainBoard Member

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    Here is a picture tutorial on how to install an ESU LokSound Selecto Micro DCC Sound decoder into a Kato SD45. I originally got a Bachmann SD45 Sound Equipped locomotive, but after the sound cut out a lot I sold it and bought a Kato instead. I love this thing. Here we go...

    This is the same we're working with today. Smooth running mechanism, split frame, all wheel drive, all wheel pickup, dual flywheels, pretty much everything you'd expect from a Kato.
    [​IMG]


    1. To take off the shell, grab the shell and gently lift it off the frame. You might need a LITTLE elbow grease because of the dimples on the side of the frame to get off the shell.
    [​IMG]

    2. You'll notice at the bottom of the loco where the fuel tank is. You'll have to take off and set aside the fuel tank.

    3. Remove the light blocking black plastic.
    [​IMG]

    4. Remove the two screws at either end of the locomotive.
    [​IMG]

    5. Gently remove the pickup springs on either side.
    [​IMG]

    6. Spread apart the sides and gently remove the printed circuit board.
    [​IMG]

    7. Use a small flathead screwdriver to push in the lower motor plastic tabs.
    [​IMG]
    [​IMG]

    8. Gently pull apart the frame halves and you'll see this:
    [​IMG]
    [​IMG]

    9. Gently remove the motor and driveline. Remember how the plastic pieces were oriented. Also remember how the trucks were put into the frame halves.

    10. Use a Dremel to grind down the metal frame like in the pictures. Use a metal file to smooth out the surface. USE EYE PROTECTION!
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    11. Put the motor back in, the driveline, the two frame halves, the two screws, and the copper pickup strips.

    12. Use a strong pair of scissors to cut out the front of the stock printed circuit board. Attach it to the front pickup tabs.
    [​IMG]

    13. Put two 220 uF 16V or 20Vcapacitors in place of the stock light-blocking piece of plastic. I had two in front, three in the middle behind the decoder, and one behind the speaker. Each capacitor I got off of Digikey and they are 7.3mm long, 4.3mm wide, and 3.1mm high. I used six of them in this application for a total of 1320uF of capacitance. I can add more if I want, but then I would not be able to completely separate the shell from the frame because of the wires.
    [​IMG]
    [​IMG]


    14. Wire up the ESU LokSound DCC Sound decoder.
    [​IMG]

    Red wire = right frame half solder point on the stock circuit board that you cut out earlier.
    Black wire = left frame half solder point on the stock circuit board that you cut out earlier.
    Gray wire = left motor tab
    Orange wire = right motor tab
    Blue wire = anode (+) of each function or lighting output and positive to the capacitors (marked with a bar)
    Pink wire (in my case) (that I had to solder to the DCC decoder per instructions) = cathode of the capacitor bank
    Brown wires (2) = to each speaker end (one speaker system only)
    White wire (with resistor) = to cathode (-) end front light LED
    Yellow wire (with resistor) = to cathode (-) end rear light LED


    15. This is how the completed installation will look with the Sugar Cube speaker (8mm by 12mm)
    [​IMG]
    [​IMG]

    Merry Christmas Internet!
     
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  2. Ryan Wilkerson

    Ryan Wilkerson TrainBoard Member

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    Nice write-up! What is the Rubinstein part number for the capacitor? How much run time do you have with them?
     
  3. gatrhumpy

    gatrhumpy TrainBoard Member

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    Not sure. I can find the Digikey part number tomorrow.
     
  4. Ryan Wilkerson

    Ryan Wilkerson TrainBoard Member

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    Thanks for finding the number.
    Funny that my phone's spell checker converted "Digikey" to "Rubinstein". So close! Hahaha...
     
  5. jpwisc

    jpwisc TrainBoard Member

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    399-10429-1-ND, I just received my order. I am looking forward to this.
     
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  6. jpwisc

    jpwisc TrainBoard Member

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    I got all my parts and started chopping the frame. I know now how crazy #gatrhumpy is, that is a lot of frame removed to make this work!
     
  7. subwayaz

    subwayaz TrainBoard Member

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    Thanks for the detailed how to gatrhumpy.
     
  8. gatrhumpy

    gatrhumpy TrainBoard Member

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    No problem! Hopefully this helps out someone else!
     
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  9. Diehard

    Diehard TrainBoard Member

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    What is the part number for the ESU LokSound Select Micro ?
    There are a few models available and I don't see where you mention it.
     
  10. ClassiCut

    ClassiCut TrainBoard Member

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    The variety of options is generally just different plug setups and in this setup your going to hard wire. If you get the Select Micro you are good.
     
  11. gatrhumpy

    gatrhumpy TrainBoard Member

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    The Select Micro is a generic ESU DCC sound decoder. You can order from places like Tony's Train Exchange, SBS4dcc.com, etc. I used the latter because they load the sound file onto the decoder for you.
     
  12. ClassiCut

    ClassiCut TrainBoard Member

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    Plus..... SBS4DCC (Bryan) will answer your questions by phone and give you a wealth of information.
     
  13. gatrhumpy

    gatrhumpy TrainBoard Member

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    Exactly. And he's quick with the programming and shipping.
     
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  14. jpwisc

    jpwisc TrainBoard Member

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    I went through Bryan for my decoders and speakers. He is quick to answer questions and ships fast!
     
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  15. RBrodzinsky

    RBrodzinsky November 18, 2022 Staff Member TrainBoard Supporter In Memoriam

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    Question on the 16V capacitors, that is a fairly close voltage rating to what N scale DCC can see; how have these performed for you?
     
  16. gatrhumpy

    gatrhumpy TrainBoard Member

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    I have not had a problem on my PowerCab system, which puts out 13.1V. If I were to take this to a club, I would ask the voltage output. Anything over 14V and I would not run these trains with the capacitors.
     
  17. RBrodzinsky

    RBrodzinsky November 18, 2022 Staff Member TrainBoard Supporter In Memoriam

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    Which sound file did you use? I see ESU has 16cyl 645E prime mover in N; and 16 cyl 645E3 (in O/HO, but not an issue for sound). But I don't see a 20 cyl 645E3

    I am debating whether to do this loco next, or a Mikado. My SD45 I want to convert is the non-DCC Friendly frame, so will take a lot more work (or a swap with Aztec, if they still have any).
     
  18. gatrhumpy

    gatrhumpy TrainBoard Member

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    ESU does not have any 20-645 sound files. I used the 645 E3 sound file, which sounds very similar.
     
  19. jdcolombo

    jdcolombo TrainBoard Member

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    Excellent work!

    John C.
     
  20. gatrhumpy

    gatrhumpy TrainBoard Member

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    Thank you sir!
     

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