Esu Class 66 Manuale utente

En g i n E E r i n g Ed i t i o n

Instruction manual

1. Edition, September 2014

Class 66/77

Content

1. Declaration of Conformity

We, ESU electronic solutions ulm GmbH & Co. KG, Edisonallee 29, D-89231 Neu-Ulm, Germany, declare in sole responsibility that the product

„ESU H0-Diesellok Class 66/77“, part number: 31050, 31051, 31052, 31053, 31054, 31055, 31056, 31057, 31058, 31059, 31070, 31071,

31072, 31073, 31074, 31075, 31076, 31077, 31078, 31079 complies with all relevant regulations of the Directive for Electromagnetic Com-

patibility (2004/108/EG). The following harmonised standards have been applied:

EN 55014-1:2006 + A1:2009: Electromagnetic Compatibility - requirements for household appliances, electric tools, and similar apparatus - Part

1: Emission - Product

EN 55014-2:1997 + A1:2001 + A2:2008: Electromagnetic Compatibility - Requirements for household appliances, electric tools, and similar

apparatus - Part 2: Immunity - Product family standard.

1. Declaration of Conformity........................................2

2. Prototype.................................................................3

3. Model .....................................................................6

3.1. Important remarks - please read this ﬁrst ......... 6

3.2. Unpacking the model ...................................... 6

3.2.2. Mounting & removing the centre pick-up ..... 6

3.3. Outward appearance and special features........ 7

4. The technology of the ESU model ............................8

4.1. Possible operating modes of the class 66/77 .... 8

4.1.1. Analogue mode ........................................... 8

4.1.2. Digital mode................................................. 8

4.1.2.1. Digital operation with DCC systems .......... 8

4.1.2.2. DCC with RailComPlus®............................ 9

4.1.2.3. Prerequisites for RailCom® Plus ................. 9

4.1.2.4. M4 registration.......................................... 9

4.1.2.5. Digital operation with Märklin® Digital...... 9

4.2. Your ﬁrst ride................................................... 9

4.2.1. Lighting functions......................................... 9

4.2.2. Sound functions ......................................... 10

4.2.3. Curve and turnout sensors.......................... 10

4.2.4. Synchronised smoke generator ................... 10

4.2.4.1. Filling the smoke generator holding tank . 10

4.2.4.2. Operating the smoke generator............... 11

4.2.5. PowerPack energy storage.......................... 11

5. Decoder Settings (Programming)............................12

5.1. Conﬁguration Variables (CVs) ........................ 12

5.1.1. Standardisation in the NMRA...................... 12

5.1.2. Bits and Bytes ............................................. 12

5.2. Programming the decoder ............................. 12

5.2.1. Programming with DCC systems................. 12

5.2.2. Programming with Märklin® 6021 ............ 12

5.2.2.1. Changing to the programming mode ...... 13

5.2.2.2. Short mode ............................................. 13

5.2.2.3. Long mode.............................................. 13

5.2.3. Programming with the Märklin® Central

Station®............................................................... 13

5.2.4. Programming with ESU LokProgrammer ..... 14

5.3. Adress settings .............................................. 14

5.3.1. Short Addresses in DCC mode.................... 14

5.3.2. Long Addresses in DCC mode .................... 14

5.3.3. Motorola® address..................................... 14

5.3.3.1 Consecutive addresses for more functions 14

5.4. Adapting the Driving Characteristics .............. 15

5.4.1. Acceleration and Deceleration .................... 15

5.4.1.1. Shunting mode........................................ 15

5.4.2. Starting Voltage, Vmax ............................... 15

5.5. Break sectors ................................................. 15

5.5.1. DC break mode .......................................... 15

5.5.2. Märklin® brake mode ................................ 15

5.5.3. Lenz® ABC brake mode ............................. 16

5.6. Adjusting the volume .................................... 16

5.6.1. Overall sound volume ................................. 16

5.6.2. Adjust individual sounds ............................. 16

5.6.3. Motor sound .............................................. 16

5.6.4. Auxiliary sounds ......................................... 16

5.7. PowerPack..................................................... 16

5.8. Decoder reset ................................................ 17

5.9. Adjusting the brightness of the lights ............ 17

5.10. Smoke generator ....................................... 17

5.10.1. Blower of the smoke generator ............... 17

5.10.2. Heating temperature ............................... 17

6. Maintenance..........................................................17

6.1. Removing the housing................................... 17

6.2. Lubrication .................................................... 17

6.3. Replacing wheel sets ..................................... 17

6.4. Replacing traction tires .................................. 18

6.5. Installing a coupler ........................................ 18

7. Accessories supplied with the model......................20

8. Technical support...................................................20

9. Spare parts ............................................................20

10. List of all important CVs.......................................21

12. Warranty Certificate.............................................23

En g i n E E r i n g Ed i t i o n

Original

Prototype

2. Prototype

With the liberalisation of the international rail goods

trafﬁc established in 2001 the newly founded rail

operators needed to procure motive power in order

to be able to handle the trafﬁc they had fought so

hard to take away from the state owned railways.

The procurement of technically sophisticated new

vehicles was often not possible due to budgetary

restraints. A more cost effective solution was offe-

red by the American Electro Motive Division (EMD)

with the class 666 that had already been tested and

proven in Great Britain. The locomotives known as

the JT 42 CWR are based on the American SD40

and ongoing development culminating in the SD

40-2, which were found to be most reliable due to

their simple, but proven design.

The ﬁrst railway institution employing the diesel

electric class 66 on German lines was the Harbour

and Freight Services AG in Cologne the so called

Häfen und Güterverkehr Köln AG (HGK). In 1999

this company purchased two units. Almost at the

same time the class 66 was introduced to other Eu-

ropean countries. Rail trafﬁc corporations having

purchased or leased class 66 locomotives can be

found in France, Belgium, the Netherlands, Lux-

embourg and Norway. So far about 650 units have

been delivered in two different version to European

customers. The somewhat long and slim outline

Class 66‘ predecessor is named JT 26 CW-66. The picture shows Deutsche Bahn 259 003 in Sed-

din on 28.9.1997

Picture: Rolf Wiemann

meets the clearance diagram of British Rail. The

square-edged design of the body and the chassis

with its massive boogies and quite a number of see-

mingly confusing pipes and cables give the class 66

an unmistakable appearance.

The General Motors twelve Cylinder Two Stroke

engine 12N-710G3B-EC can not only be heard but

also recognised due to its characteristic sound and

offers a power of 3194 HP (2350 kW). The starting

tractive effort amounts to 409 kN, the continuous

tractive effort is 260 kN. With a maximum speed of

120 km/h the class 66 locomotives can easily keep

pace with other trains using electric traction even

on mainlines. Due to the independence from cen-

tenary the client can, if need be, pick up the train

from the most remote spur or siding and take it

via DB mainlines right through to his own factory.

With their livery the class 66 locomotives form a

pleasant contrast to the standardized red livery of

the DB AG.

Since 1999 the HGK mainly handles block trains

with their class 66 locomotives albeit with varying

loads. Tank cars have been a standard load for HGK

class 66 locomotives taking the train over the entire

route to Braunschweig, Ingolstadt, Marktredwitz

and Aichstetten. But one can also ﬁnd the locomo-

Prototype

tives from Cologne in central Germany whenever

they haul a train to Leuna or Berlin, amongst others.

We have chosen the DE671 built in 2003 and with

an extended concession issued in 2011 as the pro-

totype for our model that bears white stripes on

the front.

The livery of the class 66 locomotives is accentuated

by the sharp contrast of black or grey sides with

the light green contrast patches leading around the

cabs. In Germany, Belgium and the Netherlands the

Captrain locomotives are mainly deployed hauling

container trafﬁc, block trains consisting of tank

wagons or coal cars. They also display their power

ahead of block trains made up of cars with sliding

sides carrying parts for the automotive industry. In

Germany these six axle locomotives regularly travel

from the Rhine Ruhr region as far as Berlin.

As from 2010 CB rail, a renter of locomotives sent

their German and Luxembourg subsidiaries under

the name of Ascendos Rail Leasing GmbH into the

game of rail freight trafﬁc. For operations on only

partly electriﬁed lines Ascendos has a stable of 20

class 66 locomotives and an extra three class 77.

For Modeltrain enthusiasts these locomotives with

their green livery accentuated by the turquoise and

yellow contrast stripes are highly attractive since

they are not only deployed to haul block trains with

containers, tank cars, construction materials, coal,

motor vehicles or machine parts but make them-

selves useful in track maintenance service of for

transfers of other vehicles. Particularly in the area

of construction site logistics these locomotives are

often seen with only a handful of cars. Well known

companies renting these six axle locomotives have

been and are the HGK, Crossrail, ITL or the Ruhr-

talbahn deploying them all over Germany, Belgium

and the Netherlands.

The four units owned by the SNCF Benelux and re-

gularly travelled through Belgium, the Netherlands

and Germany in their impressive and very elegant

blue silver livery. Initially it was quite easy to diffe-

rentiate them due to their different design of the

contrast areas on the front and rear. They were

mainly hauling two axle hoppers, container trains

and tank car trains.

HKG‘s DE 62 still owns the british style headlights with outer position lamp in contrast to DE

61. Picture taken on 24.08.2011 in Ulm Hbf

Picture: Jochen Frickel

The prototype of the ESU model in Montzen

/ Belgium

Picture: Rolf Wiemann

En g i n E E r i n g Ed i t i o n

Original

Prototype

Section view of class 77 showing the components locationsFigure 1:

Drawing: ESU GmbH & Co. KG

DE61 of HGK is allowed to be used in ger-

many only

Picture: Jochen Frickel

Crossrail‘s class 77 DE 6311 in Neuwied train

station

Picture: Rolf Wiemann

Model

3. Model

3.1. Important remarks - please read this ﬁrst

Congratulations to your purchase of the H0 diesel

locomotive class 66/77. Your H0 model offers va-

rious innovative functions. This manual provides a

step by step insight into the features of the class

66/77. Therefore we have one request:

Please read this manual prior to operating the mo-

del carefully. Although the model is quite robust,

inappropriate handling could lead to injury of the

operator or to damage of the locomotive. Do not

indulge in “costly” experiments.

This locomotive is not a toy and should only be•

operated under supervision.

Please make sure that the room has adequate•

ventilation when operating the smoke genera-

tor continuously!

Keep the smoke distillate away from children. It•

contains substances that may damage your he-

alth if consumed. In case of contact with your

eyes consult a doctor immediately.

Please return the pipette only into the packaging•

after you have emptied it completely. Otherwise

you may risk draining the smoke distillate.

Protect the model against wet conditions and•

humidity.

When working on the locomotive (maintenance)•

always make sure there is no power connected

to the model. Replace the housing on the chas-

sis prior to operating the locomotive after main-

tenance work.

Make sure that no wires are squeezed or that no•

short circuit may occur.

Please note: All models shown here are pre-produc-

tion samples. They may vary slightly from the series

production models!

3.2. Unpacking the model

Pull the model screwed to the plastic holder with

both hands out of the foam insert. At the bottom of

the plastic holder you will ﬁnd a hexagon spanner.

Now place the model on its side, hold the model

and the plastic holder with one hand and release

the hexagon bolt with the other hand.

For safe keeping of the spanner there are two retai-

ning clips at the bottom of the plastic holder.

Please keep all parts of the packaging and this

manual for later use. Only the original packaging

guarantees proper protection against transport da-

mage. Please ﬁx the locomotive by means of the

hexagonal bolt to the plastic holder and place it into

the foam insert and put it into the carton and the

transport box prior to shipment.

Now you must adapt your class 66/77 to the control

mode of your layout. If you are a Märklin model

train enthusiast and therefore need a locomotive

with a centre pick-up you may simply place the lo-

comotive onto the track, enter address 3 and you

are ready to run.

The centre pick-up clipped onto the locomotive ser-

ves not only for current pick-up but also activates

the electrical connection of both rails. Thus all 12

wheels pick-up current from the tracks.

If you operate a two-rail layout you must remove

the centre pick-up. How you do this is described in

chapter 3.2.2.

3.2.2. Mounting & removing the centre pick-up

Removal: Put the locomotive on its roof. Then you

apply the tool in such a way that the ends of the

four wire brackets ﬁt into the four holes below the

base plate of the centre pick-up. Carefully(!) squee-

ze the tool and then lever the centre pick-up with a

slight tug from its position.

release of hexagon boltFigure 2:

En g i n E E r i n g Ed i t i o n

Model

Mounting: For re-converting your locomotive to a

three-rail vehicle again hold the centre pick-up bet-

ween thumb and index ﬁnger and place it in the

receptacle. Please note that the centre pick-up must

be attached to bogie “1”. Finally press the centre

pick-up until there is an audible “click”. That´s it!

3.3. Outward appearance and special features of

your class 66/77

With your new class 66/77 you can operate your

model trains prototypically like never before. There

are many separately applied detail parts on the me-

tal housing as well as on the metal chassis. Of cour-

se, such details and modiﬁcations of the housing

are correct for the respective locomotive number.

All grab irons are made off sturdy plastic and are

separately applied. Separate plastic pipes are atta-

ched to the bogies.

The large speaker powered by the LokSound V4.0

M4 decoder distributes its powerful sound through

the cut-through radiator grills. New is also the sen-

sor triggering the squealing noise in curves and on

turnouts.

The ESU 5-pole high performance motor with a vir-

tually silent commutator and two ﬂywheels assure

plenty of power and smooth running. All four axles

are powered.

Four traction tires assure considerable tractive ef-

fort. Model train enthusiasts who prefer to run their

locomotives without traction tires and rather enjoy

more prototypical wheels sets ﬁnd a voucher for six

wheel sets (2-rail system) with RP 25 wheels (please

also refer to page 26!). In order to obtain these

wheel sets, simply send this voucher to ESU. In or-

der to assure perfect driving dynamics and excellent

sound without interruptions due to dirty tracks the

locomotive is equipped with a “PowerPack“energy

storage module.

A coupler shaft as per NEM 362 with short coupler

kinematics provides close coupling between loco-

motive and train in any situation.

In terms of its lighting the class 66/77 is just as

prototypically versatile as its full scale counterpart.

Of course there is directional lighting generated by

warm white LEDs that can be turned off at one end,

wherever the train is coupled to the locomotive.

During shunting all three headlights at either end

are switched on. In addition there is directional cab

lighting as well as illuminated driver’s cab-control

panel. Since these locomotives are employed inter-

nationally one can also set the lighting according to

the Belgian, Dutch and French lighting rules.

pickup shoe removalFigure 3:

Assembly of pickup shoeFigure 4:

Technical functions

4. The technology of the ESU model

The new LokSound V4.0 M4 decoder is a central

part of your new class 66/77. Its circuitry is responsi-

ble for design and control of all running and sound

functions of the class 66/77:•

Driving forward and in reverse•

Lighting functions•

Sound functions•

Smoke generator•

Besides M4 the LokSound V4.0 M4 also supports

DCC with RailComPlus, Motorola® and Selectrix®

and also be operated on analogue layouts. Pro-

gramming can be done either with DCC command

stations or with Märklin® central units, etc. the de-

coder automatically detects the mode of operation;

therefore you do not have to set anything in this

regard.

In case you wish to change any of the default set-

tings of the locomotive (such as the address or the

sound volume) we recommend to ﬁrst reading

chapter 5. This chapter lists all parameters of the

LokSound V4.0 M4 decoder and how to change

them with the various command stations available

on the market.

4.1. Possible operating modes of the class 66/77

4.1.1. Analogue mode

The class 66/77 may also be operated on conven-

tional (=analogue) DC or AC model train layouts.

The number of available functions is, however, qui-

te limited:

Driving forward and backwards•

Directional lighting•

Engine sounds (automatic)•

The smoke generator cannot be turned on in ana-

logue mode. The engine sound sets in at about

6.5 V track voltage. At 8.5 V the locomotive slow-

ly starts moving. Both DC transformers (throttles,

e.g.: ROCO®) and AC transformers (e.g.: Märklin®,

Titan) are suitable for analogue operation. Please

note, that due to the large number of different sys-

tems on the market you may not achieve trouble-

free operation with electronic throttles employing

PWM (pulse width modulation).

Attention: the class 66/77 must have come to a

complete standstill before you activate the change-

of-direction command! Never switch to the opposi-

te direction while the locomotive is moving.

4.1.2. Digital mode

For prototypical operation we recommend using

a digital command control system. The numerous

functions are only available in digital mode.

The default address (ex works) is “03” (DCC and

Märklin® Motorola®)

14 speed steps with Märklin® Motorola®.

In DCC mode the decoder automatically detects the

speed steps set in the command station.

4.1.2.1. Digital operation with DCC systems

The class 66/77 can be operated with any DCC

compliant system. Sounds and other functions of

the class 66/77 can be triggered with the function

buttons F0 through F21.

Function mapping (ex works):

Functionmapping:

Button Function

F0 Directional lighting

F1 Engine sound

F2 Horn (high)

F3 Smoke generator

F4 Cab lighting

F5 Headlights off at cab 1

F6 Headlights off at cab 2

F7 Headlights as per lighting rules in BE/FR (Third headlight off)

F8 shunting lights DE/FR/BE

F9 Horn (low)

F10 Emergency stop

F11 Platform announcement

F12 Turnout sensor off

F13 Coupler sound

F14 Illuminated driver’s cab-control panel

F15 Shunting lights as per NL

F16 Air compressor / exterior lights as per CNet,TGOJ, CLF

F17 Station announcement

F18 Short horn (high)

F19 Short horn (low)

F20 Sanding

F21 Shunting mode

En g i n E E r i n g Ed i t i o n

Model

Technical functions

The number of the functions actually available is de-

termined by your command station respectively by

your throttle. Depending on the digital system there

may be fewer functions available.

4.1.2.2. DCC with RailComPlus®

The LokSound V4.0 M4 supports RailComPlus®,

which was jointly developed by Lenz® and ESU.

This means that the decoder automatically re-

ports to RailComPlus® capable command stations.

You will never ever have to change a locomotive

address manually! Simply put the locomotive onto

the track.

4.1.2.2. Prerequisites for RailCom® Plus

RailComPlus® implies an accordingly equipped di-

gital command station. The ESU ECoS command

station supports RailComPlus®-capable decoders

from software 3.4. You don´t need to change any-

thing about the decoder settings. It will be automa-

tically recognised.

Of course you can change the locomotive name,

all functional key and locomotive symbols and after

that write it back on your decoder. This happens

automatically in the background.

If you do not wish to have the automatic recogniti-

on, you can switch it off by deleting CV 28, bit 7.

4.1.2.4. M4 registration

If you use a Märklin® systems Central Station®,

Central Station 2 or mobile station®

The locomotive will be automatically detected and

registered by the system once you have put it onto

the track. This process occurs completely automati-

cally, you do not have to adjust any settings.

DCC with RailComPlus® has the highest priority

when registering the locomotive. Therefore the de-

coder will always register with RailComPlus® and

DCC on an ESU ECoS command station even when

M4 is active. If RailComPlus® is not available then

M4 will be treated as the second priority. Therefo-

re the decoder will register with M4 on a Märklin

Central Station®.

Whenever you run your class 66/77 with a Mär-

klin® central unit under M4, then the system limits

the number of available functions to 16.

4.1.2.5. Digital operation with Märklin® Digital (6021)

You may operate the class 66/77 with the Märklin®

6021 central unit without any problems. A special

feature allows you to assign three more addresses

besides the “actual locomotive address”. They are

known as following addresses. This enables you to

access 16 functions with your 6021. Details on how

to do this are described in chapter 5.3.3.1

4.2. Your ﬁrst ride

Most certainly you wish to test your new locomo-

tive right away. We recommend going about this

step by step. Put the locomotive onto the track call

it up on your handheld throttle.

4.2.1. Lighting functions

First turn on the lights by pressing F0. Then the whi-

te forward headlights as well as the red rear lights

of the class 66/77 should light up. If you wish you

Beleuchtung Class 66/77

vorne hinten

Deutschland

Fahren

Rangieren

Belgien

Fahren

Rangieren

Nothalt:

Abwechselndes

Blinken der

weißen unteren

Lichter vorne

Niederlande

Fahren

Rangieren

Frankreich

Fahren

Rangieren

Lighting functionsFigure 5:

Technical functions

may switch on the cab lighting with F4 in order to

better see the cab interior.

If you now press F7 (while the headlights are turned

on) then the illuminated driver’s cab-control panel

will come to life. You will clearly see this through

the side windows of the cab.

It is common practice to turn of the head and tail

lights at the cab where a train is coupled to the

locomotive. Press F5 is the train coupled to cab 1

in order to switch off the head (tail) lights at that

end. When shunting without any vehicle coupled to

the locomotive you should press F8 in order to have

prototypical lighting for shunting.

In each bogie there are 4 LEDs, which are activated

during braking and thus simulate the sparks of the

brake shoes on the wheel rim as can be observed

on locomotives hauling heavy trains.

4.2.2. Sound functions

After pressing F1 (preliminary lubrication and star-

ting sequence) your class 66/77 comes to life and

continues with the typical sound of an idling two

stroke engine.

Once you go to speed step 1 the prime mover will

rev up before the locomotive slowly starts moving.

The response of the prime mover to different thrott-

le settings is for both - acceleration and slowing

down - somewhat delayed compared to diesel-

hydraulic locomotives, as is the case with the proto-

type. Shortly before coming to a standstill you will

hear the squealing brakes.

Of course you may trigger various user sounds with

your throttle (refer to the table on page 8). You may

also adjust the volume of each individual sound se-

quence. How to do this is described in chapter 5.6.

Another special feature is the station announce-

ments in different languages to suit different coun-

tries. Simply write the following values in the CV

mentioned below:

CV Value Language: station announcement

48 0 German

48 1 Dutch

48 2 French

4.2.3. Curve and turnout sensors

The class 66/77 has been equipped with a compre-

hensive set of sensors in order to reproduce proto-

typical sounds in curves and across turnouts.

Please take note of the following:

These sensors function only when the locomotive is

travelling at low speed. As soon as the locomotive

stops or drives faster than speed step 7 (of 28) the

squealing in curves and over turnouts will not be

replayed.

The curve and turnout sounds will only be active

if the engine sound is turned on. The curve sensor

works for radii of about 80 cm. The sensors may

not detect very large radii. Unfortunately certain

mechanical limits are unavoidable.

The contact brackets for the turnout sensors are lo-

cated below the axles 1 and 6 (in other words, the

outer axles). Also refer to Fig. 11 on page 18. These

brackets should not be pushed or bent manually!

Treat these brackets with great care.

Occasionally there may be some sparks at the con-

tact brackets when traversing a turnout. The cur-

ve sensors have been tested with all commonly

available DC and AC systems. While traversing a

turnout the bogies may be raised slightly.

If you do not wish to hear any sounds in curves or

on turnouts you can switch off this function with

function button F12.

4.2.4. Synchronised smoke generator

The class 66/77 is equipped with a load depen-

dent, synchronised smoke generator that can be

controlled with your command station respectively

handheld throttle. The system consists of a holding

tank for the smoke distillate, an evaporator unit

with temperature control and a blower thatch ex-

hausts the smoke in a controlled manner.

This system can adjust both the amount and the in-

tensity of the smoke discharged subject to the ope-

rating conditions and thus assures prototypical per-

formance. This system has been especially tuned for

the class 66/77 and also comprehensively tested.

Please bear in mind the following remarks in order

to assure safe operation:

Only use the ESU smoke distillate part

N0. 51990. Other liquids may lead to

damage of the paint ﬁnish, choking the

system or a faulty heating unit due to

unwanted deposits. Only activate the

smoke generator while observing the

model and in a well ventilated room.

4.2.4.1. Filling the smoke generator holding tank

First take the pipette from the packaging of the

model and pull about 0.4 to 0.5 ml smoke distillate

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