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Owners Handbook

For the Katie Locomotive

KATIE

Operating Instructions

IMPORTANT: Read these instructions carefully before operating

the locomotive

The following items are required for running this engine and are not

included with the model.

Fuel Butane gas. See ’Gas System’ section.

Water See 'Filling the boiler' section.

General Lubricating oil See 'Lubrication' section.

SAFETY PRECAUTIONS

This is a working model locomotive using steam under pressure

and highly flammable fuel. Provided it is operated with reasonable

care and attention, no problems should arise.

It is intended for use out of doors and must only be operated in a

well-ventilated area.

Whilst the locomotive is in use, hot gasses are exhausted up the

chimney and excess steam frequently blows off through the safety

valve even when stationary, so operator and spectators should not

bend over the model.

As you will appreciate, this is not a toy and is therefore unsuitable

for young unsupervised children.

Follow manufacturer’s recommendations regarding the safe

storage of Butane gas canisters.

Some areas of the model will get quite hot whilst it is operating, so

a pair of gloves is provided in the tool kit for your protection.

Always have to hand either a fire extinguisher or wet cloth when

operating the model.

Katie Instruction Booklet

CONTENTS

Tool kit. Page 4

Running in. Page 4

Access to the controls. Page 4

Identification of parts of the locomotive. Page 5

Preparing for operation. Page 6

1. Filling the Gas Tank. Page 6

2. Filling the Boiler. Page 6

3. Lubrication. Page 7

4. Lighting the Burner. Page 8

Running the locomotive. Page 9

Driving the locomotive manually. Page 10

Driving by radio control. Page 11

Storage between operating sessions. Page 12

Altering wheel gauge. Page 13

Trouble shooting & maintenance. Page 13

Steam leaks. Page 13

Regulator not shutting. Page 14

Radio control. Page 14

Gas system. Page 14

Boiler and Gas Tank Certificate, Pages 17 & 18

(EC Declaration Of Conformity).

Identification of gas burner parts. Page 19

Service and parts. Page 20

TOOL KIT

The following items are included with your locomotive.

One 60ml bottle of special steam oil for use in the cylinder

lubricator. One Allen key for cylinder socket cap screws.

One 60ml syringe with plastic tube for filling the boiler with water.

One pair of protective gloves. One cleaning duster.

One wheel setting (back to back) gauge and key.

RUNNING IN

All locomotives are test run before leaving the factory, but will

require several hours of running in, when new, to overcome initial

tightness and allow valves etc. to ‘bed in’ completely. It is

recommended that the model is run with light loads for the first few

hours of operation. Also, the loco will waste a proportion of its

water and steam until ‘run in’ due to leaking slide valves, a

tendency to prime more, and simply overcoming the initial tightness

of the moving parts.

As the model heats up and cools down each time you raise steam,

screws and nuts have a tendency to stretch and loosen a little so

you will also need to make regular checks and ‘nip up’ any that

become loose.

ACCESS TO THE CONTROLS

For normal operation, all controls are accessible without the need

to remove any part of the locomotive, however, to give access to

the gas tank when filling, the cab roof hinges up. Care should be

taken when opening the cab roof. Gently grasp either side of the

roof hinge and firstly lift the hinge vertically upwards. This will lift

the hinge clear of the cab, and allow the roof to then tilt to the side.

The gas regulator is accessible through the rear of the cab, and on

manual control engines, the steam regulator is accessible through

the right hand cab doorway and reversing lever through the left

hand cab doorway.

The radio control receiver and switch are housed in-between the

frames, below the cab floor. The batteries for the radio control

system are housed in a holder beneath the cab roof. Batteries are

not included.

IDENTIFICATION OF PARTS OF THE LOCOMOTIVE

Radio controlled version illustrated

1) Lubricator drain screw. 2) Lubricator filler cap.

3) Reversing servo (this is a reversing lever on manual models).

4) Pressure gauge. 5) Safety valve 6) Gas regulator.

7) Gas filler valve. 8) Steam regulator.

9) Steam regulator servo and linkage (not on manual versions).

10) Gas burner.

PREPARING FOR OPERATION

The locomotive must be serviced before being operated. It is

important to perform all the following operations.

1) FILLING THE GAS TANK

The filling of the gas tank should only be carried out in a well-

ventilated area, where there are no naked lights or other lighted

locomotives close by. Ordinary Butane or Iso-butane gas (as used

in gas cigarette lighters) is the preferred fuel, though for economy,

the larger canisters as used for blowlamps or camping stoves etc.

are better. The larger canisters have an EN417 threaded self

sealing valve on top and require a special adapter to couple up to

the filler valve on the locomotive. A special brass gas filler adapter

is obtainable from your local garden railway supplier or direct from

ROUNDHOUSE.

Mixed gasses are also available and may be used if ordinary

butane or iso-butane are not available, but see the ‘Gas System’

section. Before attempting to fill the gas tank, make sure that the

gas control valve is closed by turning it clockwise.

The filler valve for the gas tank is on top of the tank under the cab

roof. Invert the gas canister and place its nozzle over the gas filler

valve. Support the tank from underneath and press the canister

down. The gas will be heard hissing as it enters the tank and a

small amount will escape around the valve. This is quite normal

and is the tank venting as the liquid enters. After about 20 to 30

seconds, liquid gas will emerge from the valve showing that the

tank is full. Remove the canister immediately.

2) FILLING THE BOILER

A syringe and plastic pipe are supplied for filling of the boiler.

The boiler is filled with water through the safety valve bush, housed

inside the brass dome on top of the boiler. The brass dome is a

substantial and heavy item, being turned from solid brass. Care is

needed when removing the dome, especially when the engine is

hot, as the dome itself will be hot. Take care not to drop the dome

onto the locomotive, as the weight of it may damage the model. Lift

off the brass dome then remove the safety valve by unscrewing the

large knurled plug into which it is fitted. Fill the boiler right to the top

with clean water. Distilled water is recommended if available. As an

alternative to distilled water if this is unavailable, clean tap water

can be used in soft water areas. Also, rain water or water from a

dehumidifier can be used provided that it is adequately filtered. Do

not use deionised water as this type of water may cause long term

damage to the boiler and fittings.

There has to be a space above the water to allow steam to be

raised so, insert the end of the plastic pipe into the boiler and

withdraw 30ml of water with the syringe. Replace the safety valve

finger tight.

3) LUBRICATION

Regular lubrication of all working parts is important and should be

carried out before each operating session. There are two types of

lubrication required: The external moving linkages and bearings are

lubricated with a medium oil such as motor engine oil, and the

internal steam mechanisms such as cylinders, pistons and valves

are lubricated with a special steam oil that is mixed with the steam.

Infrequent external lubrication will allow parts to run dry, and over

oiling can form pools around operating parts that attract dirt and

grit. If too thin an oil is used it will evaporate very quickly as the

loco gets hot –leading to dry running. We recommend the use of a

20-50 motor oil for external lubrication.

Internal lubrication is achieved by steam oil that is mixed with the

steam in the displacement lubricator, housed in the left-hand side

of the cab. Remove the knurled cap from the top and slacken the

drain screw two or three turns at the bottom but do not remove it.

Any water in the lubricator will run out through the drain screw.

Tighten the drain screw and refill with the steam oil supplied, then

replace the cap. Take time filling the lubricator, especially when

cold, as the oil takes time to run down and may trap an air bubble.

Both cap and drain screw are fitted with ‘0’ rings and need only be

closed finger tight.

NOTE: Only special steam oil as supplied should be used in the

lubricator and under no circumstances should ordinary oil be

substituted, or damage may result. The gas and steam regulators

will require periodic lubrication –see the troubleshooting section

for details.

4) LIGHTING THE BURNER

WARNING: Before lighting read the section on gas system

troubleshooting (page 13) and be aware of potential problems. If

the gas system is not operating correctly, shut it off immediately

or damage may result.

Move the locomotive to another location before lighting. Butane is

heavier than air and small pockets of gas can collect around the

locomotive during filling. To light the burner, hold a lighted match or

cigarette lighter over the top of the chimney and slowly open the

gas regulator by turning it anti-clockwise. The gas should ignite

almost immediately with a pop as the flame travels down the

chimney and into the boiler tube. The burner should be audible but

not too loud.

NOTE as stated above, the gas regulator should be opened slowly

until the burner ignites. If opened too quickly, particularly when the

engine is cold or if the gas tank has just been filled, it is possible

that the flame may not travel back into the boiler flue but stay in the

smokebox. If this should happen, the burner will sound quite

different to normal and the blue flame will be visible in the

smokebox if viewed down the chimney from a safe height. Should

this happen, turn off the gas immediately or damage may result

and then re-light it. If the problem persists and it is not possible to

ignite the burner correctly, then a dirty jet should be suspected and

cleaned as detailed in the ‘troubleshooting’ scetion.

For the first couple of minutes keep the burner on low. This is

important, as until it warms up, the flame will be a little unstable

and turning it up too much could cause it to go out. Also, with a

completely full tank, liquid gas could be drawn off instead of

vaporized gas, which can also extinguish the flame.

After a couple of minutes, the gas control valve can be opened

more to speed up steam raising. Open the gas regulator slowly to

about one full turn. The full range of adjustment (closed to fully

open) is achieved within the first full rotation of the gas regulator

knob any more is unnecessary.

RUNNING THE LOCOMOTIVE

When full working pressure has been reached (about 40psi), the

safety valve will start to blow off steam. Steam generation can be

controlled by the gas valve in the cab. If the safety valve blows off

frequently during running, then too much steam is being produced,

which wastes water and gas. Turning down the burner will

decrease the amount of steam created. Conversely, if steam

pressure is not maintained during a run, then the burner should be

turned up. After a few minutes of running it may be noticed that the

gas pressure through the burner has increased. This is due to the

gas tank becoming warmer and so increasing the gas pressure.

Simply turn the gas down –this may need to be performed several

times during a run. The art of balancing steam generation to the

operational requirement by the adjustment of the gas control valve

will quickly be learned.

The gas tank has a duration of about 25 minutes, though this will

vary a little depending on gas valve setting. The boiler should not

be allowed to run dry, and the gas tank capacity is such that the

gas should run out before the water. When the gas is fully used up,

the steam pressure in the boiler will be seen to gradually drop until

the loco comes to a halt. Should the water expire before the gas is

fully used, the pressure will drop rapidly and the loco will stop.

Check the pressure gauge –if this is zero turn off the gas. No

damage will result if the gas is turned off immediately.

DRIVING THE LOCOMOTIVE MANUALLY

On manually controlled locomotives, there are three main controls,

all of which are housed in the cab.

1) The gas regulator, which should be used to control steam

generation as described earlier.

2) The reversing lever. This is in the left-hand side of the cab and is

moved fully forward for running in a forward direction and full back

to run in the reverse direction. It should be parked in the centre

(mid gear) when the locomotive is stationary for any length of time.

When in mid gear position, the valve gear is effectively in neutral

and the engine will not move under steam power.

3) The regulator. This is the main steam control valve and

regulates the speed at which the engine will run. The regulator

handle is situated in the right hand cab doorway and is moved anti-

clockwise to open and clockwise to close.

Using the reversing lever, select the desired direction of travel and

open the regulator a little. Initially, there will be a certain amount of

water in the pipes and cylinders, which will exhaust through the

chimney and, after a few moments, the engine will move jerkily,

until this clears. Once the parts have warmed up, the engine will

move off steadily and its speed can be controlled with the regulator.

Subsequent starts will be quite smooth once the cylinders etc. have

reached their normal operating temperature. To reverse the

locomotive, close the regulator to bring it to a halt, move the

reversing lever over and open the regulator again.

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